DESC:TECHNICAL FIELD
[001] This disclosure relates generally to lift axles, and more particular to a vehicle lift axle beam having a bend in the middle and formed using two halves and a process of the manufacturing the vehicle lift axle beam.

BACKGROUND
[002] A lift axle is a non-fixed axle used in commercial vehicles that can be retracted or lifted based on the vehicle and the requirement. Various different lift axle designs are known which are based on method of retraction, steering capability, and additional safety features. For example, pneumatic and hydraulic systems can be used for deploying and retracting the lift axles. In the pneumatic and hydraulic systems, a change in pressure (hydraulic fluid pressure or air pressure) ‘loads’ and ‘unloads’ the lift-able axle. Increased pressure lowers the lift axle, as a result of which the tires associated with the lift axle start contacting the road surface. When the tires contact the road surface, the lift axle begins to support a part of the total vehicle load. The greater the pressure applied to the lift axle mechanism, the greater is the load supported by the lift axle. Controls for raising and lowering the lift axle or regulating the load carried by the lift axle can be installed in various ways. For example, some installations include automatic load sensing valve/device for deployment or retraction of the lift axle. Some other installations include manual controls for retraction or deployment operable via a switch operated by the driver.
[003] The existing lift axles include a tubular beam (which may be manufactured via a cold drawn process or a hot drawn process or casting) with welded saddle at the top and bottom of the tubular beam. Further, the existing tubular beams do not have sufficient strength to overcome the various bending, torsional, and shear stresses acting on the beam.
[004] There is, therefore, a need to form a tubular lift axle beam having enough strength to overcome the stresses acting on the beam, and further allows for mounting of brackets to locate and clamp lift axle lower arm.

SUMMARY OF THE INVENTION
[005] In an embodiment, a vehicle lift axle beam is disclosed. The vehicle lift axle beam may include a bottom axle-half defining an elongated structure extending between a first-end and a second-end. The bottom axle-half may define a first cross-section profile across a middle region, a first saddle region near the first-end, and a second saddle region near the second-end of the bottom axle-half. The bottom axle-half further may define a second cross-section profile at the first-end and the second-end of the bottom axle-half. The vehicle lift axle beam may further includes a top axle-half defining an elongated structure extending between a first-end and a second-end. The top axle-half may define a first cross-section profile across a middle region, a first saddle region near the first-end, and a second saddle region near the second-end of the top axle-half. The top axle-half may further define a second cross-section profile at the first-end and the second-end of the top axle-half. The top axle-half may be attached to the bottom axle-half to create the vehicle lift axle beam. The vehicle lift axle beam may define a third cross section profile across a middle region, a first saddle region near a first-end, and a second saddle region near a second-end of the vehicle lift axle beam. The third cross section profile may be a combination of the first cross-section associated with the bottom axle-half and the first cross-section associated with the top axle-half. The vehicle lift axle beam may further define a fourth cross section profile at the first-end and the second-end of the vehicle lift axle beam. The fourth cross section may be a combination of the second cross-section associated with the bottom axle-half and the second cross-section associated with the top axle-half.
[006] In an embodiment, a process of manufacturing a vehicle lift axle beam is disclosed. The process may include forming a bottom axle-half via a single-stage forming process. The single stage forming process may be for imparting a variable cross-section profile and a bend in a middle region to a sheet to create the bottom axle-half. The process may further include forming a top axle-half via a two-stage forming process. The two-stage forming process may include a first-stage forming process performed on a sheet for imparting a variable cross-section profile to the sheet to create a linear structure having the variable cross-section profile and a second-stage reverse forming process performed on the linear body having the variable cross-section profile for imparting a bend in a middle region, to create the top axle-half having the variable cross-section profile and the bend in the middle region. The process may further include attaching the top axle-half to the bottom axle-half to create the vehicle lift axle beam. The vehicle lift axle beam may defines a third cross section profile across a middle region, a first saddle region near a first-end, and a second saddle region near a second-end of the vehicle lift axle beam and a fourth cross section profile at the first-end and the second-end of the vehicle lift axle beam.

BRIEF DESCRIPTION OF THE DRAWINGS
[007] The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and, together with the description, serve to explain the disclosed principles.
[008] FIG. 1 illustrates a perspective view of a vehicle chassis including a lift axle assembly, in accordance with some embodiments of the present disclosure.
[009] FIG. 2A illustrates a perspective view of the lift axle assembly (assembled), in accordance with some embodiments.
[010] FIG. 2B illustrates a perspective view of the lift axle assembly (assembled), in accordance with some embodiments.
[011] FIG. 3 illustrates an exploded view of the vehicle lift axle beam, in accordance with some embodiments.
[012] FIG. 4A illustrates an exploded view of the lift axle assembly including the vehicle lift axle beam (assembled) in accordance with some embodiments.
[013] FIG. 4B illustrates a magnified view of the lift axle assembly including the vehicle lift axle beam (assembled) in accordance with some embodiments.
[014] FIG. 4C illustrates a perspective view of the lift axle assembly including the vehicle lift axle beam (assembled) and wheel spindles, in accordance with some embodiments.
[015] FIG. 5 is a flowchart of a process of manufacturing the vehicle lift axle beam is illustrated, in accordance with some embodiments.

DETAILED DESCRIPTION OF THE DRAWINGS
[016] Exemplary embodiments are described with reference to the accompanying drawings. Wherever convenient, the same reference numbers are used throughout the drawings to refer to the same or like parts. While examples and features of disclosed principles are described herein, modifications, adaptations, and other implementations are possible without departing from the spirit and scope of the disclosed embodiments. It is intended that the following detailed description be considered as exemplary only, with the true scope and spirit being indicated by the following claims. Additional illustrative embodiments are listed below.
[017] A commercial vehicle or any other high-load capacity vehicle generally includes multiple number of axles including one or more lift axles. For example, these vehicles may include two front axles (i.e. a first front axle and a second front axle) one lift axle. The lift axle may include a beam and two wheel assemblies (i.e. a left wheel assembly and a right wheel assembly) attached to the left and right ends of the beam. The beam may further include brake assemblies associated with the two wheel assemblies. The brake assemblies may be externally attached to the beam, for example, using brackets and fasteners (e.g. nut-bolts, screws, etc.). The beam, for example, may have a hollow tubular configuration and may be manufactured via a cold drawn process or a hot drawn process or casting with welded saddle at the top and bottom of the beam. The existing beams (i.e. the vehicle lift axle beams) may not have sufficient strength to bear with the various bending, torsional, and shear stresses acting thereon.
[018] To this end, a vehicle lift axle beam is disclosed that may include a bottom axle-half defining an elongated structure extending between a first-end and a second-end. The bottom axle-half may define a first cross-section profile across a middle region, a first saddle region near the first-end, and a second saddle region near the second-end of the bottom axle-half. The bottom axle-half further may define a second cross-section profile at the first-end and the second-end of the bottom axle-half. The vehicle lift axle beam may further include a top axle-half defining an elongated structure extending between a first-end and a second-end. The top axle-half may define a first cross-section profile across a middle region, a first saddle region near the first-end, and a second saddle region near the second-end of the top axle-half. The top axle-half may further define a second cross-section profile at the first-end and the second-end of the top axle-half. The top axle-half may be attached to the bottom axle-half to create the vehicle lift axle beam. The vehicle lift axle beam may define a third cross section profile across a middle region, a first saddle region near a first-end, and a second saddle region near a second-end of the vehicle lift axle beam. The third cross section profile may be a combination of the first cross-section associated with the bottom axle-half and the first cross-section associated with the top axle-half. The vehicle lift axle beam may further define a fourth cross section profile at the first-end and the second-end of the vehicle lift axle beam. The fourth cross section may be a combination of the second cross-section associated with the bottom axle-half and the second cross-section associated with the top axle-half.
[019] Referring now to FIG. 1, a perspective view of a vehicle chassis 100 including a lift axle assembly 102 is illustrated, in accordance with some embodiments of the present disclosure. The chassis 100 may be associated with a commercial vehicle or any other high-load capacity vehicle. As such, the chassis 100 may include a first front axle assembly 104 and a second front axle assembly 106. The chassis 100 may further include the lift axle assembly 102.
[020] Referring to FIGs. 2A-2B, a perspective view of the lift axle assembly 102 (assembled), and a perspective view of the lift axle assembly 102 including the vehicle lift axle beam 202 (assembled), respectively are illustrated, in accordance with some embodiments. As shown in FIGs. 2A-2B, the lift axle assembly 102 may include a vehicle lift axle beam 202 (also referred to as beam 202 in this disclosure). The vehicle lift axle beam 202, for example, may have a hollow tubular configuration and may be manufactured via a cold drawn process or a hot drawn process or casting with welded saddle at the top and bottom of the vehicle lift axle beam 202. Further, as shown in FIG. 2A, the lift axle assembly 102 may include a kit assembly 208.
[021] As mentioned above, the existing vehicle lift axle beam may not have sufficient strength to bear with the various bending, torsional, and shear stresses acting thereon. To this end, the lift axle assembly 102 may further include two wheel assemblies - a left wheel assembly 204A and a right wheel assembly 204B attached to the left and right ends of the vehicle lift axle beam 202. The lift axle assembly 102 may further include a brake assembly associated with each of the left wheel assembly 204A and the right wheel assembly 204B. in particular, as shown in FIG. 2, the lift axle assembly 102 may further a left brake assembly 206A associated with the left wheel assembly 204A and a right brake assembly 206B associates with the right wheel assembly 204B.
[022] Referring now to FIG. 3, an exploded view of the vehicle lift axle beam 202 is illustrated, in accordance with some embodiments. The vehicle lift axle beam 202, as shown in FIG. 3, may include a bottom axle-half 302 and a top axle half 304. The bottom axle-half 302 and the top axle half 304 may be manufactured individually and then later attached to each other to create the vehicle lift axle beam 202. The vehicle lift axle beam 202 is a drop-type axle beam for lift axle system, especially, for multi-axle commercial vehicles (i.e. vehicles with three or more axles).
[023] In particular, the bottom axle-half 302 may be manufactured via a single-stage forming process. The single stage forming process may impart a variable cross-section profile and a bend in a middle region to a sheet to create the bottom axle-half 302. The top axle-half 304 may be formed via a two-stage forming process that may include a first-stage forming process and a second-stage reverse forming process. The first-stage forming process may be performed on a sheet for imparting a variable cross-section profile to the sheet to create a linear structure having the variable cross-section profile. Thereafter, the second-stage reverse forming process may be performed on the linear body having the variable cross-section profile for imparting a bend in a middle region, to create the top axle-half 304 having the variable cross-section profile and the bend in the middle region.
[024] The bottom axle-half 302 and the top axle-half 304 are unsymmetrical members that may be welded along the length at an interface, to create the vehicle lift axle beam 202. The vehicle lift axle beam 202 may be integrated with the suspension system of the vehicle including a lift axle trailing arm. Further, as will be explained in the subsequent sections of this disclosure, various brackets may be attached (e.g. welded) to the vehicle lift axle beam 202.
[025] As such, the bottom axle-half 302 may define an elongated structure that may extend between a first-end 302A and a second-end 302B. The bottom axle-half 302 may include the first-end 302A (i.e. a region at the first-end 302A), a first saddle region 306A near the first-end 302A, middle region 308, a second saddle region 306B near the second-end 302B of the bottom axle-half 302, and the second-end 302B (i.e. a region at the second-end 302B). Further, as shown in FIG. 3, the bottom axle-half 302 may define a bend in the middle region 308 of the bottom axle-half 302. This bend in the middle region 308 may allow the positioning of the drive shaft which otherwise might be coinciding within the positioning of the vehicle lift axle beam 202. The bend at the middle region therefore provides for clearance with propeller shaft and ground clearance.
[026] The bottom axle-half 302 may define a first cross-section profile across the middle region 308, the first saddle region 306A near the first-end 302A, and the second saddle region 306B near the second-end 302B of the bottom axle-half 302. In some embodiments, the first cross-section profile across the middle region 308, the first saddle region 306A near the first-end 302A, and the second saddle region 306B near the second-end 302B of the bottom axle-half 302 may be is a U-shaped cross-section profile. The first cross-section profile may be defined along a predefined length L2 of the bottom axle-half 302 extending between the first-end 302A and the middle region 308, and along a predefined length L2 of the bottom axle-half 302 extending between the second-end 302B and the middle region 308. In particular, the first cross-section profile may be a polygonal-like cross section which may include two or more corners. For example, as shown in FIG. 3, the first cross-section profile may be square-like or a rectangle-like cross section having two corners.
[027] The bottom axle-half 302 may further define a second cross-section profile at the first-end 302A and the second-end 302B of the bottom axle-half 302. As such, the second cross-section profile may be defined at the region at the first-end 302A and the region at the second-end 302B. In other words, the second cross-section profile may be defined along a predefined length L1 of the bottom axle-half 302 extending from the extreme first-end 302A along a predefined length L1 of the bottom axle-half 302 extending from the extreme second-end 302B. In some embodiments, the second cross-section profile at the first-end 302A and the second-end 302B of the bottom axle-half 302 may be a C-shaped cross-section profile. In other words, the second cross-section profile may be semi-circular shaped profile.
[028] The top axle-half 304 may define an elongated structure extending between a first-end 304A and a second-end 304B. The top axle-half 304 may include a the first-end 304A, a middle region 312, a first saddle region 306A near the first-end 304A, a second saddle region 306B near the second-end 304B, and the second-end 304B of the top axle-half 304. Further, as shown in FIG. 3, the top axle-half 304 may define a bend in the middle region 312 of the top axle-half 304. This bend in the middle region 312 may allow the positioning of the drive shaft which otherwise might be coinciding within the positioning of the vehicle lift axle beam 202.
[029] The top axle-half 304 may define a first cross-section profile across the middle region 312, the first saddle region 310A near the first-end 304A, and the second saddle region 310B near the second-end 304B of the top axle-half 304. The first cross-section profile may be defined along a predefined length L2 of the top axle-half 304 extending between the first-end 304A and the middle region 312, and along a predefined length L2 of the top axle-half 304 extending between the second-end 304B and the middle region 312. In some embodiments, the first cross-section profile across the middle region 312, the first saddle region 310A, and the second saddle region 310B of the top axle-half 304 may be a U-shaped cross-section profile. In particular, the first cross-section profile may be a polygonal-like cross section which may include two or more corners. For example, as shown in FIG. 3, the first cross-section profile may be square-like or a rectangle-like cross section having two corners.
[030] The top axle-half 304 may further define a second cross-section profile at the first-end 304A and the second-end 304B of the top axle-half 304. As such, the second cross-section profile may be defined at the region at the first-end 304A and the region at the second-end 304B. In other words, the second cross-section profile may be defined along a predefined length L1 of the top axle-half 304 extending from the extreme first-end 304A, and along a predefined length L1 of the top axle-half 304 extending from the extreme second-end 304B. In some embodiments, the second cross-section profile at the first-end 304A and the second-end 304B of the top axle-half 304 may be a C-shaped cross-section profile. In other words, the second cross-section profile may be semi-circular shaped profile.
[031] Referring now to FIGs. 4A-4C. FIG. 4A illustrates an exploded view of the lift axle assembly 102 including the vehicle lift axle beam 202 (assembled) in accordance with some embodiments. FIG. 4B illustrates a magnified view of the lift axle assembly 102 including the vehicle lift axle beam 202 (assembled) in accordance with some embodiments. FIG. 4C illustrates a perspective view of the lift axle assembly 102 including the vehicle lift axle beam 202 (assembled) and wheel spindles in accordance with some embodiments.
[032] As shown in FIGs. 4A, 4C, when assembled, the vehicle lift axle beam 202 may define a first-end 402A, a second-end 402B, a first saddle region 404A near the first-end 402A, a middle region 406, and a second saddle region 404B near the second-end 402B. The vehicle lift axle beam 202, when assembled, may define a third cross section profile across the middle region 406, the first saddle region 404A, and the second saddle region 404B of the vehicle lift axle beam 202. The third cross section profile may be a combination of the first cross-section associated with the bottom axle-half 302 and the first cross-section associated with the top axle-half 304. The first cross-section profile may be defined along the predefined length L2 of the bottom axle-half 302 and the top axle-half 304 extending between the first-end 302A, 304A and the middle region 308, 312, and the predefined length L2 of the bottom axle-half 302 and the top axle-half 304 extending between the first-end 302A, 304A and the middle region 308, 312. As such, the third cross section profile the middle region 406, the first saddle region 404A, and the second saddle region 404B of the vehicle lift axle beam 202 may be is a polygonal cross-section profile. For example, as shown in FIGs. 4A, 4C, the third cross section profile may be substantially square profile.
[033] The vehicle lift axle beam 202, when assembled, may further define a fourth cross section profile at the first-end 402A (i.e. at a region at the first-end 402A) and the second-end 402B (i.e. a region at the second-end 402B) of the vehicle lift axle beam. In other words, the second cross-section profile may be defined along the predefined length L1 of the top axle-half 304 extending from the extreme first-end 304A along a predefined length L1 of the top axle-half 304 extending from the extreme second-end 304B. The fourth cross section may be a combination of the second cross-section associated with the bottom axle-half 302 and the second cross-section associated with the top axle-half 304. As such, the fourth cross section profile at the first-end 402A and the second-end 402B of the vehicle lift axle beam 202 may be a circular cross-section profile. The circular ends may be used to connect spindles through friction weld. Further, the spindles may facilitate mounting of wheel assemblies and mounting of torque plates for brake assembly.
[034] As shown in FIGs. 4A, 4C, the vehicle lift axle beam 202 may be configured to support a wheel assembly (also referred to as wheel end) assembly at each of the left-end and the right-end. The fourth cross section profile at the first-end 402A and the second-end 402B of the vehicle lift axle beam 202 may be configured to connect with a spindle 408A, 408B, respectively (the spindle 408A associated with the first-end 402A and the spindle 408B associated with the second-end 402B). In some embodiments, the fourth cross section profile at the first-end 402A and the second-end 402B may be connected with the spindles 408A, 408B, respectively via a friction weld. The spindles 408A, 408B may facilitate mounting of the wheel assemblies 204A, 204B, respectively.
[035] In some embodiments, the vehicle lift axle beam 202 may further include a front bracket and a back bracket configured to be attached at each of the first saddle region and the second saddle region of the vehicle lift axle beam 202. In particular, the vehicle lift axle beam 202 may include a front bracket 410A and a back bracket 412A configured to be attached at the first saddle region 404A of the vehicle lift axle beam. Further, the vehicle lift axle beam 202 may include a front bracket 410B and a back bracket 412B configured to be attached at the second saddle region 404B of the vehicle lift axle beam 202.
[036] In some embodiments, the front brackets 410A, 410B and a back brackets 412A, 412B may be configured to be attached at each of the first saddle region 404A and the second saddle region 404B (along the sides), respectively, via welding. It should be noted that the front brackets 410A, 410B and the back brackets 412A, 412B may facilitate mounting of top bracket assemblies and bottom bracket assemblies. In particular, the front bracket 410A and the back bracket 412A may facilitate mounting of a top bracket assembly 414A and a bottom bracket assembly 416A. The front bracket 410B and the back bracket 412B may facilitate mounting of a top bracket assembly 414B and a bottom bracket assembly 416B. It should be noted that the top bracket assemblies 414A, 414B and the bottom bracket assemblies 416A, 416B may facilitate mounting of respective brake assemblies.
[037] In some embodiments, each of the top bracket assemblies 414A, 414B may be configured to be integrated with a bump stopper (not shown in FIGs. 4A-4C). Further, in some embodiments, each of the top bracket assemblies 414A, 414B may be configured to mount a rebound chain (not shown in FIGs. 4A-4C). Furthermore, in some embodiments, each of the top bracket assemblies 414A, 414B may be further configured to facilitate a joint between the front bracket and the back bracket to thereby provide torsional rigidity. In particular, the top bracket assembly 414A may facilitate a joint between the front bracket 410A and the back bracket 412A to thereby provide torsional rigidity. The top bracket assembly 414B may facilitate a joint between the front bracket 410B and the back bracket 412B to thereby provide torsional rigidity.
[038] In some embodiment, each of the top bracket assemblies 414A, 414B may be configured to be fastened with the front bracket and the back bracket via a set of bolts. As such, the top bracket assembly 414A may be configured to be fastened with the front bracket 410A and the back bracket 412A via a set of bolts 418 (for example, two bolts, as shown in FIG. 4A). The top bracket assembly 414B may be configured to be fastened with the front bracket 410B and the back bracket 412B via a set of bolts 418 (for example, two bolts, as shown in FIG. 4A). In some embodiments, positive locking may be provided to the bolt-heads of the bolts 418 to prevent anti rotation of the bolt during tightening. In some embodiments, as shown in FIGs. 4A, 4C, the lift axle assembly 102 may include brake torque plates 428A, 428B positioned towards the first-end 402A and the second-end 402B, respectively.
[039] Referring now to FIG. 4B, a magnified view of a section (A) of the lift axle assembly 102 showing the bottom bracket assembly 416 and the back bracket 412B is illustrated, in accordance with some embodiments. In some embodiments, each of the bottom bracket assemblies 416A, 416B may include an outer front-side flange and an outer back-side flange. The bottom bracket assemblies 416A, 416B may include a dowel arrangement at the respective outer front-side flange and an outer back-side flange to facilitate mounting of the front bracket and the back bracket. For example, as shown in FIGs. 4A, 4C, the bottom bracket assembly 416B may include an outer front-side flange 420 and an outer back-side flange 422. As such, the bottom bracket assembly 416B may include a dowel arrangement 424 at the outer front-side flange 420 and a dowel arrangement 426 at the outer back-side flange 422 to facilitate mounting of the front bracket 410B and the back bracket 412B. The bottom bracket assemblies 416A, 416B may facilitate mounting of the locating dowel at center, to thereby position a lower arm at the center to eliminate axle skewness.
[040] Referring now to FIG. 5, a flowchart of a process 500 of manufacturing the vehicle lift axle beam 202 is illustrated, in accordance with some embodiments. The process 600 is explained in conjunction with FIGs. 2-4.
[041] At step 502, the bottom axle-half 302 may be formed via a single-stage forming process. The single stage forming process may impart a variable cross-section profile and a bend in the middle region 308 to a sheet to create the bottom axle-half 302. It should be noted that the bottom axle-half 302 may define an elongated structure extending between the first-end 302A and the second-end 302B. The bottom axle-half 302 may define the first cross-section profile across the middle region 308, the first saddle region 306A near the first-end 302A, and a second saddle region 306B near the second-end 302B of the bottom axle-half 302. The bottom axle-half 302 may further define the second cross-section profile at the first-end 302A and the second-end 302B of the bottom axle-half 302. As mentioned above, the first cross-section profile across the middle region 308, the first saddle region 306A, and the second saddle region 306B of the bottom axle-half 302 may be a U-shaped cross-section profile. Further, the second cross-section profile at the first-end 302A and the second-end 302B of the bottom axle-half 302 may be a C-shaped cross-section profile.
[042] The single-stage forming process for forming the bottom axle-half 302 may include performing a drop operation or performing a bending process in same direction, using a die.
[043] At step 504, the top axle-half 304 may be formed via a two-stage forming process. The top axle-half 304 may define an elongated structure extending between the first-end 304A and the second-end 304B. The two-stage forming process may include a first-stage forming process performed on a sheet for imparting the variable cross-section profile to the sheet to create a linear structure having the variable cross-section profile. The first-stage forming process may include a channel hot forming process, performed using a die. As will be appreciated, this die may be common for both the bottom axle-half 302 and the top axle-half 304.
[044] The two-stage forming process may further include a second-stage reverse forming process performed on the linear body (obtained as a result of the first-stage forming process) having the variable cross-section profile for imparting the bend in the middle region 312, to create the top axle-half 304 having the variable cross-section profile and the bend in the middle region 312. The second-stage reverse forming process may be based on a drop cold forming or a bending cold forming process.
[045] By way of an example, the material for the bottom axle-half 302 and the top axle-half 304 may be “SAILMA 450” having 16 mm thickness, yield strength of 460 Mega Pascal (MPa), tensile strength of 570 Mpa. The cold forming process may be performed at a die speed of 11 mm/sec for a time period of 150 mm roller travel. A die lubricant having a friction coefficient of 0.12 may be used.
[046] The axle-half 304 may define the first cross-section profile across the middle region 312, the first saddle region 310A near the first-end 304A, and the second saddle 310B region near the second-end 304B of the top axle-half 304. The top axle-half 304 may further define the second cross-section profile at the first-end 304A and the second-end 304B of the top axle-half 304. As mentioned above, the first cross-section profile across the middle region 312, the first saddle region 310A, and the second saddle region 310B of the top axle-half 304 may be a U-shaped cross-section profile. Further, the second cross-section profile at the first-end 304A and the second-end 304B of the top axle-half 304 may be a C-shaped cross-section profile.
[047] At step 506, the top axle-half 304 may be attached to the bottom axle-half 302 to create the vehicle lift axle beam 202. For example, the top axle-half 304 may be attached to the bottom axle-half 302 via welding. The vehicle lift axle beam 202 may define the third cross section profile across a middle region 406, the first saddle region 404A near a first-end 402A, and a second saddle region 404B near a second-end 402B of the vehicle lift axle beam 202. The third cross section profile across the middle region 406, the first saddle region 404A, and the second saddle region 404B of the vehicle lift axle beam 202 may be a polygonal cross-section profile. The vehicle lift axle beam 202 may further define the fourth cross section profile at the first-end 402A and the second-end 402B of the vehicle lift axle beam 202. The fourth cross section profile at the first-end 402A and the second-end 402B of the vehicle lift axle beam 202 may be a circular cross-section profile.
[048] It is intended that the disclosure and examples be considered as exemplary only, with a true scope and spirit of disclosed embodiments being indicated by the following claims.
,CLAIMS:We claim:
1. A vehicle lift axle beam (202) comprising:
a bottom axle-half (302) defining an elongated structure extending between a first-end (302A) and a second-end (302B), the bottom axle-half (302) further defining:
a first cross-section profile across a middle region (308), a first saddle region (306A) near the first-end (302A), and a second saddle region (306B) near the second-end (302B) of the bottom axle-half (302); and
a second cross-section profile at the first-end (302A) and the second-end (302B) of the bottom axle-half (302); and
a top axle-half (304) defining an elongated structure extending between a first-end (304A) and a second-end (304A), the top axle-half (304) further defining:
a first cross-section profile across a middle region (312), a first saddle region (310A) near the first-end (304A), and a second saddle region (310B) near the second-end (304B) of the top axle-half (304); and
a second cross-section profile at the first-end (304A) and the second-end (304B) of the top axle-half (304); and
wherein the top axle-half (304) is attached to the bottom axle-half (302) to create the vehicle lift axle beam (202), wherein the vehicle lift axle beam (202) defines:
a third cross section profile across a middle region (406), a first saddle region (404A) near a first-end (402A), and a second saddle region (404B) near a second-end (402A) of the vehicle lift axle beam (202), wherein the third cross section profile is a combination of the first cross-section associated with the bottom axle-half (302) and the first cross-section associated with the top axle-half (304); and
a fourth cross section profile at the first-end (402A) and the second-end (402B) of the vehicle lift axle beam (202), wherein the fourth cross section is a combination of the second cross-section associated with the bottom axle-half (302) and the second cross-section associated with the top axle-half (304).

2. The vehicle lift axle beam (202) as claimed in claim 1, wherein the first cross-section profile across the middle region (308, 312), the first saddle region (306A, 310A) near the first-end (302A, 304A), and the second saddle region (306B, 310B) near the second-end (302B, 304B) of the bottom axle-half (302) and the top axle-half (304) is a U-shaped cross-section profile.

3. The vehicle lift axle beam (202) as claimed in claim 1, wherein the second cross-section profile at the first-end (302A, 304A) and the second-end (302B, 304B) of the bottom axle-half (302) and the top axle-half (304) is a C-shaped cross-section profile.

4. The vehicle lift axle beam (202) as claimed in claim 1, wherein the third cross section profile across the middle region (406), the first saddle region (404A) near the first-end (402A), and the second saddle (404B) region near the second-end (402B) of the vehicle lift axle beam (202) is a polygonal cross-section profile.

5. The vehicle lift axle beam (202) as claimed in claim 1, wherein the fourth cross section profile at the first-end (402A) and the second-end (402B) of the vehicle lift axle beam (202) is a circular cross-section profile.

6. The vehicle lift axle beam (202) as claimed in claim 5, wherein the fourth cross section profile at the first-end (402A) and the second-end (402B) of the vehicle lift axle beam (202) is configured to connect with a spindle (408A, 408B) via a friction weld, wherein the spindle (408A, 408B) facilitates mounting of a wheel end.

7. The vehicle lift axle beam (202) as claimed in claim 1, wherein the bottom axle-half (302) and the top axle-half (304) further define a bend in the middle region (308, 312) of the bottom axle-half (302) and the top axle-half (304), respectively.

8. The vehicle lift axle beam (202) as claimed in claim 1, further comprising a front bracket (410A, 410B) and a back bracket (412A, 412B) configured to be attached at the first saddle region (404A) and the second saddle region (404B) of the vehicle lift axle beam (202) via welding, wherein the front bracket (410A, 410B) and the back bracket (412A, 412B) facilitate mounting of a top bracket assembly (414A, 414B) and a bottom bracket assembly (416A, 416B), and wherein the top bracket assembly (414A, 414B) and the bottom bracket assembly (416A, 416B) facilitate mounting of a brake assembly (206A, 206B).

9. The vehicle lift axle beam (202) as claimed in claim 8, wherein the top bracket assembly (414A, 414B) is configured to be integrated with a bump stopper, wherein the top bracket assembly (414A, 414B) is further configured to mount a rebound chain, wherein the top bracket assembly (414A, 414B) is further configured to facilitate a joint between the front bracket (410A, 410B) and the back bracket (412A, 412B) to thereby provide torsional rigidity, and wherein the top bracket assembly (414A, 414B) is further configured to be fastened with the front bracket (410A, 410B) and the back bracket (412A, 412B) via a set of bolts.

10. The vehicle lift axle beam (202) as claimed in claim 8, wherein the bottom bracket assembly (416A, 416B) comprises a dowel arrangement at an outer front-side flange and an outer back-side flange to facilitate mounting of the front bracket (410A, 410B) and the back bracket (412A, 412B).

11. The vehicle lift axle beam (202) as claimed in claim 1, wherein the bottom axle-half (302) is formed via a single-stage forming process, wherein the single stage forming process is for imparting a variable cross-section profile and a middle bend to a sheet to create the bottom axle-half (302) having the variable cross-section profile and the bend in the middle region.

12. The vehicle lift axle beam (202) as claimed in claim 7, wherein the top axle-half (304) is formed via a two-stage forming process, wherein the two-stage forming process comprises:
a first-stage forming process on a sheet for imparting a cross-section profile to the sheet to create a linear structure having a variable cross-section profile; and
a second-stage reverse forming process on the linear body having the variable cross-section profile for imparting the bend in the middle region, to create the top axle-half (304) having the variable cross-section profile and the bend in the middle region.

13. A process of manufacturing a vehicle lift axle beam (202), the process comprising:
forming a bottom axle-half (302) via a single-stage forming process, wherein the single stage forming process is for imparting a variable cross-section profile and a bend in a middle region (308) to a sheet to create the bottom axle-half (302);
forming a top axle-half (304) via a two-stage forming process, wherein the two-stage forming process comprises:
a first-stage forming process performed on a sheet for imparting a variable cross-section profile to the sheet to create a linear structure having the variable cross-section profile; and
a second-stage reverse forming process performed on the linear body having the variable cross-section profile for imparting a bend in a middle region (312), to create the top axle-half (304) having the variable cross-section profile and the bend in the middle region (312); and
attaching the top axle-half (304) to the bottom axle-half (302) to create the vehicle lift axle beam (202), wherein the vehicle lift axle beam (202) defines:
a third cross section profile across a middle region (406), a first saddle region (404A) near a first-end (402A), and a second saddle region (404B) near a second-end (402B) of the vehicle lift axle beam (202), and
a fourth cross section profile at the first-end (402A) and the second-end (402B) of the vehicle lift axle beam (202).

14. The process as claimed in claim 13,
wherein the bottom axle-half (302) defines an elongated structure extending between the first-end (302A) and the second-end (302B), the bottom axle-half (302) further defining:
a first cross-section profile across a middle region (308), a first saddle region (306A) near the first-end (302A), and a second saddle region (306B) near the second-end (302B) of the bottom axle-half (302); and
a second cross-section profile at the first-end (302A) and the second-end (302B) of the bottom axle-half (302); and
wherein the top axle-half (304) defines an elongated structure extending between the first-end (302A) and the second-end (302B), the top axle-half (304) further defining:
a first cross-section profile across a middle region (312), a first saddle region (310A) near the first-end (304A), and a second saddle region (310B) near the second-end (304B) of the top axle-half (304); and
a second cross-section profile at the first-end (304A) and the second-end (304B) of the top axle-half (304).