Wheel End Support Assembly with Locator Bushing Alignment
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Solution Overview
Problem
Existing wheel end support assemblies face challenges in accurately aligning brake torque plates with spindles during assembly, leading to potential misalignment and increased manufacturing costs due to tight tolerances required in multiple fastener holes.
Innovation Solution
A wheel end support assembly that includes a spindle, a brake torque plate, a locator bushing with distinct portions, and a sensor, where the locator bushing aligns the brake torque plate to the spindle using a single component, allowing for larger fastener hole diameters and flexible tabs for self-centering, facilitating easier assembly and improved rotational positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple fastener holes are used to align the brake torque plate with the spindle, then the alignment can be achieved, but tight tolerances are required which increases manufacturing costs
Solution Approach 1:
A dedicated alignment tool is introduced as an intermediary component between the brake torque plate and the spindle. This alignment tool includes alignment features that mate with corresponding features on both components, providing precise positioning during assembly. The alignment tool acts as a temporary mediator that ensures accurate alignment without requiring tight tolerances on the fastener holes themselves, thereby reducing manufacturing costs while maintaining alignment precision.
2Manufacturing precision
If tight tolerances are required for fastener holes to ensure proper alignment, then alignment accuracy is improved, but the assembly process becomes more difficult and time-consuming
Solution Approach 1:
The alignment features are pre-formed on the brake torque plate and spindle during manufacturing, before the final assembly process. These preliminary alignment features (such as dowel pins, recesses, or keyed features) are built into the components themselves, so that during assembly, the components naturally guide themselves into the correct alignment position without requiring tight tolerances on the fastener holes or complex alignment procedures by the assembler.
3Device complexity
If a single locator bushing is used to align the brake torque plate to the spindle, then the number of components is reduced and assembly is simplified, but achieving precise rotational positioning becomes more challenging
Solution Approach 1:
The locator bushing incorporates asymmetric alignment features such as a keyway, eccentric positioning, or non-circular cross-section elements that provide unique rotational positioning. The asymmetric geometry ensures that the brake torque plate can only be installed in one specific rotational orientation relative to the spindle, eliminating the need for multiple bushings or complex adjustment mechanisms while maintaining precise rotational accuracy.
Data Source
AI summary
A wheel end support assembly and method of assembly. The assembly may include a spindle, a brake torque plate, and a locator bushing. The locator bushing is received in a first locator hole of the spindle and a second locator hole of the brake torque plate and aligns the brake torque plate to the spindle.