Vehicle chassis assembly

• US 7,559,578 B2
• Filed: 10/17/2005
• Issued: 07/14/2009
• Est. Priority Date: 10/18/2004
• Status: Active Grant

• Current Assignee: Workhorse Group Inc.
• Original Assignee: Workhorse Custom Chassis, LLC (Workhorse Group Inc.)
• Inventors: van Leeve, Dion, van Niekerk, Hennie, Milne, Kelvin, Seaman, Wayne, Eloff, Johann, Francois, Anton
• Primary Examiner(s): Nguyen; John Q.
• Assistant Examiner(s): VERLEY, NICOLE T
• Application Number:
  US11/252,219
• Publication Number:
  US 20060151229A1
• Time in Patent Office: 1,366 Days
• Field of Search: 280/781, 280/124.128, 280/790, 280/683, 280/789, 280/788, 280796-798, 180/296, 180/375, 180/376, 180/378, 180/311, 180/312, 180/89.2, 180/309, 180/89.1, 296/203.1, 296/205
• US Class Current: 280/781
• CPC Class Codes: B60G 2206/011 Modular constructions
• CPC Class Codes: B60G 2206/91 Assembly procedures
• CPC Class Codes: B60G 2300/024 Light trucks
• CPC Class Codes: B60G 2300/38 Low or lowerable bed vehicles
• CPC Class Codes: B60K 13/04 concerning exhaust collecting exhaust gases with central suction systems not forming part of vehicles, e.g. in workshops or tunnels B08B15/002, otherwise along carriageways E01C1/005; extensions for melting snow on roads E01H5/00, E01H6/00; exhaust or silencing apparatus for internal combustion engines per se F01N; pipes, joints or supports therefor F16L
• CPC Class Codes: B60K 17/22 characterised by arrangement, location, or type of main drive shafting, e.g. cardan shaft
• CPC Class Codes: B60K 17/344 having a transfer gear
• CPC Class Codes: B62D 21/02 comprising longitudinally or transversely arranged frame members
• CPC Class Codes: B62D 21/17 forming fluid or electrical conduit means or having other means to accommodate the transmission of a force or signal
• CPC Class Codes: B62D 25/168 Mud guards for utility vehicles
• CPC Class Codes: B62D 25/2054 Load carrying floors for commercial vehicles
• CPC Class Codes: B62D 33/04 Enclosed load compartments ; Frameworks for movable panels, tarpaulins or side curtains side curtains per se B60J5/065; tarpaulins per se B60J7/00, B60P7/04

Abstract

A vehicle chassis assembly includes a frame assembly having a plurality of frame members connected together, a drivetrain, a suspension system, and an exhaust system. The connection of the frame members provides a low-profile configuration for reduced step height and a kick-up portion to allow ascent of steeper inclines. The frame further includes an exhaust pipe supported within a frame member and two castings bolted to removable wheel arches. The exhaust pipe has a circular cross-section that changes to a rectangular cross-section near the back of the chassis assembly.

Claims

1. A vehicle chassis assembly comprising:

a plurality of wheels, each wheel having a rotational axis;

a frame assembly supported by the wheels, wherein a portion of the frame assembly is located below the rotational axis of at least one of the wheels, the frame assembly comprising a plurality of frame members defining a first frame portion and a rear frame portion angling upward with respect to the first frame portion,

wherein the entire rear frame portion is located rearward of all of the plurality of wheels, and the rear frame portion extends upward and rearward from the first frame portion in a cantilever arrangement, and wherein the rear frame portion comprises a first angling frame member and a second angling frame member extending from the first frame portion to a back edge of the chassis assembly in a direction oblique to a centerline of the chassis assembly; and

an exhaust pipe extending longitudinally through the first angling frame member.

2. The vehicle chassis assembly of claim 1, wherein a portion of a top surface of the frame assembly is below the rotational axis of at least one of the wheels, and a portion of the rear frame portion is above the rotational axis of at least one of the wheels.

3. The vehicle chassis assembly of claim 1, wherein the exhaust pipe is supported within the first frame portion and the rear frame portion.

4. The vehicle chassis assembly of claim 1, wherein a portion of the exhaust pipe is cooperatively dimensioned with the first angling frame member.

5. The vehicle chassis assembly of claim 1, further comprising a rectangular frame member having a substantially rectangular cross-section, wherein the exhaust pipe has a rectangular portion having a substantially rectangular cross-section, the rectangular portion of the exhaust pipe dimensioned to fit within the rectangular frame member, wherein the exhaust pipe extends longitudinally through the rectangular frame member.

6. The vehicle chassis assembly of claim 1, wherein the exhaust pipe comprises a first portion having a substantially circular cross-section and a second portion having a substantially non-circular cross-section, the second portion proximate an outlet of the exhaust pipe.

7. The vehicle chassis assembly of claim 6, wherein the second portion of the exhaust pipe has a substantially rectangular cross-section.

8. The vehicle chassis assembly of claim 6, wherein the outlet of the exhaust pipe is at a rear end of the frame assembly.

9. The vehicle chassis assembly of claim 1, wherein the first frame portion further comprises:

an elevated front frame portion;

a lowered middle frame portion located between the front frame portion and the rear frame portion; and

a neck portion connecting the front frame portion to the middle frame portion, the neck portion comprising a goose-neck connection.

10. The vehicle chassis assembly of claim 1, wherein the frame assembly further comprises a casting connected proximate a rear wheel and at least one of the frame members.

11. The vehicle chassis assembly of claim 10, wherein the frame assembly further comprises a wheel arch that is removable from the frame assembly.

12. The vehicle chassis assembly of claim 10, further comprising a suspension system comprising an air bag abutting the casting.

13. The vehicle chassis assembly of claim 10, wherein the casting is connected to the frame member via bolted connections.

14. The vehicle chassis assembly of claim 10, wherein the casting further comprises a flange having bolt holes for bolting to the frame member.

15. The vehicle chassis assembly of claim 10, wherein the casting further comprises a first horizontally-extending flange having bolt holes for bolting to a first frame member and a second vertically-extending flange having bolt holes for bolting to a second frame member.

16. The vehicle chassis assembly of claim 1, further comprising a vehicle drivetrain comprising:

an engine;

a transmission operably coupled to the engine;

a transfer case; and

a connecting shaft operably coupling the transmission to the transfer case, the connecting shaft having a constant-velocity joint.

17. The vehicle chassis assembly of claim 16, wherein the constant-velocity joint enables the connecting shaft to spin without barreling or vibration at an angle of misalignment in the range of from 1°

to 8°

.

18. The vehicle chassis assembly of claim 1, wherein the frame members are arranged in a grid structure.

19. The vehicle chassis assembly of claim 1, wherein one of the frame members has an open bottom and contains the exhaust pipe extending longitudinally therethrough.

20. The vehicle chassis assembly of claim 19, wherein the exhaust pipe is supported within the frame member and extends longitudinally through the frame member.

21. The vehicle chassis assembly of claim 19, wherein the exhaust pipe comprises a first portion having a substantially circular cross-section and a second portion having a substantially non-circular cross-section, the second portion proximate an outlet of the exhaust pipe.

22. The vehicle chassis assembly of claim 1, wherein the first frame portion further comprises a removable cross-member adapted to support a drivetrain component and a structural support member adapted to counteract twisting forces on the frame assembly.

23. The vehicle chassis assembly of claim 1, wherein the first frame portion comprises an elevated front frame portion and a middle frame portion connected to the front frame portion, the front frame portion having two substantially parallel main frame members containing a drivetrain component therebetween, and the frame assembly further comprises an arched bracing member extending between the two main frame members and over the drivetrain component.

24. The vehicle chassis assembly of claim 1, wherein the first frame portion comprises an elevated front frame portion and a middle frame portion connected to the front frame portion, and the frame assembly further comprises a structural support member located at a front end of the frame assembly, the structural support member comprising:

an upper cross-member;

a lower cross-member connected to at least one of the plurality of frame members;

two angling members connecting the upper cross-member to the lower cross-member; and

two prop members depending from the upper cross-member, each of the prop members connected to at least one of the frame members.

25. A vehicle chassis assembly having a front end and a back end, comprising

a first frame portion having a front frame portion and a middle frame portion connected to the front frame portion and having a top surface;

and

a rear frame portion connected to and extending from the middle frame portion and angling upward with respect to the middle frame portion,

the rear frame portion comprising a first angling portion extending rearward from the middle frame portion and angling upward with respect to the middle frame portion at a first angle, and a second angling portion extending rearward from the first angling portion to a rear end of the chassis assembly, the second angling portion angling upward with respect to the middle frame portion at a second angle, the second angle being different from the first angle.

26. The vehicle chassis assembly of claim 25, wherein the front frame portion is positioned above the middle frame portion.

27. The vehicle chassis assembly of claim 26, wherein the front frame portion and the middle frame portion are connected by a neck portion.

28. The vehicle chassis assembly of claim 25, further comprising a first rear wheel having a first rotational axis and second rear wheel having a second rotational axis, wherein the top surface of the middle frame portion is below the first rotational axis and the second rotational axis and a portion of the upwardly-extending rear frame portion is above the first rotational axis and the second rotational axis.

29. The vehicle chassis assembly of claim 25, wherein the first angle is smaller than the second angle, such that the second angled portion angles more sharply upward with respect to the middle frame portion than the first angled portion.

30. A vehicle chassis assembly comprising:

a frame assembly comprising a plurality of frame members, including a rectangular frame member having a substantially rectangular cross-section and a substantially rectangular, longitudinal inner cavity therein; and

an exhaust pipe supported within the frame members, the exhaust pipe having a rectangular portion having a substantially rectangular cross-section, the rectangular portion of the exhaust pipe dimensioned similar to the inner cavity of the rectangular frame member,

wherein the rectangular portion of the exhaust pipe extends longitudinally through the inner cavity of the rectangular frame member.

31. The vehicle chassis assembly of claim 30, wherein the rectangular portion is proximate an outlet of the exhaust pipe.

32. The vehicle chassis assembly of claim 31, wherein the exhaust pipe further comprises a circular portion having a substantially circular cross-section.

33. The vehicle chassis assembly of claim 30, wherein the plurality of frame members define a first frame portion and a rear frame portion angling upward with respect to the first frame portion, wherein the rectangular frame member is part of the rear frame portion.

34. The vehicle chassis assembly of claim 30, wherein the rectangular frame member has a distal end and the exhaust pipe has a distal end that extends through the distal end of the rectangular frame member.

35. The vehicle chassis assembly of claim 34, wherein the distal end of the exhaust pipe is at a rear end of the frame assembly.

36. The vehicle chassis assembly of claim 30, further comprising a plurality of wheels supporting the frame assembly, at least one of the wheels having a rotational axis, the rotational axis being located above a top surface of the frame assembly.

37. The vehicle chassis assembly of claim 30, further comprising a first rear wheel and a second rear wheel supporting the frame assembly, the rear wheels having a rotational axis, and wherein a portion of a top surface of the frame assembly is below the rotational axis.

38. A vehicle chassis assembly comprising:

a frame assembly comprising;

an elevated front frame portion comprising a plurality of frame members defining a platform, the front frame portion being supported by a pair of front wheels having a first rotational axis;

a middle frame portion comprising a plurality of frame members arranged in a grid structure having a top surface, the middle frame portion having a removable wheel arch, a casting connected to the wheel arch and one of the frame members, and a center frame member having an open bottom, the middle frame portion being supported by a pair of rear wheels having a second rotational axis, the first rotational axis and the second rotational axis being located above the top surface;

a neck portion connecting the front frame portion and the middle frame portion, the neck portion comprising a goose-neck connection;

a rear frame portion connected to the middle frame portion and angling upward with respect to the middle frame portion, the rear frame portion including a rectangular frame member having a substantially rectangular cross-section; and

an exhaust pipe comprising a first portion having a substantially circular cross-section, the first portion of the exhaust pipe supported within the center frame member, and a second portion having a substantially rectangular cross-section, the second portion of the exhaust pipe dimensioned to fit within the rectangular frame member.

39. A vehicle chassis assembly comprising:

a plurality of wheels, each wheel having a rotational axis;

a frame assembly supported by the wheels, wherein a portion of the frame assembly is located below the rotational axis of at least one of the wheels, the frame assembly comprising a plurality of frame members defining a first frame portion and a rear frame portion angling upward with respect to the first frame portion, the frame assembly further comprising a first angling frame member and a second angling frame member extending to a back edge of the chassis assembly in a direction oblique to a centerline of the chassis assembly; and

an exhaust pipe extending longitudinally through the first angling frame member.

40. The vehicle chassis assembly of claim 39, wherein a portion of the exhaust pipe is cooperatively dimensioned with the first angling frame member.

41. A vehicle chassis assembly comprising:

a frame assembly comprising a plurality of frame members, including a rectangular frame member having a substantially rectangular cross-section; and

an exhaust pipe supported within the frame members, the exhaust pipe having a rectangular portion having a substantially rectangular cross-section, the rectangular portion of the exhaust pipe dimensioned to fit within the rectangular frame member,

wherein the rectangular frame member has a distal end and the exhaust pipe has a distal end that extends through the distal end of the rectangular frame member.

42. The vehicle chassis assembly of claim 41, wherein the distal end of the exhaust pipe is at a rear end of the frame assembly.

43. A vehicle chassis assembly comprising:

a frame assembly comprising a plurality of frame members; and

an exhaust pipe supported within the frame assembly, the exhaust pipe having a first portion supported within a first frame member of the frame assembly and extending longitudinally through the first frame member, and a second portion supported within a second frame member of the frame assembly and extending longitudinally through the second frame member,

wherein the first frame member and the first portion of the exhaust pipe extend parallel to a centerline of the frame assembly and the second frame member and the second portion of the exhaust pipe are angled with respect to the centerline of the frame assembly.

44. The vehicle chassis assembly of claim 43, wherein the first portion of the exhaust pipe has a first cross sectional shape and the second portion of the exhaust pipe has a second cross sectional shape that is different from the first cross-sectional shape.

45. The vehicle chassis assembly of claim 43, wherein the second portion of the exhaust pipe is dimensioned similarly to a cross sectional shape of the second frame member.

46. A vehicle chassis assembly comprising:

a plurality of wheels, each wheel having a rotational axis; and

a frame assembly supported by the wheels, wherein a portion of the frame assembly is located below the rotational axis of at least one of the wheels, the frame assembly comprising a plurality of frame members defining a first frame portion and a rear frame portion angling upward with respect to the first frame portion, wherein one of the frame members has an open bottom and contains an exhaust pipe supported within the frame member and extending longitudinally through the frame member,

wherein the entire rear frame portion is located rearward of all of the plurality of wheels, and the rear frame portion extends upward and rearward from the first frame portion in a cantilever arrangement.