Robert Boschgmbh

David Thomas Sadanowicz

Larry William Brackmann

Don Paul Ward

William Eugene Sherman, Ii

Charles Byron Horner, Jr

Eric James Barber

Timothy James Posey

Randall Michael Zonca

James Darwin Bowman

Jeffery D Pontius

Robert Edward Sierminski

William A Reimer, Jr

Jeffery Adam Kalmbach

A method of manufacturing vehicle brake boosters includes load testing a plurality of reaction discs and sorting the load-tested reaction discs into multiple, separate batches based on the load test results. A first batch of plunger plates is formed to an axial length to correspond with a first of the separate batches of reaction discs. A first batch of the vehicle brake boosters is assembled with a first one of the multiple, separate batches of reaction discs and the first batch of plunger plates to achieve a target jump-in force. A second batch of plunger plates is formed to an axial length to correspond with a second one of the separate batches of reaction discs. A second batch of the vehicle brake boosters is assembled with a second one of the multiple separate batches of reaction discs and the second batch of plunger plates to achieve the target jump-in force.

Method of manufacturing brake boosters

A vehicle wheel assembly has a vehicle wheel with a number of angularly spaced mounting bolt receiving apertures, a wheel hub with axially inboard and outboard surfaces and a plurality of radially outwardly protruding bosses interspersed with clearance spaces and a disc brake rotor having a like plurality of radially inwardly protruding bosses interspersed with clearance spaces. A first set of threaded fasteners couple the wheel to the outboard surface of the hub and a second set of threaded fasteners couple the rotor to the inboard surface of the hub. Each hub boss includes an axial depression in the region of the bore for receiving one of the second set of threaded fasteners allowing a head of the threaded fastener to be axially recessed inboard of the wheel receiving portion of the outboard hub surface.

Wheel hub and brake rotor assembly

Brake shield

A wheel hub for a corner assembly on a vehicle wherein a wheel and a rotor for a brake system are attached to the wheel hub. The wheel hub has a cylindrical body with a peripheral surface thereon having a flange to which the rotor and the rim of a wheel are attached and a bearing surface that receives a bearing fixed to a stationary member to establish a perpendicular alignment between first and second engagement faces on the rotor and friction members carried by a caliper. A attachment clip attached to the flange resiliently urges the rotor toward the flange to sustain the perpendicular alignment even though the rotor may axially translate during a brake application.

Wheel hub

Knuckle

A module corner assembly wherein a wheel hub is permanently attached to a knuckle and various surfaces on the wheel hub and knuckle are machined in a same fixture utilized in holding the knuckle to deform an end on the wheel hub against a cone of a bearing. When a rotor is thereafter attached to the wheel hub it is also machined in the same fixture such that a perpendicular relationship is established between the axis of the wheel bearing and braking surfaces on the rotor and as a result a desired lateral run out relationship is achieved between the axis of the bearing and rotor surfaces.

Method of manufacturing a modular corner assembly

A knuckle () for a corner assembly () wherein a cylindrical body () has an outboard race () and an inboard race () located therein for correspondingly receiving a first roller assembly () and a second roller assembly () carried by a wheel hub () such that brake engagement surfaces () and () on a rotor () are located in a parallel relationship with faces on a friction members () and () associated with caliper () and perpendicular with the axis of the wheel hub () to obtain a desired lateral run out relationship between the rotor () and the axis of the first () and second () roller assemblies retained in the wheel hub ().

Method of manufacturing a corner assembly

A process for manufacturing and assembling a corner assembly for a vehicle to achieve a perpendicular relationship between an axle of a vehicle and first and second braking surfaces on a rotor. In this process, after an inner race of a bearing is pressed onto a wheel hub and an outer race is pressed into a support structure to define a sub-assembly. The sub-assembly is placed onto a locating fixture such that the outer race supports the sub-assembly in a desired alignment where an out board surface on a radial flange is in a perpendicular relationship with the axis of the wheel hub. An arbor is inserted into an axle bore surrounding the axis of the wheel hub and the sub-assembly is rotated on the inner race to simulate operational condition of a vehicle as the surface of the out-board flange is finished machined to define a perpendicular relationship with the axis of the wheel hub. Once the out board surface is finish machined, the wheel hub is in a condition to receive a rotor by bringing an alignment surface on the rotor into engagement with the finished surface of the wheel hub. The rotor is retained on the hub through studs that extend from the wheel hub for attaching a wheel to the wheel rotor. The wheel hub is located such that radial braking surfaces on the rotor are in perpendicular planes with respect to the axis of the axle and parallel to the surfaces of the friction pads.

Process of manufacturing a corner assembly

A corner module for use in a motor vehicle having a bearing pack through which a wheel hub for the motor vehicle is connected with a support member. The bearing pack includes an inner race and an outer race for retaining first and second roller elements such that a wheel attached to the hub may rotate with respect to the support member. The bearing pack is characterized by an exciter ring that is located between the first and second roller elements and the outer race is characterized by an opening that is in radial alignment with the exciter ring. A sensor that is fixed to the support member has a functional length and a sensing area that extends through the radial opening in the outer race and into the bearing pack to a position adjacent the exciter ring such that the functional length and sensing area is protected from exposure to contamination that may be present in the environment. The sensing area is activated by movement of the exciter ring to provide an electronic control unit with a signal relating to the rotation of the wheel and used in the control of an anti-skid brake system.

Bearing assembly for a vehicle

A process for manufacturing a corner assembly for a vehicle. A wheel hub is partially machined to define a journal section and a radial mounting flange on an out-board surface of the hub. Bolts are pressed into axial openings in the mounting flange and the hub further machining to produce a concentric wheel pilot, rotor pilot and bearing journal surfaces that are perpendicular to radial faces on an out-board surface of the mounting flange. The hub is pressed into a bearing retained of a support member and a rotor is placed on the rotor pilot surface such that the bolts extend through openings located on the inner peripheral surface of the rotor. The hub is rotated to gage lateral deflection with respect to its axis. If the deflection is less than 0.06 mm, the wheel hub and rotor are accepted for installation on a vehicle and rejected if greater that 0.06 mm.

A method of attaching a bearing ( ) and hub ( ) to a knuckle ( ) in a corner assembly ( ) of a vehicle to prevent the introduction of lateral moments into a plurality of rollers ( &prime;) retained in the bearing ( ). The bearing ( ) has an inner race ( ) and an outer race ( ) with the plurality of rollers ( &prime;) being retained between an outer race ( ) and an inner race ( ). The hub ( ) has a cylindrical body with a flange ( ) located adjacent a first end ( ) and a mounting surface ( ) located adjacent a second end ( ). The flange ( ) has a plurality of axial openings ( ) that are spaced in an arc with respect to an axis of the cylindrical body. After the inner race ( ) is located on the mounting surface ( ), the inner race ( ) is fixed to the cylindrical body. Thereafter, hub ( ) is placed on a tool ( ) such that a plurality of pins ( ) on the tool ( ) extend through the plurality of openings ( ) in the flange ( ) and engage the outer race ( ) of the bearing ( ). The tool ( ) is aligned with an opening ( ) in the knuckle ( ) and a force is only applied to the outer race ( ) to push the bearing ( ) into opening ( ) and position the hub ( ) in knuckle ( ).

Method of securing a bearing and hub to a knuckle

A drum-in-hat park brake assembly having a first brake shoe retained on a backing plate by a first pin and a second brake shoe retained by a second pin. The first and second pins permit the first and second brake shoes to be moved in a radial plane and to rotate about an axis of an opening in the backing plate. The first and second brake shoes each have a first engagement end which is aligned on the backing plate by an anchor post and a second engagement end which is selectively spaced apart by an adjuster mechanism. A spring arrangement urges the first and second brake shoes toward the anchor post and into engagement with the adjuster mechanism. An actuator assembly is connected to the first engagement end of the first and second brake shoes and upon receiving an input force moves first and second friction pads associated with the first and second brake shoes into radial engagement with a drum. The radial engagement causes the first and second brake pads to rotate and bring one of the first engagement ends into contact with the anchor post. The anchor post provides resistance to the rotation of the first and second brake pads during a corresponding brake application. The anchor post is characterized by a projection that extends from a wheel bearing housing fixed to a cast knuckle for a suspension system of the vehicle to provide a direct link between a fixed support in the vehicle and the first and second pads to resist rotative torque developed through the engagement of the friction pads with the drum during a brake application.

Growing community of inventors

Canton, MI, United States of America

David Thomas Sadanowicz