Meritor Heavy Vehicle Technology, LLC

Arvin Meritor Technology, LLC

Meritor Heavy Vehicle Systems Limited

John L Bennett

Tomaz Dopico Varela

Mark Smith

William Carl Sullivan

Dean M House

John K Ma

Edward Jay Eshelman

Chihping Kuan

Robert J Martin

Dale K Bell

David K Platner

Ronald N Brissette

Michael E Johnson

Tom Sanko

Jyh-Chiang Wang

Herbert A Larsen

A two-speed transfer case includes an input shaft that is driven by a vehicle engine, a first output shaft that is coupled to a rear axle, and a second output shaft that is coupled to a front axle. The transfer case also includes a high range gear set and a low range gear set. The high range gear set includes a first gear supported on the input shaft and a second gear supported on the first output shaft. The low range gear set includes a third gear supported on the input shaft and a fourth gear supported on the second output shaft. A shifting mechanism cooperates with the second and fourth gears and the first and second output shafts to provide a plurality of operational output configurations. The shifting mechanism is integrated into a housing that substantially encloses the input shaft and the first and second output shafts.

Two-speed transfer case with integrated declutch

A vehicle drive assembly includes an integrated two-speed motor that can selectively drive an output at a high operating speed or a low operating speed. The two-speed motor includes a stator mounted to a non-rotating outer housing, and a rotor that is mounted for rotation relative to the stator. The rotor is supported an inner rotor support that defines an inner cavity. A two-speed shifting mechanism is incorporated into the inner cavity and is used to drive an output. The two-speed shifting mechanism includes a gear assembly and first and second clutch assemblies that cooperate with each other to provide low and high speed output capability as needed.

Integrated two-speed motor

A wheel end assembly includes an output shaft that is directly mountable to a wheel adapter to drive a vehicle wheel. A gear assembly is coupled to the output shaft to transfer driving force from an input to the output shaft. The gear assembly includes an output gear that is directly coupled to the output shaft. Thus, the wheel adapter and output gear are both supported directly on the output shaft. The gear assembly and output shaft are substantially enclosed within a housing that is mounted to a non-rotating vehicle component. The output shaft is solely supported by a pair of bearings for rotation relative to the housing. The bearings are installed for direct engagement with the output shaft and housing.

Vehicle wheel end assembly with wheel adapter

An axle assembly includes a first and a second electric motor which drive a gearbox assembly substantially therebetween. The electric motors drive the gearbox assembly which drives the vehicle wheels through a first and second axle shaft located along a first axis. The electric motors are located along axes which are substantially transverse to the first axis. The electric motors drive the gearbox assembly which includes a first stage gear reduction, a second stage gear reduction and a third stage gear reduction. A relatively lightweight and compact axle assembly is thereby provided which will benefit from an electric motor of reduced size.

Axle assembly with transverse mounted electric motors

An axle assembly includes a first and a second electric motor which drive a gearbox assembly substantially therebetween. The electric motors drive the gearbox assembly which drives the vehicle wheels through a first and second axle shaft located along a first axis. The electric motors are located along axes which are substantially parallel to the first axis. The electric motors drive the gearbox assembly which includes a first stage gear reduction, a second stage gear reduction and a third stage gear reduction. A relatively lightweight and compact axle assembly is thereby provided which will benefit from an electric motor of reduced size.

Axle assembly with parallel mounted electric motors

A gearbox assembly includes a housing which contains a differential gear set and a two-speed reduction gear set. A spider drives differential pinion gears nested between outer pinion gears. A first and a second clutch that can be engaged 'on the fly' achieve the two-speed functionally of the gearbox assembly. Another gearbox assembly includes an on-demand locking differential with a differential clutch located between differential axle side gears to selectively lock the differential axle side gears together and thereby lock the axle shafts.

Two-speed gearbox with integrated differential

A suspension system includes a swing arm which pivots about a pivot axis. A hub assembly, hub gear box and input gear box are mounted to an independently pivoting swing arm. The pivot axis is located closer to the ground than a rotational axis defined by the hub assemblies and the input gear box. A coupling extends from the input gear box to receive an input driveline from a drive source such as vehicle engine. The coupling is located proximate the pivot axis to minimize relative movement during articulation of the swing arm. An axle housing extends between the input gear box and an opposite hub gear box to support a drive shaft and serves as a torsion bar.

Semi-independent swing arm suspension system for a low floor vehicle

A drive axle assembly for a low floor vehicle utilizes a single input gear assembly to drive a pair of laterally spaced wheel ends. The input gear assembly is positioned next to one of the wheel ends so that the vehicle floor can be lowered to facilitate passenger access to the vehicle. Each wheel end includes a gear reduction assembly with a ring gear rotatably mounted within a gear housing. A drive gear is operatively coupled to the input gear assembly and is in meshing engagement with the ring gear. The gear reduction assembly also includes an output or driven gear, which is larger than the drive gear, to provide the desired gear reduction. The driven gear is also in meshing engagement with the ring gear. A pair of idler gears is rotatably mounted within the gear housing and are in meshing engagement with both the drive and driven gear. The idler gears and drive gear do not have a common centerline. The assembly thus provides toothed contact via three gear sets combinations, which equalizes loading and eliminates the need for support bearings for the drive and driven gears.

Planetary drive assembly with idlers for low floor vehicle

A method of fabricating a driveline assembly including the steps of inserting a first member within a second member, heating the first member to a temperature greater than that of the second member and inserting both members into a die. The inner surface of the die includes an interlocking torque transferring profile. Fluid pressure is applied to the inner diameter of the inner member to expand both members into the profile on the inner surface of the die. The inner and outer members are then removed from the die and cooled such that both members are at a common temperature. Because the inner member was at an elevated temperature, and thereby expanded a greater amount than the outer member, cooling of the members results in a clearance between the members that provides for relative axial movement between the inner and outer members.

Drive shaft manufacturing process

A drive unit assembly utilizes a single input to drive a pair of laterally spaced wheel ends. Each wheel end is suspended independently from the other. The input is operatively coupled to only one of the wheel ends and an exposed axle shaft assembly interconnects the input to the opposite wheel end. The axle shaft assembly includes multiple shaft members to interconnect the laterally spaced wheel ends. One of the axle shaft members is mounted to a vehicle floor structure with a bearing mount and includes connection joints at either end to accommodate the independent motion of each wheel end. The floor and the shaft member move together during suspension travel, allowing the floor to have a lower profile than is traditionally available.

Drive assembly for low floor vehicle

A steer axle for a heavy duty vehicle is provided including an axle assembly having an axle housing. A steer knuckle is connected to an end portion of the axle housing by king pins. The steer knuckle rotates relative to the axle housing about the king pins. A wheel end assembly including a brake drum and a pair of brake shoes is supported on an outer wall of the steer knuckle. Preferably, one end of a cam shaft is supported by the wheel end assembly, such as by a spindle. According to the present invention, the steer knuckle includes a boss extending from a portion of the steer knuckle. The boss includes a hole, and preferably, a bushing is received in the hole to support the other end of the cam shaft. Other brake components such as an air chamber, rod, and a brake adjuster are supported by the knuckle and connected to the cam shaft to rotate the cam shaft about its axis and force the brake shoes away from one another with a cam and into engagement with the brake drum.

Steer knuckle with integrated cam support

An improved transfer case has fewer parts than the prior art to achieve the pneumatic three-position function. In the prior art the pneumatic cylinders were provided by bolt-on housings which required additional components to achieve a fluid tight connection. The present invention incorporates its fluid cylinders within bores formed into the transfer case housings. In this way, the required number of housing components is greatly reduced compared to the prior art.

Pneumatic three-position shift mechanism with fewer components

An improved press fit joint is particularly useful for iron parts. An outer part receives an inner part which is press fit into a bore in the outer part. The outer part has a hole, and the inner part has a dimple which is aligned with the hole when the inner part is forced into the outer part. The dimple has a dimension which is greater than the dimension of the hole. A puddle weld is formed within the hole and in the dimple. The puddle weld thus provides a secondary retention holding the inner part within the outer part.

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Fraser, MI, United States of America

John L Bennett