Load cell assembly for a towing vehicle

An adjustable fifth wheel coupling system, comprising:

• a first mounting portion with a track connectable to a towing vehicle;
• a second mounting portion coupleable to a fifth wheel trailer towable by the towing vehicle;
• and
• a cast load cell, comprising:
• a mounting plate adjustably engaging the track of the first mounting portion;
• a load sensing portion integrally formed with and connected to the mounting plate portion, the load sensing portion having a flexure portion spaced apart from the mounting plate portion and defining a flexure gap therebetween that allows the load sensing portion to move relative to the mounting plate portion in response to a load applied on the load sensing portion, the load sensing portion having a sensor cavity therein above at least a portion of the flexure gap;
• a connector mounting portion integrally formed with and connected to the load sensing portion above the flexure gap, the connector mounting portion configured to movably receive a connecting portion of the second mounting portion;
• and
• a load sensor mounted in the sensor cavity above a portion of the flexure gap;
• wherein the mounting plate portion, the load sensing portion, and shaft mounting portion define an integral, weld-free, substantially homogenous unitary cast member with the sensing cavity therein and the load sensor is attached thereto.

A fifth wheel coupling system for releasably interconnecting a towing vehicle and a fifth wheel trailer configured to carry a load, comprising:

• a first engagement structure coupled to the towing vehicle;
• a second engagement structure coupled to the fifth wheel trailer,
• a cast load cell assembly, comprising:
• a first mounting portion coupleable to the first engagement structure, the first mounting portion having an upper surface defining a first longitudinal plane, the first mounting portion including a plurality of holes positioned to receive fasteners to couple the first mounting portion to the first engagement structure;
• a load sensing portion formed integrally with and connected to the first mounting portion and having a flexure portion that includes a flexure gap, wherein the load sensing portion includes at least one sensor cavity adjacent to the flexure gap and positioned in a second longitudinal plane, and wherein the second longitudinal plane is spaced apart from the first longitudinal plane and the flexure gap;
• a second mounting portion coupleable to the second engagement structure and movable relative to the first engagement structure, the second mounting portion formed integrally with and connected to the load sensing portion and positioned at least partially in the second longitudinal plane;
• the second mounting portion having a receptacle configured to receive at least part of the second engagement structure, wherein a second longitudinal plane extends through at least a portion of the receptacle;
• and
• a load sensor connected to the load sensing portion and positioned within the sensor cavity above a portion of the flexure gap;
• wherein the first mounting portion, the load sensing portion, and a second mounting portion define a weld-free, substantially homogenous, unitary cast member.

A fifth wheel coupling system for releasably interconnecting a towing vehicle and a fifth wheel trailer configured to carry a load, comprising:

• a first engagement structure coupled to the towing vehicle;
• a second engagement structure coupled to the fifth wheel trailer, a weld free, substantially homogenous unitary cast load cell having—
• a load sensing portion having—
• a gap with first and second end portions, wherein the gap allows the load sensing portion to flex and move;
• and
• a sensor cavity adjacent the first or second end portions in a first longitudinal plane spaced apart from the gap;
• a load mounting portion integrally formed with the load sensing portion, the load mounting portion connected to the load sensing portion spaced apart from the gap and disposed at least partially in the first longitudinal plane;
• the load mounting portion has a receptacle formed as a receiver configured to receive the second engagement structure, wherein the first longitudinal plane extends through and at least a portion of the receptacle;
• a vehicle mounting portion integrally formed with the load sensing portion, the vehicle mounting portion disposed in a second longitudinal plane offset from the first longitudinal plane and configured to be affixed to the first engagement member;
• and
• a load sensor connected to the load sensing portion and positioned within the sensor cavity.