Preassembled Axle End Assembly for Easier Wheel Hub and Brake Mounting
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Solution Overview
Problem
The assembly of wheel brake and wheel hub components on commercial vehicle axles is complex due to the need for precise positioning and connection of heavy components, often requiring special tools and risking damage during installation, and existing solutions do not allow for easy disassembly for repairs.
Innovation Solution
A preassembled axle end assembly with a hollow shaft element that integrates the wheel brake and wheel hub, allowing for simplified mounting on the axle body with a threaded connection, enabling easy assembly and secure attachment, and including a brake adapter for direct torque transmission and a spacer sleeve for additional support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If wheel brake and wheel hub components are assembled separately on the axle, then precise positioning and secure connection can be achieved, but the assembly process becomes complex and requires multiple individual steps with special tools
Solution Approach 1:
The invention divides the wheel end assembly into a pre-assembled unit (containing wheel hub, wheel bearings, and brake disc) and the axle body, which are separately manufactured and then connected. This segmentation allows each component to be optimized independently while simplifying the final assembly process to just two main steps: pressing the pre-assembled unit onto the hollow shaft element and securing it with the central nut.
Solution Approach 2:
The wheel hub assembly with wheel bearings and brake disc is pre-assembled as a complete unit before being mounted on the axle. This preliminary assembly ensures precise positioning and proper alignment are achieved during manufacturing rather than during field installation, eliminating the need for complex positioning procedures during axle assembly.
2Strength
If heavy components are connected using bolted connections, then secure attachment can be achieved, but access to bolted connections is limited and requires special tightening tools
Solution Approach 1:
The invention combines the central nut connection with the hollow shaft element design, where the central nut threads directly onto the hollow shaft element that protrudes from the pre-assembled unit. This merging eliminates the need for separate bolted connections and allows assembly using standard threading tools, greatly improving accessibility while maintaining strong mechanical connection.
Solution Approach 2:
The connection mechanism is extracted from the traditional bolted flange design and replaced with a threaded hollow shaft element that extends from the pre-assembled unit. This extraction allows the connection point to be accessible from the end of the axle, enabling use of standard tools rather than requiring special long-reach tightening tools.
3Stability of the object's composition
If the axle housing is mounted in fixed positions on mounting blocks, then stable support can be achieved, but the installation position of the disc brake is constrained and requires complex mounting fixtures
Solution Approach 1:
The invention introduces adjustability into the brake disc mounting system by providing multiple mounting holes in the brake disc and corresponding mounting holes in the hollow shaft element. This dynamic configuration allows the brake disc to be positioned at different locations along the hollow shaft element, enabling adaptation to different vehicle requirements while maintaining stable support from the mounting blocks.
Solution Approach 2:
The hollow shaft element serves multiple functions: it provides the connection interface for the pre-assembled unit, offers adjustable mounting positions for the brake disc through multiple holes, and acts as the rotational axis for the wheel hub. This multi-functionality eliminates the need for separate positioning fixtures while maintaining stable mounting.
4Strength
If wheel bearings are pressed into the wheel hub, then secure fixation can be achieved, but the assembly sequence becomes constrained and requires specific ordering of operations
Solution Approach 1:
The wheel bearings are pressed into the wheel hub during the pre-assembly phase before the entire unit is mounted on the axle. This preliminary action allows the bearing installation to be performed in a controlled manufacturing environment with proper tooling, ensuring secure fixation while simplifying the field assembly sequence to just mounting the complete pre-assembled unit.
Data Source
AI summary
An axle end subassembly (1) comprising a wheel brake arrangement (3) and a wheel hub arrangement (4) is characterized in that same is designed as a preassembled unit comprising a hollow shaft element (2, 2') on which the wheel brake arrangement (3) and the wheel hub arrangement (4) are disposed.