Title: Bearing bracket with strut attachment and wheel axle suspension comprising such a bearing bracket.

The invention relates to a bearing bracket to be attached to a chassis, said bearing bracket comprising a pair of opposite side plates which are spaced apart to receive between them a leading end of a trailing arm, the side plates having aligned apertures to pass through a pivot bolt to pivotally mount the leading end of the trailing arm to the bearing bracket, wherein the bearing bracket is provided on one side plate with a strut attachment collar, which has on one end a base that is positioned against the side plate, said strut attachment collar furthermore having an overhang structure that extends from the base, which overhang structure has a chassis facing side providing an attachment surface for a strut beam.

Such a bearing bracket is generally attached to an overhead chassis beam or other chassis component of a vehicle, in particular a heavy vehicle such as a truck, a trailer or a semitrailer. The purpose of the bearing bracket is to connect a trailing arm to the vehicle chassis, such that it can swivel around a pivot in the bearing bracket. Often these bearing brackets are welded to the chassis beam.

EP 1 481 824 A1 shows in Figs 6-8 thereof a bearing bracket with a strut connecting piece that is clamped to the side plate of the bearing bracket by means of the pivot bolt by which also the trailing arm is mounted to the bearing bracket. In particular the strut connecting piece has a base plate which rests against a leg of a U-shaped adjusting bracket located outside the side plate of the bearing bracket. Mounting such an assembly to a bearing bracket can be quite complex due to the number of parts that is clamped together with one bolt.

It is an object of the invention to provide an alternative bearing bracket assembly.

This object is achieved by a bearing bracket to be attached to a chassis, said bearing bracket comprising a pair of opposite side plates which are spaced apart to receive between them a leading end of a trailing arm, the side plates having aligned apertures to pass through a pivot bolt to pivotally mount the leading end of the trailing arm to the bearing bracket, wherein the bearing bracket is provided on one side plate with a strut attachment collar, which has on one end a base that is positioned against the side plate, said strut attachment collar furthermore having an overhang structure that extends from the base, which overhang structure has a chassis facing side providing an attachment surface for a strut beam, wherein the base is an annular base positioned on the side plate such that it surrounds the opening for the pivot bolt, and wherein the annular base is welded to the side plate on an outer contour of the annular base.

The annular base of the strut attachment collar is welded all around the outer contour of the annular base to the side plate of the bearing bracket. The annular base has an inner contour having a diameter that is larger than the diameter of the bolt head of the pivot bolt. The chassis facing side of the overhang structure faces the overhead chassis, and provides an attachment surface for one end of a strut beam. The other end of the strut beam may be attached to an overhead chassis component.

In a preferred embodiment the base is welded to the side plate all around the outer contour by a continuous weld. The weld thus has a closed contour, which causes an evenly distributed tension in the weld during dynamic loads applied on the bearing bracket during normal operation of the vehicle. This welded structure has an increased lifetime.

In another possible embodiment the base is welded to the side plate all around the outer contour by a plurality of welds interrupted by gaps. Preferably the base is welded to the side plate by two welds which on a top side and a lower side are interrupted. An advantage of this is that the strut can be welded to the strut attachment collar beforehand and a sub-assembly is created. Afterwards the collar of the sub-assembly can be welded to the bearing bracket and the free end of the strut beam to an overhead chassis component.

In yet another embodiment of the bearing bracket the side plates are provided with protrusions that are arranged at a distance from opposite ends of the elongate hole for cooperation with an outer contour of an eccentric disc that engages the protrusions. In this embodiment the annular base is provided on opposite sides with a recess. The recesses are positioned over the protrusions, such that the head surface of the annular base abuts flat on the side plate. The annular base is welded also over the protrusions on the outer contour of the annular base. An advantage of this embodiment is that the side plates of the bearing brackets can all be made the same. At the side plate without the strut attachment collar also an eccentric disc is placed. Thus there are needed only two mirrored side plates of the same type, all with protrusion for cooperation with an eccentric disc. On the ones that a strut attachment is required, the strut attachment collar of this specific embodiment can be welded. This makes the production more efficient and cost effective. In a preferred embodiment the centre of the base is positioned above the centre of the opening for the pivot bolt in the side wall. The distance between the mentioned centres may be 5 mm. An advantage of this is that the distance between the weld at the upper side of the base and the centre axis of the bolt is increased, whereby the transmission of forces into the weld is reduced, which increases the lifetime of the weld.

In a possible embodiment the annular base has a circular outer contour, and preferably a circular inner contour.

In addition the overhang may be formed as an obliquely sectioned cylinder-section profile. This embodiment is readily made by cutting the collar from a tubular base material, in particular a tubular profiled section element having or a circular cross-section. As a cutting process laser cutting may be selected. An advantage is that the shapes of different collars may be complementary within the tubular base material, whereby multiple collars can be cut from one tubular element, without any waste material.

In another embodiment the annular base has a rectangular outer contour, preferably a square outer contour. In this embodiment the base may have a rectangular inner contour.

In an embodiment the overhang is formed as an obliquely sectioned box-section profile. Also in the case, a cutting process laser cutting may be selected. An advantage is that the shapes of different collars may be complementary within the tubular base material, whereby multiple collars can be cut from one tubular element, without any waste material.

Also an embodiment having a base with a rectangular outer contour and a circular inner contour is possible. A circular inner contour is advantageous when the collar is combined with a circular eccentric disc used for adjusting the position of the pivot bolt in the bearing bracket.

The overhang structure may comprise a flat top wall and triangular opposing parallel lateral walls connected to the top wall.

The overhang structure may also comprise a flat top wall and triangular opposing lateral walls connected to the top wall, wherein the opposing lateral walls taper towards the top wall. This shape is comparable to a truncated and obliquely cut square pyramid.

The strut beam can be attached to the overhang in several ways, e.g. by welding or by bolting. In one embodiment the attachment surface of the overhang structure comprises a welding surface for welding a strut beam to. The welding surface may be a flattened outer surface of the overhang. The flattened outer surface is facing towards the overhead chassis. In another embodiment at least one mounting flange is formed on the chassis facing side, said mounting flange protruding from the chassis facing side of the overhang structure. In particular the flange may extend in an axial direction of the collar. The flange may be provided with mounting holes for bolting the strut beam to the flange. On the other hand the flange may also be used to weld the strut beam to.

Another aspect of the invention relates to a bearing bracket according to the preamble of claim 19, wherein the base is an arc-shaped base positioned on the side plate such that it surrounds the opening for the pivot bolt over an arc of at least 315°, wherein the base has an interrupted contour, with a gap at the side opposite the chassis facing side, and wherein the arc-shaped base is welded to the side plate only on an outer contour of the base by a continuous weld extending over the entire arc of at least 315°.

The invention also relates to a wheel axle suspension for a vehicle, comprising on either lateral side:

- a bearing bracket according to the invention as described in the above, wherein the bearing bracket is attached to a chassis,

- a strut beam attached with one end to the strut attachment collar and attached with another end to the chassis,

- a trailing arm having a leading end which is positioned between the side plates of the bearing bracket, and which is pivotally attached to the bearing bracket by a pivot bolt extending through the leading end of the trailing arm and through the apertures in the side plates of the bearing bracket,

- an air spring mounted to the trailing arm at a location remote from the pivoting leading end, said air spring supporting the chassis.

In a further embodiment the apertures in the side plates of the bearing bracket are slotted holes, wherein the base of the strut attachment collar has a circular inner contour, and wherein an eccentric disc is arranged within said circular inner contour of the base, the eccentric disc having a hole through which the pivot bolt extends, such that by rotation of the eccentric disc the position of the pivot bolt in the slotted hole is adjusted.

The invention also relates to a vehicle including a wheel axle suspension as described in the above. Another aspect of the invention relates to a method for manufacturing a strut attachment collar for a bearing bracket according to any of the claims 1-18, wherein the strut attachment collar is formed by a metal casting process.

Another aspect of the invention relates to a method for manufacturing a strut attachment collar for a bearing bracket as described in the above, wherein:

- a metal tubular profiled section element, having a rectangular cross-section or a circular cross-section, is provided;

- the strut attachment collar is cut from the metal tubular profile by means of a cutting process, preferably a laser cutting process.

The invention will be further elucidated with reference to the drawing:

Fig. 1 shows an isometric view of a wheel axle suspension according to the invention,

Fig. 2 shows in an exploded view an assembly of a bearing bracket according to the invention and a strut beam,

Fig. 3 shows in an isometric view an assembly of a bearing bracket according to the invention and a strut beam,

Fig. 4 shows the assembly of Fig. 3 in a side elevational view,

Fig. 5 shows the assembly of Fig. 3 in a front view,

Fig. 6 shows a side elevational view of another embodiment of a bearing bracket according to the invention,

Fig. 7 illustrates in an isometric view a tubular blank from which multiple strut attachment collars are cut,

Fig. 8 shows in an isometric view another embodiment of a strut attachment collar according to the invention,

Fig. 9 shows a side elevational view of the strut attachment collar of Fig. 8,

Fig. 10 shows a front elevational view of the strut attachment collar of Fig. 8, Fig. 11 shows in an isometric view another embodiment of a strut attachment collar according to the invention,

Fig. 12 shows a side elevational view of the strut attachment collar of Fig. 11 ,

Fig. 13 shows a front elevational view of the strut attachment collar of Fig. 11 ,

Fig. 14 shows in an isometric view another embodiment of a strut attachment collar according to the invention,

Fig. 15 shows a side elevational view of the strut attachment collar of Fig. 14,

Fig. 16 shows a front elevational view of the strut attachment collar of Fig. 14,

Fig. 17 shows a top elevational view of the strut attachment collar of Fig. 14,

Fig. 18 shows in an isometric view another embodiment of a strut attachment collar according to the invention,

Fig. 19 shows a side elevational view of the strut attachment collar of Fig. 18,

Fig. 20 shows in an isometric view another embodiment of a strut attachment collar according to the invention with a strut beam attached thereto,

Fig. 21 illustrates in an exploded view the assembly of a bearing bracket according to the invention and a trailing arm,

Fig. 22 shows in a side elevational view the assembly of Fig. 21 in a mounted state,

Fig. 23 shows in an isometric view an embodiment of a bearing bracket according to another aspect of the invention,

Fig. 24 shows the bearing bracket of Fig. 23 in a side elevational view,

Fig. 25 shows in an exploded view an assembly of another bearing bracket according to the invention and a strut beam, and

Fig. 26 shows in a side elevational view the assembly of Fig. 25. Fig. 1 shows an air sprung wheel axle suspension 1 for a vehicle, such as a truck, a trailer or a semi-trailer. The suspension has on either lateral side a bearing bracket 2 attached to a chassis beam 31 of a vehicle chassis 3. As can be best seen in Fig. 2, the bearing bracket 2 comprises a pair of opposite side plates 21 which are spaced apart. The side plates 21 have aligned apertures 22 to pass through a pivot bolt.

The suspension comprises a trailing arm 4 having a leading end 41 which is positioned between the side plates 21 of the bearing bracket 2 and which is pivotally attached to the bearing bracket 2 by a pivot bolt 5 extending through the leading end 41 of the trailing arm 4 and through the apertures 22 in the side plates 21 of the bearing bracket 2.

An air spring 6 is mounted to the trailing arm 4 at a trailing end 42 of the trailing arm 4, which is remote from the pivoting leading end 41. The air spring 6 supports the chassis 3.

Between the leading end 41 and the trailing end 42, the trailing arm 4 has an axle attachment zone 43, where an axle body 9 is rigidly attached to the trailing arm 4. The axle body 9 is in the embodiment of Fig. 1 a thin-walled tubular axle body with a circular cross section. In this embodiment there is an axle pad 7 arranged between the axle attachment zone and the axle body, which axle pad 7 provides an axle seat for the axle body 9. The assembly of axle attachment zone 43, axle pad 7 and axle body 9 is clamped together by a pair of U-bolts 8.

The bearing bracket 2 is provided on one side plate 21 with a strut attachment collar 10. A strut beam 32 is attached with one end 32A to the strut attachment collar 10 and with another end 32B to a transverse chassis beam 33 of the chassis 3.

The strut attachment collar 10 has on one end a base 101 that is positioned against the side plate 21 of the bearing bracket. The strut attachment collar 10 furthermore has an overhang structure 102 that extends from the base 101. The overhang structure 102 has a chassis facing side 103 providing an attachment surface for the strut beam 32. The base 101 is an annular base positioned on the side plate 21 such that it surrounds the opening 22 for the pivot bolt 5. The annular base 101 is welded to the side plate 21 only on an outer contour of the annular base 101. Welding only on the outside of the annular base makes the welding process much easier. The weld is indicated by reference numeral 11 in Figs 3 and 4. In the specific embodiment shown in Figs 3 and 4, the base is welded to the side plate 21 all around the outer contour by a continuous weld 11. In Fig. 6 an alternative embodiment is illustrated in which the base 101 is welded to the side plate 21 all around the outer contour by a pair of welds 13 interrupted by gaps 14. Another number of welds separated by gaps is also possible.

The annular base 101 has a circular outer contour, and a circular inner contour. This collar 10 can be cut from a metal tubular profiled section element having a circular cross-section, as is illustrated in Fig. 7. The shape can be made such that two collars 10 complement each other in a cylindrical shape, whereby the material loss due to the cutting process can be minimized. A laser cutting process can be used to cut the collars 10 from the tubular blank.

The end 32A of the strut beam 32 is welded to the chassis facing side 103 of the strut attachment collar 10. This weld is indicated in Figs 3 and 5 with reference numeral 12. The strut attachment collar according to the invention can also be made by a metal casting process. An embodiment made by casting is shown in Figs 8-10. In this embodiment the strut attachment collar 200 has an annular base 201 with a substantially circular shape. The annular base 201 has a chamfered edge 202 which improves the circumferential welded connection 11 (not shown in Figs 8-10, cf. Fig. 3) that connects the base 201 to the side plate 21 of the bearing bracket 2. The collar 200 has an overhang 204, which has on a chassis facing side thereof a flattened outer surface 205, which forms a welding surface for welding the strut beam 32 (cf. Fig. 3) to.

Another embodiment of a strut attachment collar, which can be made from cutting a hollow profiled section element is shown in Fig. 11-13. This collar 300 has an annular base 301 with a substantially square annular shape. The annular base 301 thus has a square outer contour and a square inner contour as is best visible in Fig. 12. The collar 300 has an overhang 304 which is formed as an obliquely sectioned box-section profile as is best visible in Fig. 11. The overhang structure 304 comprises a flat top wall 304A and opposing parallel lateral walls 304B which are connected to the top wall 304A. The lateral walls 304B substantially have a triangular shape, which is best seen in Fig. 13. The outer surface of the top wall 304A is flat and forms a welding surface for welding the strut beam.

Another embodiment of a strut attachment collar, which can be made by casting is shown in Figs 14-17. This collar 400 has an annular base 401 with a substantially square annular shape. The annular base 401 has a square outer contour and a square inner contour. The collar 400 has an overhang structure 404. The overhang structure comprises a flat top wall 404A and opposing lateral walls 404B connected to the top wall 404A. The opposing lateral walls 404B are substantially triangular, which is best seen in Fig. 16. Furthermore, the opposing lateral walls are tapering towards the top wall 404A, which is best seen in Fig. 15, and tapering towards each other which is best seen in Fig. 17.

Yet another embodiment of a strut attachment collar, which can be made by casting is shown in Figs 18 and 19. This strut attachment collar 500 has an annular base 501 with a square outer contour and a circular inner contour (see Fig. 19). The collar 500 has an overhang structure 504 which comprises a flat top wall 504A and opposing parallel lateral walls 504B which are connected to the top wall 504A. The lateral walls 504B substantially have a triangular shape. The outer surface of the top wall 504A is flat and forms a welding surface for welding the strut beam 32 (cf. Fig. 3). This embodiment, having an annular base with a circular inner contour, could be used with an eccentric disc for positioning the pivot bolt as will be described further below with reference to Figs 20-21.

Fig. 20 shows another embodiment of a strut attachment collar. The attachment collar 600 has an annular base 601 with a substantially circular shape. The collar 600 has an overhang structure 604, which has at least one mounting flange 605, which is formed on the chassis facing side of the overhang structure. The mounting flange 605 protrudes from the chassis facing side of the overhang structure 604 and extends in an axial direction of the collar 600. The mounting flange 605 is provided with mounting holes for bolting the strut beam 32 to the flange 605 by means of bolts 607.

In Figs 23 and 24 another aspect of the invention is illustrated. These figures show a bearing bracket 702 to be attached to a chassis. The bearing bracket 702 comprising a pair of opposite side plates 721 which are spaced apart to receive between them a leading end of a trailing arm. The side plates 721 having aligned apertures to pass through a pivot bolt to pivotally mount the leading end of the trailing arm to the bearing bracket 702.

The bearing bracket 702 is provided on one side plate with a strut attachment collar 710. The strut attachment collar 710 has on one end a base 711 , that is positioned against the side plate 721. The strut attachment collar 710 furthermore having an overhang structure 712 that extends from the base 711. The overhang structure 712 has a chassis facing side 713 providing an attachment surface for a strut beam. The base 711 is an arc-shaped base positioned on the side plate 721 such that it surrounds the opening 722 for the pivot bolt over an arc of at least 315°, which is best visible in Fig. 24. The base 711 has an interrupted contour, with a gap 714 at the side opposite the chassis facing side 713. The arc-shaped base 711 is welded to the side plate 721 only on an outer contour of the base 711 by a continuous weld 715 extending over the entire arc of at least 315°. Figs 21 and 22 illustrate a possible way to mount a trailing arm 4 to the bearing bracket 2 of Fig.1. The bearing bracket 2 is attached to the chassis 3 as is shown in Fig.1 and the strut beam 32 is attached with one end to the strut attachment collar 10 and attached with another end to the chassis 3 as is shown in Fig.1.

The trailing arm 4 has a leading end 41. In this embodiment the leading end 41 comprises an eyelet 42 in which a bearing bushing 43 is arranged. In this particular example the eyelet 42 is a two-part eyelet with two eyelet halves, but this is not essential. The eyelet may also be a one-piece eyelet formed integrally (i.e. in one piece) with the trailing arm. The bearing bushing 43, sometimes called a “silent block”, comprises a metal inner bushing 44 and a rubber outer bushing 45. The leading end 41 is positioned between the side plates 21 of the bearing bracket 2 as is illustrated in Fig. 21, such that the bearing bushing 43, in particular the metal inner bushing 44 thereof, is aligned with the apertures 22 in the side plates 21. The leading end 41 is pivotally attached to the bearing bracket 2 by a pivot bolt 5 extending through the inner bushing 44 and through the apertures 22 in the side plates 21 of the bearing bracket 2. Thereto a nut 5A is screwed on the pivot bolt 5 to clamp the ends of the metal inner bushing 44 between the side plates 21. The rubber outer bushing 45 then allows a pivoting movement of the eyelet 42 with respect to the rigidly clamped inner bushing 44 and the bearing bracket 2. On the inner side of the side plates 21 additional washer rings 54, 55 can be arranged which reinforce the side plates 21 around the holes 22. The inner bushing 44 is thus clamped between the washer rings 54, 55.

The apertures 22 in the side plates 21 of the bearing bracket 2 are slotted holes as is visible in Fig. 2 and Fig. 21. The base 101 of the strut attachment collar 10 has a circular inner contour. An eccentric disc 50 is arranged within said circular inner contour of the base 101. Another eccentric disc 52 is arranged on an outer side of the opposite side plate 21. The eccentric discs 50 and 52 have a hole 51, 53 through which the pivot bolt 5 extends. The hole 51 of the eccentric disc 50 is a slotted hole. The position of the pivot bolt 5 in the slotted hole 22 in the side plate 21 is adjustable by rotation of the eccentric discs 50, 51. Thereby the longitudinal position of the leading end 41 of the trailing arm and therefore of the trailing arm as a whole can be adjusted. This allows to align the axle body with respect to the chassis.

The circular inner contour of the collar 10 delimits the movement of the eccentric disc 50 to a rotation. The slotted shape of the apertures 22 and the slotted shape of the hole 51 then allow a degree of movement to the bolt 5 that extends through the hole 51 in the eccentric disc 50. In Figs 25 and 26 is a bearing bracket 802. The bearing bracket 802 has a pair of opposite side plates 821 which are spaced apart. The side plates 821 have aligned apertures 822 to pass through a shaft of a pivot bolt 5.

An eccentric disc 814 is arranged on an outer side of the respective side plates 821 of the bearing bracket 802. The eccentric disc 814 is provided with a bolt opening, through which the shaft of the pivot bolt 5 extends. Thus, the shaft of the pivot bolt 5 extends through the elongate holes 822 of the side plates 821, the leading end of the trailing arm, and the bolt opening of the eccentric discs 814. The eccentric disc 814 is for adjustment of the position of the pivot bolt 5 in the adjustment direction, which is the longitudinal direction of the slotted hole 822 and which is substantially parallel to the longitudinal direction of the vehicle.

The side plates 821 are provided with protrusions 823, in the specific embodiment shown in Figs 25 and 26 with two protrusions 823, that are arranged at a distance from opposite ends of the elongate hole 822 such that an outer contour of the eccentric disc 814 engages the protrusions 823 while rotating about the pivot axis. The eccentric disc 814 is essentially an eccentric cam with a circular outer contour. The protrusions 823 may for example be stamped in the side plate 821. By rotating the eccentric disc 814 clockwise (cf. Fig. 14A), the distance between the eccentric hole in the eccentric disc 814 and the right protrusion 823 increases whereby the hole in the disc 814 moves to the left. The eccentric disc 814 rotates with respect to the bolt shaft 51, but also carries along said shaft 51 towards the left. By rotating the eccentric disc 814 counter clockwise, the distance between the eccentric hole in the eccentric disc 814 and the left protrusion 823 increases, whereby the hole in the eccentric disc 814 moves to the left. The eccentric disc 814 rotates with respect to the bolt shaft, but also carries said shaft along towards the right. Thus, by rotatably adjusting the eccentric disc 814 a certain degree, the position of the bolt shaft in the elongate hole 822 can be adjusted. Thus the trailing arm can be aligned such that the wheel axle body is perpendicular to the longitudinal direction.

The strut attachment collar 810 has a annular base 8101 , which is provided on opposite sides with a recess 8104. The annular base 8101 is positioned against the side plate 821 , such that it surrounds the elongate hole 822, as was already described in the above for other embodiments. The recesses 8104 are positioned over the protrusions 823, such that the head surface of the annular base 8101 abuts flat on the side plate 821 and the annular base 8101 can be welded around the outer contour thereof to the side plate 821. The resulting circumferential weld also runs over the protrusions 823.