Wheel and brake assembly with mechanical stop

Abstract

In some examples of the invention, an assembly includes a wheel configured to rotate about an axis and a brake system configured to reduce rotation of the wheel. The brake system includes a disc stack having a rotor disc rotationally coupled to the wheel and a stator disc, where the wheel is configured to rotate relative to the stator disc. The brake system includes an actuator configured to compress the disc stack. The brake system is configured to apply a reaction force to the disc stack when the actuator compresses the disc stack. The assembly includes a mechanical stop configured to encounter the brake system, where the mechanical stop is configured to limit linear displacement between the actuator and the disc stack.

Description

Technical Field

[0001] This disclosure relates to a braking system for a vehicle. Background Technology

[0002] Vehicles such as aircraft may use wheel braking systems that include multi-disc braking systems. For example, such a multi-disc braking system may include a stack of discs comprising multiple rotor discs engaged with the wheel and multiple stator discs interleaved with the rotor discs. The rotor discs and the wheel are configured to rotate about an axle, while the stator discs remain stationary. To decelerate the rotational motion of the rotating wheel, the braking system may displace a piston against a pressure plate to compress the rotating rotor discs engaged with the wheel against the stationary stator discs, thereby generating a torque that decelerates the rotational motion of the wheel. In some examples, the rotor discs may engage with the wheel via rotor drive keys positioned on the inner surface of the wheel. In some examples, the stator discs may engage with a stationary torque tube surrounding the axle via splines positioned on the torque tube. In some such examples, the braking system may be configured to compress the rotor discs and stator discs between a piston and a backplate supported by the torque tube. Summary of the Invention

[0003] This disclosure describes exemplary wheel assemblies configured to help limit the maximum achievable displacement between the piston housing and the brake disc stack when utilizing a braking system to reduce and / or substantially prevent wheel rotation. The braking system is configured to compress the brake disc stack to reduce and / or limit rotational movement of the wheel about its wheel axis. For example, an actuator may be configured to compress the disc stack against a portion of a torque tube that engages with it. In some cases, the compressive force of the actuator can cause linear deformation of the torque tube. This linear deformation may require additional piston stroke to ensure that the compressive force on the disc stack is maintained during specific operating conditions such as deny-takeoff (RTO) stops. The assemblies disclosed herein use a mechanical stop to remove a portion of the compressive force from the torque tube when it deforms linearly. This mechanical stop is configured to limit the maximum distance between the actuator housing and the disc stack at the end of its life, even during brake disc stack compression.

[0004] In some examples, a component includes: a wheel configured to rotate about a wheel axis; a braking system including: a disc stack comprising a rotor disc and a stator disc, wherein the rotor disc is rotatably coupled to the wheel, and wherein the wheel is configured to rotate relative to the stator disc; and an actuator defining an actuator housing and configured to compress the disc stack, wherein the braking system is configured to compress the disc stack by limiting linear movement of the disc stack by applying a reaction force to the disc stack when the actuator compresses the disc stack, and wherein a portion of the braking system is configured to deform linearly when the braking system applies the reaction force; and a mechanical stop configured such that the linear deformation of the portion of the braking system causes the mechanical stop to reduce the reaction force applied by the braking system when it encounters the braking system, such that the mechanical stop limits linear displacement of the disc stack relative to the actuator housing.

[0005] In some examples, a component includes: a wheel configured to rotate about a wheel axis; a braking system including: a disc stack; a torque tube configured to engage the disc stack; a backplate attached to the torque tube, wherein the backplate is configured to restrict movement of the disc stack in a direction parallel to the wheel axis; and an actuator configured to compress the disc stack against the backplate using a compressive force, wherein the backplate is configured to apply a reaction force to the disc stack when the actuator compresses the disc stack; and a mechanical stop configured to encounter the disc stack, wherein: the mechanical stop... The actuator is configured to reduce the reaction force when the mechanical stop encounters the disc stack, and the mechanical stop is configured to restrict the movement of the disc stack in a direction parallel to the wheel axis when the mechanical stop encounters the disc stack, such that the mechanical stop restricts the linear displacement of the disc stack relative to the actuator; the actuator defines a first length between the actuator and the mechanical stop in the absence of the compressive force, and the actuator defines a second length between the actuator and the backplate in the absence of the compressive force, the first length and the second length being measured in a direction parallel to the wheel axis, and the first length being greater than the second length.

[0006] An exemplary technique includes: using an actuator of a brake system to compress a disc stack of the brake system, wherein the disc stack includes a rotor disc and a stator disc rotatably coupled to a wheel, wherein the wheel is configured to rotate about the stator disc, wherein the brake system applies a reaction force to the disc stack when the actuator compresses the disc stack; and limiting the movement of the disc stack by reducing the reaction force applied by the brake system by using the compression of the disc stack by the actuator to cause the brake system to encounter a mechanical stop.

[0007] Details of one or more examples are set forth in the accompanying drawings and the following description. Other features, objects, and advantages will be apparent from the description and drawings, as well as from the claims. Attached Figure Description

[0008] Figure 1 This is a perspective view showing an exemplary wheel that includes multiple rotor drive keys on the inner surface of the wheel.

[0009] Figure 2 It shows including Figure 1 A schematic cross-sectional view of an exemplary wheel and brake system.

[0010] Figure 3 This is a plan view showing an exemplary assembly including a mechanical stop with a selected cross-section.

[0011] Figure 4 This is an exemplary perspective view of a disk stack.

[0012] Figure 5 It is shown Figure 3 A plan view of an exemplary component having a selected cross-section.

[0013] Figure 6 It is a plan view with a selected cross section showing the displacement defined by the actuator.

[0014] Figure 7 This is a plan view showing an exemplary assembly including a mechanical stop integrated with the wheel, having a selected cross-section.

[0015] Figure 8 This is a plan view showing an exemplary assembly including a mechanical stop integrated with the rotor drive key, having a selected cross-section.

[0016] Figure 9 It is a plan view showing a portion of the component relative to the wheel axis.

[0017] Figure 10 This is a flowchart illustrating an exemplary method for reducing reaction force using mechanical stops. Detailed Implementation

[0018] This disclosure describes articles, systems, and techniques relating to: assemblies including wheels and braking systems, and more specifically, assemblies including one or more structures configured to limit axial displacement of brake discs under certain conditions. The wheel is configured to rotate about a wheel axis. The braking system includes a disc stack comprising one or more rotor discs and one or more stator discs. For example, the disc stack may include a plurality of rotor discs interleaved with a plurality of stator discs. The rotor discs are rotatably coupled to the wheel such that rotation of the wheel about a wheel axis causes rotation of the rotor discs about the wheel axis. The stator discs are configured to remain substantially stationary relative to the wheel and the rotor discs. The braking system is configured to compress the disc stack to cause engagement of friction surfaces on the rotating rotor discs and friction surfaces on the stationary stator discs, thereby reducing the rotational speed of the rotor discs about the wheel axis. The rotor discs are configured to engage the wheel such that the reduction in the rotational speed of the rotor discs causes a reduction in the speed of the wheel.

[0019] The braking system includes an actuator that defines an actuator housing and is configured to compress a stack of discs to cause deceleration of the rotor disc and the wheel. For example, the actuator may be configured to abut against a backplate-supported stack of discs by a torque tube, wherein the backplate and the torque tube are configured to remain substantially rotationally stationary relative to the stator disc. The braking system may be configured such that when the actuator applies a compressive force against the backplate-supported stack of discs (e.g., to decelerate the wheel), the backplate transmits a portion of the compressive force to the supporting torque tube. The transmitted portion of the compressive force may cause linear deformation of the torque tube (e.g., in a direction substantially parallel to the wheel axis), thereby increasing the displacement between the actuator housing and the stack of discs.

[0020] The component disclosed herein is configured to help limit displacement between the actuator housing and the brake disc stack when the actuator applies compressive force. In an example, the component is configured to help limit this displacement when the compressive force causes excessive linear deformation of the torque tube. Therefore, the component described herein can be configured to reduce and / or minimize the additional piston stroke required to maintain compressive force on the disc stack during specific operating conditions such as deny-on-takeoff (RTO) stops. The component can be configured to limit the maximum distance between the piston housing and the disc stack at the end of its life, even during brake disc stack compression.

[0021] The components described herein include a mechanical stop configured to transfer a load from the torque tube when the compressive force of the actuator causes linear deformation of the torque tube. The mechanical stop may be configured to unload the torque tube to limit displacement (e.g., maximum distance) between the actuator housing and the brake disc stack. In some examples, the component is configured such that the actuator abuts against the mechanical stop compressing the disc stack when the mechanical stop unloads the load from the torque tube. For example, in some examples, the component is configured such that the brake system abuts against the backplate compressing the disc stack until the torque tube undergoes a certain amount of linear deformation, at which point the mechanical stop encounters the disc stack to at least partially unload the load from the backplate and the torque tube. In examples, the component is configured to reduce and / or substantially stop the linear deformation of the torque tube as the mechanical stop transfers the load from the torque tube. In other examples, mechanical stops are configured to limit or even prevent axial movement of the backplate of the braking system (caused by linear deformation of the torque tube), and actuators are further configured to abut against the backplate compression disc stack even after the torque tube has undergone a certain amount of linear deformation.

[0022] This component allows for a reduction in the amount of reserve actuator capacity (e.g., piston stroke) typically provided for situations where the torque tube undergoes significant linear deformation (e.g., in high-temperature environments following emergency braking events or other relatively high-energy vehicle stopping conditions). The component can be configured to reduce the required stroke length necessary for the actuator to effectively engage the braking system when the torque tube undergoes significant linear deformation (e.g., during the period when the vehicle is statically held by the braking system while parked). By reducing and / or essentially stopping linear deformation, this component allows for a reduction in the required actuator stroke length. This can result in some degree of space saving when the braking system is positioned within the wheel well. Additionally, by reducing the required stroke, additional brake disc thickness can be added to unused space, thereby increasing the amount of wear-prone brake disc thickness and potentially increasing the life of the brake assembly.

[0023] In some examples, the wheel supports the mechanical stop. In these examples, the wheel supports the mechanical stop such that when the actuator abuts against the mechanical stop and compresses the disc stack, the mechanical stop transmits a portion (e.g., substantially all) of the compressive force to the wheel. This transmission of compressive force to the wheel reduces (or substantially eliminates) the amount of compressive force acting on the torque tube, thereby reducing (or substantially eliminating) any further linear deformation of the torque tube and associated translation of the brake disc stack. In these examples, the mechanical stop is configured to limit the maximum displacement that may occur between the actuator housing and the brake disc stack when the mechanical stop encounters the disc stack.

[0024] The component can be configured such that a linear deformation of the torque tube greater than or equal to a threshold linear deformation (e.g., by applying a compressive force by an actuator) causes a mechanical stop to contact the disc stack. The component can be configured such that a first linear deformation of the torque tube maintains the displacement between the mechanical stop and the disc stack, and a second linear deformation of the torque tube greater than the first linear deformation causes the mechanical stop to contact the disc stack. The first and second linear deformations can each be deformations in a direction substantially parallel to the wheel axis. In an example, the torque tube is configured such that the actuator induces a first linear deformation under a first thermal load and a second linear deformation under a second thermal load greater than the first thermal load. The thermal load can be defined by, for example, the temperature at one or more points on the torque tube, the temperature of another component in the wheel and brake system, the temperature within the wheel well, or some other suitable parameter. In an example, the torque tube can have a configuration (e.g., may include a material and / or geometry) that causes the torque tube to undergo a greater degree of linear deformation than other components of the brake system and / or wheel under a given thermal load. For example, the torque tube can be relatively thin compared to the rotor drive key or other components of the braking system, which can result in a relatively higher temperature for the torque tube under a given thermal environment (e.g., the thermal environment after an emergency stop).

[0025] Therefore, the component can be configured such that the mechanical stop encounters the disc stack depending on the state of the torque tube. For example, the component can be configured such that under relatively low thermal loads, the actuator's compressive force is insufficient to produce the linear deformation of the torque tube necessary to cause the mechanical stop to encounter the disc stack (i.e., the linear deformation is less than the second linear deformation described above). Therefore, the component can be configured to operate effectively under specific conditions in which wheel braking is achieved without transferring the compressive load from the torque tube to the mechanical stop. The component can be configured such that under sufficiently high thermal loads (e.g., after an emergency stop), the actuator's compressive force can produce a linear deformation of the torque tube sufficient to cause the mechanical stop to encounter the disc stack (i.e., the second linear deformation).

[0026] In the example, the actuator defines a first length between a portion of the actuator and a mechanical stop in the absence of compressive force. The actuator may also define a second length between this portion of the actuator and a backplate in the absence of compressive force. The first length may be greater than the second length. The first and second lengths may be measured, for example, in a direction parallel to the wheel axis of the wheel to which the brake assembly is attached. This portion of the actuator may be, for example, a contact area through which the actuator is configured to apply compressive force to the disc stack.

[0027] In some examples, the mechanical stop is rotatably coupled to the wheel. The mechanical stop may be configured to rotate with the wheel and to encounter a portion of the braking system that also rotates with the wheel (e.g., a rotor disc) to limit and / or prevent contact between the rotating and relatively stationary portions of the system. For example, the mechanical stop may be configured to rotate substantially synchronously about the wheel axis as the wheel rotates about the wheel axis. In some examples, a pin engaging the wheel defines the mechanical stop. In some examples, the inner surface of the wheel includes a flange defining the mechanical stop. In still other examples, a rotor drive key attached to the wheel and configured to engage the rotor disc defines the mechanical stop. The mechanical stop may be configured to encounter a portion of the disc stack that is rotatably coupled to the wheel. The mechanical stop may be configured to encounter the rotor disc or a rotor disc component (e.g., a drive insert) configured to rotate synchronously with the rotor disc. In examples, when the actuator is configured to abut against a backplate to compress the disc stack, the mechanical stop is configured to encounter the rotor disc adjacent to or closest to the backplate.

[0028] Figure 1 This is a perspective view showing an exemplary wheel 10. In some examples, wheel 10 is part of an aircraft vehicle. In other examples, wheel 10 may be part of any other vehicle, such as any land vehicle or other vehicle. Figure 1 In the example shown, wheel 10 includes a wheel rim 12 defining an outer surface 14 and an inner surface 16. Wheel rim 12 includes a mandrel 18 and a wheel hub 19. In some examples, the inner surface 16 may include the inner diameter of the mandrel 18 of wheel 10. For example, in some cases, the inner surface 16 may be referred to as the inner diameter surface of wheel 10. The inner surface 16 and wheel hub 19 may define a wheel recess 17 (e.g., a volume) between the inner surface 16 and the wheel hub 19. In some examples, a tire (not shown) may be mounted on the outer surface 14 of rim 12. Wheel 10 may include an inner bead seat 20 and an outer bead seat 21 configured to retain the tire on the outer surface 14 of rim 12. In the example, wheel 10 may include an inner section 22 (e.g., including the inner bead seat 20) and an outer section 23 (e.g., including the outer bead seat 21). Wheel 10 is configured to rotate about an axis of rotation A.

[0029] The wheel 10 includes a plurality of rotor drive keys 24, such as rotor drive keys 25 and 15, on its inner surface 16. In some examples, each of the plurality of rotor drive keys 24 extends in a substantially axial direction of the wheel 10 (e.g., in a direction parallel to the axis of rotation A). The plurality of rotor drive keys 24 (“rotor drive keys 24”) and the inner surface 16 are configured to be substantially stationary relative to each other, such that when the wheel 10 (and the inner surface 16) rotates about the axis of rotation A, each of the rotor drive keys (e.g., rotor drive keys 15, 25) translates in a closed path about the axis of rotation A. Thus, when the wheel 10, the inner surface 16, and the rotor drive keys 24 rotate about the axis of rotation A, a force acting in the opposite direction of rotation on one or more of the rotor drive keys 24 acts to slow or stop the rotation. As will be discussed, the rotor drive keys 24 may be configured to receive torque from a braking system (not shown) configured to reduce and / or stop the rotation of the wheel 10. The rotor drive key 24 may be integrally formed with the inner surface 16, or it may be separate from the inner surface 16 and mechanically attached to the inner surface.

[0030] Figure 2 This is a schematic cross-sectional view showing a wheel 10 and an exemplary braking system 40. The wheel 10 includes a wheel rim 12, an outer surface 14, an inner surface 16, a wheel well 17, a wheel hub 19, an inner bead seat 20, an outer bead seat 21, an inner section 22, an outer section 23, and a rotor drive key 25. Figure 2 A wheel rim 12 is shown as a split rim wheel, wherein lug bolts 26 and lug nuts 27 connect the inner section 22 and the outer section 23; however, in other examples, the wheel rim 12 may utilize other configurations (e.g., a solid rim).

[0031] Wheel 10 is configured to rotate about axis A extending through axial assembly 28. Axial assembly 28 is configured to support wheel 10 while allowing wheel 10 to rotate about axis A using bearings 29 and 30. For example, bearings 29 and 30 may define a substantially circular track around axial assembly 28. Torque tube 31 is coupled to axial assembly 28 (e.g., via bolts 32 and 33) such that torque tube 31 remains substantially stationary as wheel 10 rotates about axial assembly 28 and axis A. Torque tube 31 may at least partially surround the exterior of axial assembly 28. Axial assembly 28 may be mechanically coupled to a strut attached to a vehicle (e.g., landing gear strut (not shown)).

[0032] Braking system 40 is positioned within wheel 10 and configured to engage main torque tube 31 and rotor drive key 25. Braking system 40 is configured to generate torque to resist rotation of wheel 10 about axis A and transmit this torque to rotor drive key 25, thereby reducing and / or eliminating rotation of wheel 10 about axis A. Braking system 40 includes a disc stack 42 comprising one or more rotor discs (e.g., rotor discs 43, 44, 45) and one or more stator discs (e.g., stator discs 47, 48). Rotor discs 43, 44, 45 and / or stator discs 47, 48 may have any suitable configuration. For example, rotor discs 43, 44, 45 and / or stator discs 47, 48 may each be a substantially annular disc surrounding axial assembly 28. Stator discs 47, 48 are coupled to torque tube 31 via spline 49 and remain rotationally stationary with respect to torque tube 31 (and axial assembly 28) when wheel 10 rotates. Rotor discs 43, 44, and 45 are rotatably connected to rotor drive key 25 and inner surface 16 and rotate substantially synchronously with wheel 10 about axis A.

[0033] Actuator 39 is configured to compress the disk stack 42 so that the friction surfaces of rotor disks 43, 44, 45 contact the friction surfaces of stator disks 47, 48, thereby generating a shear force between the disks. Alternatively, the friction surfaces of the rotor disks and / or stator disks may contact the friction surfaces of pressure plate 51 or back plate 50. The shear force causes the rotor disks 43, 44, 45 to exert torque on the rotor drive key 25 in opposition to the rotation of wheel 10. In some examples, actuator 39 is configured to compress disk stack 42 using pressure plate 51. In these examples, actuator 39 may be configured to cause pressure plate 51 to translate toward disk stack 42 when actuator 39 compresses disk stack 42. In examples, actuator 39 is configured to cause piston 54 to translate relative to actuator body 52 (“actuator body 52”) to apply compression to disk stack 42. Actuator 39 may use any suitable method to cause piston 54 to translate. In some examples, actuator 39 is configured to cause piston 54 to translate by supplying and / or discharging pressurized hydraulic fluid from piston chamber. Alternatively or conversely, in some examples, actuator 39 is configured to cause piston 54 to translate by motion (e.g., rotational motion) generated by an electric motor.

[0034] exist Figure 2In the example shown, actuator 39 is configured to press against back plate 50 against disk stack 42. Back plate 50 may be supported by torque tube 31. For example, back plate 50 may be configured to be substantially stationary relative to torque tube 31. When wheel 10 rotates about torque tube 31, wheel 10 may rotate about back plate 50. Braking system 40 may be configured such that the compressive force applied by actuator 39 to disk stack 42 causes disk stack 42 to translate toward back plate 50. For example, the compressive force may cause rotor disks 43, 44, 45 to translate toward back plate 50 over rotor drive key 25 and stator disks 47, 48 to translate toward back plate 50 over spline 49.

[0035] The back plate 50 is configured to resist translation of the disk stack 42 and apply a reaction force to the disk stack 42 opposite to the compressive force applied by the actuator 39, causing the disk stack 42 to be compressed by the actuator 39 between the pressure plate 51 and the back plate 50. When the torque tube 31 supports the back plate 50, the back plate 50 further applies a force to the torque tube 31 in response to the compressive force. In the example, the actuator 39 is configured to apply a compressive force to the disk stack 42 toward the back plate 50 and substantially parallel to axis A.

[0036] Therefore, the braking system 40 can be used to reduce and / or eliminate the rotation of the wheel 10 by using the compressive force applied to the disc stack 42 by the actuator 39. The backplate 50 can be configured to resist the compressive force, thereby causing the disc stack 42 to compress. The torque tube 31 can be configured to support the backplate 50 such that when the actuator 39 applies a compressive force to the disc stack 42, the torque tube 31 is subjected to a force (e.g., substantially parallel to axis A).

[0037] Wheel 10 can be used with any kind of private, commercial, or military aircraft or other type of vehicle. Wheel 10 can be mounted to the vehicle via, for example, axial assembly 28. Axis assembly 28 can be mounted on a strut of landing gear (not shown) or other suitable component of the vehicle to connect wheel 10 to the vehicle. Wheel 10 can rotate about axis A and axial assembly 28 to apply motion to the vehicle. Wheel 10 has been shown and described to provide context for the braking system described herein; however, in other examples, the braking system described herein can be used with any suitable wheel assembly.

[0038] Figure 3 An exemplary component 70 is shown, which includes an exemplary portion of a wheel 10 and an exemplary portion of a brake system 40 located within a wheel well 17 defined by the wheel 10. Figure 3 A cross-section of a selected portion of the wheel 10 and the braking system 40 is depicted, wherein the cross-section is parallel to... Figure 1 It is intercepted along the axial direction A. For example... Figure 3As shown, in the example, the rotor drive key 25 is supported by the wheel 10 via one or more fasteners 35 (e.g., bolts) that attach the rotor drive key 25 to the wheel 10, and the torque tube 31 is engaged with a portion of the axial assembly 28 by, for example, bolts 32.

[0039] Wheel 10 and rotor discs 43, 44, 45 are configured to rotate about torque tube 31 and axis A. Stator discs 47, 48, actuator 39, spline 49, and axial assembly 28 are configured to remain substantially rotationally stationary relative to torque tube 31. When torque tube 31 engages with axial assembly 28 and disc stack 42 is in an uncompressed state (e.g., actuator 39 is not compressing disc stack 42 in the direction toward back plate 50), torque tube 31 is configured to maintain a displacement D between torque tube 31 and wheel 10. Displacement D serves to prevent contact between the rotationally stationary torque tube 31 and the rotating wheel 10 when wheel 10 rotates about axis A. As mentioned above, such contact could lead to premature repair or replacement of wheel 10 and / or braking system 40.

[0040] Actuator 39 is configured to compress disk stack 42 to reduce the rotational speed of wheel 10 and / or substantially prevent rotational movement of wheel 10 (e.g., when wheel 10 is parked). Actuator 39 may be configured to apply a compressive force to disk stack 42, thereby causing friction surfaces on rotor disks 43, 44, 45 and friction surfaces on stator disks 47, 48 to engage. Actuator 39 may be configured to apply a compressive force to cause friction surfaces of rotor disks and / or stator disks to engage friction surfaces of pressure plate 51 or back plate 50. In an example, actuator 39 is configured to apply a compressive force (e.g., force F) substantially parallel to axis A to disk stack 42. In an example, actuator 39 includes a body 52 (“actuator body 52”) and a piston 54. Actuator 39 may be configured to cause piston 54 to translate relative to actuator body 52 to apply a compressive force to disk stack 42. In the example, actuator 39 is configured to cause piston face 53 to apply a compressive force (e.g., via pressure plate 51) to the disk stack 42. A portion of actuator 39 (e.g., actuator body 52) is configured to remain substantially stationary relative to a portion of torque tube 31 and / or axial assembly 28 when the actuator 39 applies the compressive force. In some examples, torque tube 31 and / or axial assembly 28 are configured to restrict movement of actuator body 52 when the actuator 39 applies the compressive force to the disk stack 42. In the example, actuator 39 is mechanically connected to torque tube 31 and / or axial assembly 28.

[0041] For example, Figure 3 The actuator 39 is shown with the piston 54 in a first position and a second position relative to the actuator body 52. Figure 3The first position of piston 54 is shown in dashed lines, and the second position of piston 54 is shown in solid lines. Actuator 39 can be configured to translate piston 54 from the first position to the second position such that piston face 53 applies a compressive force to disk stack 42. The first and second positions are displaced from each other by an amount of piston stroke T. That is, actuator 39 can be configured to define a first displacement between piston face 53 and point P on actuator body 39 in the first position, and a second displacement between piston face 53 and point P in the second position, wherein the first and second displacements define piston stroke T. Actuator 39 can be configured to cause piston 54 to translate over piston stroke T to apply a compressive force to disk stack 42.

[0042] The disk stack 42 is configured to reduce the rotational speed of the wheel 10 and / or substantially prevent rotational movement of the wheel 10 when the actuator 39 compresses the disk stack 42 (e.g., in a parked state). The compressive force applied by the actuator 39 causes the friction surfaces on the rotating rotor disks 43, 44, 45 to engage the friction surfaces on the relatively stationary stator disks 47, 48. The engagement with the friction surfaces of the stator disks 47, 48 and / or the pressure plate 51 and / or the back plate 50 causes the rotor disks 43, 44, 45 to apply torque to the wheel 10 (e.g., via the rotor drive key 25), thereby reducing the speed of the wheel 10. When the wheel 10 is substantially stationary relative to the torque tube 31 (e.g., when the vehicle is parked) and the actuator 39 is compressing the disk stack 42, the rotor disks 43, 44, 45 can resist the rotational movement of the wheel 10.

[0043] Figure 4 A perspective view of an exemplary disk stack 42 is shown, illustrating stator disks 47 and 48 interposed with rotor disks 43, 44, and 45. The disk stack 42 is positioned between a pressure plate 51 and a back plate 50. Axis A is included for reference. Figures 1 to 3 The disk stack 42 is shown in an uncompressed state, where the relative frictional surfaces of adjacent stator and rotor disks are disengaged. For example, as in... Figure 4 As shown, an air gap G exists between rotor disk 43 and the adjacent stator disk 47, such that the friction surface 56 of rotor disk 43 and the friction surface 58 of stator disk 47 are substantially disengaged (e.g., not in contact with each other). The air gap G can have any suitable value (e.g., it can be larger or smaller relative to disk stack 42 than shown). Each of stator disks 47, 48 and rotor disks 43, 44, 45 can have a first friction surface (e.g., friction surface 56 of rotor disk 43) and a second friction surface (e.g., friction surface 60 of rotor disk 43) on the side of the respective disk opposite to the first friction surface. In some examples, each of stator disks 47, 48 and rotor disks 43, 44, 45 can be a substantially annular disk, but in other examples it can have other shapes.

[0044] Rotor discs 44, 45, and 46 are configured to work with wheel 10 ( Figures 1 to 3 They rotate substantially synchronously. In some examples, each of the rotor disks 43, 44, and 45 includes a plurality of drive slots configured to engage the rotor drive key of the wheel 10 to induce rotation. For example, rotor disk 43 includes a drive slot 62 located on the outer periphery 64 of rotor disk 43. Drive slot 62 is configured to engage the rotor drive key (e.g., rotor drive key 25). Figures 1 to 3 This causes the rotor disc 43 to rotate substantially synchronously with the wheel 10. The stator discs 47 and 48 are configured to rotate relative to the torque tube 31 as the rotor discs 43, 44, and 45 rotate. Figures 2 to 3 It basically remains stationary while rotating.

[0045] Each of the stator disks 47 and 48 may include a plurality of spline slots configured to engage the splines of the torque tube 31 to substantially keep the stator disks 47 and 48 stationary relative to the rotor disks 43, 44, and 45. That is, the stator disks 47 and 48 are configured not to rotate while the rotor disks 43, 44, and 45 rotate. For example, stator disk 47 includes a spline slot 66 located on its inner periphery 68. Spline slot 66 is configured to engage splines (e.g., spline 49). Figure 2 and Figure 3 This causes the stator disk 47 to remain substantially stationary relative to the torque tube 31. Similarly, the pressure plate 51 and / or back plate 50 may include a plurality of splines (e.g., splines 71 on the inner periphery 72 of the pressure plate 51), which are configured to cause the pressure plate 51 and / or back plate 50 to remain substantially stationary relative to the torque tube 31. When the actuator 39 ( Figure 2 and Figure 3 When a compressive force F is applied (e.g., to the pressure plate 51), the disk stack 42 is compressed between the pressure plate 51 and the back plate 50, thereby eliminating the gap G and causing the friction surfaces (e.g., friction surfaces 56 and 58) to engage.

[0046] The back plate 50 is configured to apply a reaction force F1 to the disk stack 42 in response to a compressive force F applied to the back plate 50. In some examples, the back plate 50 is configured to engage part of the torque tube 31 such that the torque tube 31 substantially restricts the movement of the back plate 50 in a direction away from the pressure plate 51 in a direction parallel to axis A. In some examples, the back plate 50 is configured to apply a force F2 to the torque tube 31 in response to the compressive force F. Figure 3 and Figure 4 Therefore, torque tube 31 ( Figure 2 and Figure 3The actuator 39 can be configured such that when it applies a compressive force F to the disk stack 42, the torque tube 31 experiences a force F2 based on the compressive force F. In the example, the compressive force F and the force F2 are substantially parallel to axis A.

[0047] Disk stack 42 may include, in addition to Figures 2 to 4 Components other than those depicted and / or described above. For example, disk stack 42 may include one or more rotor drive inserts configured to at least partially insert into drive slots in the rotor disks. For example, disk stack 42 may include rotor drive insert 76 ( Figure 3 The rotor drive insert is configured to at least partially insert into the drive slot 62 of the rotor disk 43. Figure 4 Inside. For example, disk stack 42 may include one or more spline inserts configured to at least partially insert into the spline slots of the stator disk. For instance, disk stack 42 may include spline insert 78 ( Figure 3 The spline insert is configured to at least partially insert into the spline slot 66 of the stator disk 47. Figure 4 As used herein, disk stack 42 may include one or more rotor disks such as rotor disks 43, 44, 45, one or more stator disks such as stator disks 47, 48, and other components configured as substantially rigid bodies to rotate and / or translate with at least one of the rotor disks (e.g., rotor disks 43, 44, 45) and / or stator disks (e.g., stator disks 47, 48).

[0048] In the example, torque tube 31 ( Figure 3 The torque tube 31 may include a ductile material that causes linear deformation under certain conditions, such as high thermal loads following an emergency stop of the vehicle using the braking system 40. For example, when the actuator 39 applies a compressive force F that causes a force F2 on the torque tube 31, the ductility of the material can cause the force F2 to induce linear deformation. This linear deformation of the torque tube 31 may be substantially parallel to axis A. In some examples, the linear deformation may cause the torque tube 31 to extend toward wheel 10, thereby reducing the displacement D between the torque tube 31 and wheel 10. Figure 3 The linear deformation of the torque tube 31 increases the displacement between the actuator body 39 (e.g., point P) and the disc stack 42, thereby increasing the piston stroke T required by the actuator 39 to ensure the maintenance of the compressive force F. Component 70 is configured to limit the piston stroke T required by the actuator 39 by limiting the maximum distance between the actuator housing 52 (e.g., point P) and the disc stack 42 under specific operating conditions such as a refused-takeoff (RTO) stop. Therefore, component 70 can be used to reduce the reserve capacity requirement of the actuator 39 that the braking system 40 might otherwise require when operating under specific conditions.

[0049] The reduction in displacement D between torque tube 31 and wheel 10 becomes more pronounced as the operational life of a given disc stack 42 nears its end. For example, linear deformation of torque tube 31 can cause a greater reduction in displacement D as rotor discs 43, 44, 45 and stator discs 47, 48 wear and as the thickness of individual discs (e.g., thickness substantially parallel to axis A) decreases. For example, at the end of its life, a greater reduction in displacement D can occur due to higher temperatures caused by the reduction of radiator material as the disc stack 42 and / or other components of brake assembly 40 wear during its lifespan. Ensuring that at least a portion of displacement D is maintained between torque tube 31 and wheel 10 limits the dependence of displacement D on the thickness of disc stack 42, thus allowing for less frequent replacement of disc stack 42. Furthermore, as the thickness of individual discs decreases, the available stroke of piston 54 can become a factor as displacement D decreases. By ensuring that a portion of the displacement D is maintained throughout the life of the brake system 40, the necessary translation of the piston 54 in the direction parallel to axis A, which would cause sufficient compression of the disc stack 42 in the end-of-life scenario, can be reduced, thereby allowing for a certain degree of space saving within the assembly 70.

[0050] like Figure 3 As shown, component 70 includes a mechanical stop 74 configured to restrict translation of the disk stack 42 under certain operating conditions when the actuator 39 applies a compressive force F to the disk stack 42. In the example, the mechanical stop 74 is configured to restrict translation of the disk stack 42 in a direction substantially parallel to axis A. For example, the mechanical stop 74 may be configured to restrict translation of the disk stack 42 when the torque tube 31 deforms linearly in a manner that results in a reduction of displacement D (e.g., when the actuator 39 causes linear deformation of the torque tube 31). The mechanical stop 74 may be configured to restrict translation of the disk stack 42 when the torque tube 31 deforms linearly over a displacement less than displacement D. In some examples, the mechanical stop 74 is configured to apply a reaction force to the disk stack 42 when the mechanical stop 74 encounters the disk stack 42. For example, the mechanical stop 74 can be configured such that when the torque tube 31 deforms linearly under the influence of force F2, the mechanical stop 74 encounters the disc stack 42 and applies a reaction force to the disc stack to reduce the force F2 experienced by the torque tube 31. The reduction of the force F2 on the torque tube 31 can substantially stop the linear deformation and the resulting extension of the torque tube 31 toward the wheel 10, thereby preserving at least a portion of the displacement D between the torque tube 31 and the wheel 10, and limiting the linear translation of the disc stack 42 when the actuator 39 applies the compressive force F.

[0051] For example, Figure 5The assembly 70 is shown with the mechanical stop 74 encountering the disk stack 42. The actuator 39 has translated the piston 54 from a first position (indicated by dashed lines) to a second position (indicated by solid lines) such that the piston face 53 encounters the disk stack 42 (e.g., pressure plate 51) to apply a compressive force F to the disk stack 42. The actuator 39 has caused the piston 54 to translate along the piston stroke Tm to apply the compressive force F. The compressive force F causes the disk stack 42 to translate linearly toward the back plate 50.

[0052] Mechanical stop 74 can be configured to encounter one or more rotor discs (e.g., rotor discs 43, 44, 45) and / or one or more stator discs (e.g., stator discs 47, 48) when the compressive force F causes linear deformation of the torque tube 31 under certain conditions. When mechanical stop 74 encounters the disc stack 42 (e.g., drive insert 76 and / or rotor disc 45), mechanical stop 74 applies a reaction force F3 opposite to the compressive force F. The application of reaction force F3 reduces and / or substantially eliminates the necessary reaction force imparted by the back plate 50, thereby reducing and / or substantially eliminating the force F4 on the torque tube 31. Reducing and / or substantially eliminating the force F4 on the torque tube 31 mitigates and / or substantially eliminates further linear deformation of the torque tube 31. Mitigating and / or substantially eliminating further linear deformation of the torque tube 31 limits further linear translation of the disc stack 42 in a direction away from the actuator body 52 (e.g., point P), thereby limiting the amount of piston stroke Tm required to maintain sufficient compressive force F. Therefore, when the mechanical stop 74 has encountered the disc stack 42, the brake system 40 limits the maximum distance between the actuator housing 52 (e.g., point P) and the disc stack 42 under certain operating conditions. This reduces the reserve capacity requirement of the actuator 39 that would otherwise be necessary in the absence of the mechanical stop 74.

[0053] In the example, the mechanical stop 74 is configured to reduce and / or substantially eliminate the force F4 on the torque tube 31 when the actuator 39 causes the torque tube 31 to undergo a threshold linear deformation (e.g., by applying a reaction force F3). The mechanical stop 74 may be configured to reduce and / or substantially eliminate the force F4 on the torque tube 31 when the actuator 39 causes the torque tube 31 to undergo a displacement D ( Figure 3 ) decrease to displacement D2( Figure 5When the torque tube 31 undergoes linear deformation, it encounters the disk stack 42 to apply a reaction force F3. The mechanical stop 74 can be configured to at least partially relieve the load on the torque tube 31 (e.g., by applying the reaction force F3) to substantially stop the linear deformation, thereby limiting the maximum distance between the actuator housing 52 (e.g., point P) and the disk stack 42. In the example, the assembly 70 is configured such that when the mechanical stop 74 encounters the disk stack 42, the actuator 39 at least partially abuts against the mechanical stop 74 to compress the disk stack 42. When the mechanical stop 74 encounters the disk stack 42, the assembly 70 can be configured such that the actuator 39 abuts against both the back plate 50 and the mechanical stop 74 to compress the disk stack 42, such that the mechanical stop 74 substantially reduces the amount of compressive force F transmitted to the torque tube 31.

[0054] The mechanical stop 74 may be configured to have a greater axial stiffness than the torque tube 31 in a direction substantially parallel to the direction of the compressive force F. For example, the mechanical stop 74 may comprise a material and / or have a geometry that causes the axial stiffness of the mechanical stop 74 to exceed that of the torque tube 31. The greater axial stiffness can be used to ensure that the mechanical stop 74 adequately relieves the load on the torque tube 31 without allowing additional linear deformation of the mechanical stop 74 and / or the torque tube 31.

[0055] The mechanical stop 74 can be configured to encounter any portion of the disc stack 42. In some examples, the mechanical stop 74 is configured to encounter the drive insert (e.g., drive insert 76) of the disc stack 42 when the actuator 39 compresses the disc stack 42. Alternatively, the mechanical stop can be configured to encounter the spline insert (e.g., spline insert 78) of the disc stack 42 when the actuator 39 compresses the disc stack 42. In other examples, the mechanical stop 74 is configured to encounter a disc in the disc stack 42 that has a greater displacement than another disc in the disc stack 42 relative to the actuator 39, so that the compressive force F causes a greater number of friction surfaces within the disc stack 42 to engage (e.g., substantially maintaining braking power).

[0056] The mechanical stop 74 can be configured such that when the mechanical stop 74 encounters the disk stack 42, a plurality of rotor disks and / or stator disks are compressed between the actuator 39 and the mechanical stop 74. In an example, the mechanical stop 74 is configured to encounter the rotor disk (e.g., rotor disk 45) in the disk stack 42 that is adjacent to or closest to the back plate 50. For example, the mechanical stop 74 can be configured to encounter rotor disk 45 when the torque tube 31 undergoes threshold linear deformation, such that the compression of the disk stack 42 against the mechanical stop 74 continues to induce engagement of the friction surfaces between rotor disk 43 and stator disk 47, between stator disk 47 and rotor disk 44, between rotor disk 44 and stator disk 48, and between stator disk 48 and rotor disk 45.

[0057] Figure 6The assembly 70 is shown in the case where the disk stack 42 is in an uncompressed state (e.g., without compressive force applied by the actuator 39). The assembly 70 is configured such that, in the absence of compressive force from the actuator 39, the assembly 70 maintains a substantially clearance (measured in a direction parallel to axis A) between the disk stack 42 and the mechanical stop 74. The assembly 70 can be configured such that when the actuator 39 compresses the disk stack 42, the disk stack 42 encounters the back plate 50 before encountering the mechanical stop 74. In the example, in the absence of compressive force from the actuator 39, the actuator 39 defines a first length L1 between the actuator 39 and the mechanical stop 74 and a second length L2 between the actuator 39 and the back plate 50, wherein the first length L1 is greater than the second length L2. The first length L1 and the second length L2 may be defined by a specific point on the actuator 39, such as a point P on the actuator body 52. ​​The first length L1 and the second length L2 may be substantially parallel. In the example, the first length L1 and the second length L2 can be substantially parallel to axis A.

[0058] The disk stack 42 is configured to translate substantially parallel to axis A when compressed by actuator 39. Component 70 can be configured such that the first length L1 and the second length L2 are substantially parallel to the translational direction of the disk stack 42. Therefore, component 70 can be configured such that compression of the disk stack 42 causes the disk stack 42 (e.g., rotor disk 45) to encounter the back plate 50 before encountering the mechanical stop 74. Additionally, component 70 can be configured such that a threshold linear deformation of the torque tube 31 substantially causes the disk stack 42 to encounter the mechanical stop 74 (e.g., linear deformation over the distance ΔL between the first distance L1 and the second distance L2). Therefore, component 70 can be configured such that when actuator 39 causes the torque tube 31 to undergo linear deformation below the threshold linear deformation (or substantially no linear deformation), actuator 39 causes compression of the disk stack 42 against the back plate 50 while maintaining displacement between the disk stack 42 and the mechanical stop 74. When the actuator 39 causes the torque tube 31 to undergo linear deformation that is substantially equal to or greater than the threshold linear deformation, the actuator 39 causes the back plate 50 and the mechanical stop 74 to compress the disc stack 42.

[0059] although Figure 3 , Figure 5 and Figure 6 The discussion focuses on the reduction of linear deformation of torque tube 31 in a direction substantially parallel to axis A, specifically the displacement D, which is substantially parallel to axis A. Figure 3However, the disclosure herein is not limited thereto. The mechanical stop 74 may be configured to reduce and / or eliminate linear deformation of the torque tube 31 occurring in any direction, and the displacement D may be a displacement in any direction and between any portions of the assembly 70. In the example, the displacement D is the displacement between a first portion (e.g., a first component) and a second portion (e.g., a second component) of the assembly 70, wherein the first portion is configured to rotate as the wheel 10 rotates, and the second portion is configured to remain substantially stationary relative to the rotation of the first portion.

[0060] The mechanical stop 74 can be supported in any way sufficient to allow the mechanical stop 74 to encounter the disk stack 42 and apply a reaction force F3 to the disk stack 42. The mechanical stop 74 can be configured such that the movement of the mechanical stop 74 is substantially limited in response to the application of the reaction force F3. The movement of the mechanical stop 74 can be achieved through the wheel 10, the braking system 40, and the axial assembly 28. Figure 1 Or any other component or system sufficient to limit the movement of the mechanical stop 74 when the mechanical stop 74 applies a reaction force F3. The mechanical stop 74 may be configured such that when the mechanical stop 74 applies a reaction force F3 to the disc stack 42, the wheel 10, the brake system 40, the axial assembly 28 ( Figure 1 One of the components or parts of another system applies substantially equal and opposite forces to the mechanical stop 74 to limit its movement. Wheel 10, brake system 40, axial assembly 28 Figure 1 This part of the mechanical stop 74 or other components or systems supporting the mechanical stop 74 may be configured to have greater axial stiffness than the torque tube 31 in a direction substantially parallel to the direction of the compressive force F, so as to allow the mechanical stop 74 to transfer the load from the torque tube 31 in a manner that limits any additional linear deformation of the torque tube 31.

[0061] In some examples, a portion of wheel 10 is configured to substantially restrict the movement of mechanical stop 74 when it encounters disc stack 42. For example, wheel 10 may support mechanical stop 74 such that when actuator 39 abuts against mechanical stop 74 to compress disc stack 42, mechanical stop 74 transmits at least a portion of the compressive force F to wheel 10. In examples, mechanical stop 74 is configured to transmit a portion or substantially all of the reaction force F3 to wheel 10. Wheel 10 may be configured to apply substantially equal and opposite forces to mechanical stop 74 to restrict the movement of mechanical stop 74. Thus, mechanical stop 74 may be configured to at least partially remove a portion of the compressive force F from torque tube 31 when mechanical stop 74 encounters disc stack 42 by transmitting a portion of the compressive force F from torque tube 31 to wheel 10.

[0062] In some examples, the mechanical stop 74 is rotatably coupled to the wheel 10 such that rotation of the wheel 10 causes rotation of the mechanical stop 74. For example, the mechanical stop 74 may be configured to rotate synchronously with the wheel 10. In some examples, the mechanical stop 74 is rotatably coupled to the wheel 10 and configured to encounter portions of the disc stack 42 rotatably coupled to the wheel 10 (e.g., rotor disc 45 and / or drive insert 76) to substantially avoid contact between the mechanical stop 74 and portions of the disc stack 42 configured to be rotationally mismatched with the mechanical stop 74. This can be used to minimize or even prevent contact between components configured to rotate with the wheel 10 (e.g., the mechanical stop 74) and components configured to remain substantially stationary relative to the torque tube 31. Such contact could result in unplanned maintenance or premature replacement of one or more components of the wheel 10 or the braking system 40.

[0063] The mechanical stop 74 can have any suitable configuration. In some examples, the mechanical stop 74 is an elongated member that engages with the wheel 10 and defines a handle 77. The handle 77 is configured to encounter the disc stack 42 and exert a reaction force F3 on the disc stack 42. The mechanical stop 74 can be configured and positioned such that the handle 77 extends in a direction from the inner surface 16 of the wheel 10 toward the disc stack 42. The handle 77 can be configured to encounter the disc stack 42 when the mechanical stop 74 encounters the disc stack 42. In some examples, the mechanical stop 74 includes a pin 73 defining the handle 77 and having a head 75 attached to the handle 77. The wheel 10 can be configured to engage a portion of the pin 73 to limit at least the movement of the handle 77 relative to the wheel 10. For example, the wheel 10 can be configured to substantially trap a portion of the mechanical stop 74 (e.g., the head 75) between the inner section 22 and the outer section 23 of the wheel 10. The wheel 10 may be configured to restrict the movement of the pin 73 in any suitable manner, including by internal or external threads defined by the wheel 10, fasteners and / or locking devices configured to engage the pin 73 and the wheel 10, interference and / or engineered fit between the pin 73 and the recess defined by the wheel 10, or welding, brazing or other connection between the pin 73 and the wheel 10.

[0064] Figure 7 Another exemplary mechanical stop 80 is shown, which is configured as a step or flange engaging with the wheel 10. Mechanical stop 80 is an example of mechanical stop 74. Mechanical stop 80 extends from the inner surface 16 of the wheel 10 (e.g., radially inward from the inner surface 16). Mechanical stop 80 may be configured to act as a substantially rigid body relative to the wheel 10. In some examples, mechanical stop 80 defines a support surface 82 configured to undergo a threshold linear deformation (e.g., causing a displacement D2) in the torque tube 31. Figure 5When the linear deformation of the bearing surface 82 encounters the disk pile 42, the bearing surface 82 can be configured to apply a reaction force F3 to the disk pile 42 when the bearing surface 82 encounters the disk pile 42. Figure 5 In the example, the support surface 82 is configured to substantially face a portion of the disk stack 42. The support surface 82 may be configured to substantially abut a portion of the disk stack 42 when the mechanical stop 80 encounters the disk stack 42.

[0065] The support surface 82 may be a substantially planar surface in some examples and a curved surface in others. In some examples, the support surface 82 defines a surface complementary to the surface of the disc stack 42. For example, the support surface 82 may be configured to complement the surface of a brake disc (e.g., rotor disc 45) when the support surface 82 encounters the surface of that brake disc. For example, in some examples, the support surface 82 includes a first planar surface, and the surface of the brake disc defines a second planar surface, wherein the first and second planar surfaces are substantially parallel (e.g., parallel or nearly parallel within manufacturing tolerances) when the disc stack 42 is positioned within the wheel well 17. Alternatively, one of the first or second support surfaces may be a convex surface, and the other may be a concave surface configured to receive and at least partially mate with the convex surface when the mechanical stop 80 encounters the disc stack 42. For example, one of the first support surface or the second support surface may define a protrusion, and the other of the first support surface or the second support surface may define a recess configured to receive the protrusion and at least partially mate with the protrusion when the mechanical stop 80 encounters the stack 42.

[0066] The support surface 82 is defined by a height measured in a direction perpendicular to axis A, wherein this height is sufficient to cause the support surface 82 to encounter the disk stack 42 when the actuator 39 causes a threshold linear deformation of the torque tube 31. The support surface 82 may be defined by a width measured in a direction perpendicular to both the height and axis A. In some examples, the width of the support surface 82 is defined by an arc around axis A. The support surface 82 may be defined by a substantially constant height within its width. In some examples, the support surface is defined by a height that varies within its width.

[0067] Figure 8 Another exemplary mechanical stop 84 is shown, which is illustrated as engaging with a component 86 (“wheel component 86”) of the wheel 10. Mechanical stop 84 is an example of mechanical stop 74 and / or mechanical stop 80. Figure 8In the example shown, the mechanical stop 84 engages with the wheel component 86. The wheel component 86 may be part of the rotor drive key 25. The wheel component 86 may be configured to be substantially stationary relative to the inner surface 16 of the wheel 10, such that when the wheel 10 (and the inner surface 16) rotates about axis A, the wheel component 86 rotates about axis A. Therefore, the rotation of the wheel component 86 about axis A causes the mechanical stop 84 to rotate about axis A. The wheel component 86 may be, for example, part of the rotor drive key 25, or some other component of assembly 70 configured to rotate about axis A as the wheel 10 rotates about axis A.

[0068] The wheel component 86 is configured to apply a reaction force (e.g., reaction force F3) to the disc stack 42 on the mechanical stop 84. Figure 5 The mechanical stop 84 is restricted from movement when the actuator 39 abuts against the mechanical stop 84 compressing the disc stack 42. In some examples, the mechanical stop 84 is configured such that when the actuator 39 abuts against the mechanical stop 84 compressing the disc stack 42, the mechanical stop 84 transmits the force caused by the compressive force acting on the mechanical stop 84 by the actuator 39 to the wheel assembly 86. The wheel assembly 86 may be configured to apply substantially equal and opposite forces to the mechanical stop 84 to restrict movement of the mechanical stop 84 in a direction parallel to axis A.

[0069] Wheel 10 is configured to limit the movement of wheel component 86 relative to wheel 10 when wheel component 86 applies a force to mechanical stop 84 (e.g., when actuator 39 causes mechanical stop 84 to transmit force to wheel component 86). For example, wheel 10 may be configured to limit wheel component 86 to move substantially parallel to the compressive force (e.g., compressive force F) applied by actuator 39 to disk stack 42. Figure 3 , Figure 5 Movement in the direction of the direction of the motion. The wheel 10 can be configured to apply substantially equal and opposite forces to the wheel assembly 86 when the mechanical stop 84 transmits force to the wheel assembly 86. Therefore, the mechanical stop 84 can be configured to substantially transmit a portion of the compressive force F applied by the actuator 39 from the disc stack 42 to the wheel 10. The mechanical stop 84 can be configured to reduce and / or substantially eliminate the load on the torque tube 31 caused by the actuator 39, such that the linear deformation of the torque tube 31 is reduced and / or substantially stopped and the maximum distance between the actuator housing 52 (e.g., point P) and the disc stack 42 is limited.

[0070] In the example, wheel component 86 is attached to or defined by rotor drive key 25. For example, wheel component 86 may be part of rotor drive key 25, and mechanical stop 84 may be an integral (e.g., substantially inseparable) part of rotor drive key 25, or may be separate from and attached to rotor drive key 25. As discussed above, wheel 10 may be configured to limit movement of rotor drive key 25 relative to wheel 10 using one or more fasteners 35 (e.g., bolts) to attach rotor drive key 25 to wheel 10. In the example, instead of or in addition to fasteners 35, wheel 10 may be configured to receive a protrusion 88 of rotor drive key 25 within a recess 90 defined by wheel 10.

[0071] The rotor drive key 25 can be configured to apply a force (e.g., via fastener 35, protrusion 88, or another attachment mechanism) to the wheel 10 when the mechanical stop 84 transmits a force (e.g., caused by a compressive force acting on the mechanical stop 84 by the actuator 39) to the rotor drive key 25. The wheel 10 can be configured to apply substantially equal and opposite forces to the rotor drive key 25 when the mechanical stop 84 transmits a force to the rotor drive key 25. Therefore, the rotor drive key 25 can be configured to substantially transmit a portion of the compressive force F applied by the actuator 39 from the disk stack 42 to the wheel 10 when the mechanical stop 84 encounters the disk stack 42.

[0072] In some examples, the rotor drive key 25 is configured to have a greater axial stiffness than the torque tube 31 in a direction substantially parallel to the direction of the compressive force F. For example, the rotor drive key 25 may comprise a material and / or have a geometry that causes the axial stiffness of the rotor drive key 25 to exceed that of the torque tube 31. The greater axial stiffness allows the rotor drive key 25 to adequately unload the torque tube 31 without causing linear deformation of the rotor drive key 25 and / or without causing additional linear deformation of the torque tube 31.

[0073] exist Figure 8 In the example shown, mechanical stop 84 defines a support surface 92, which is configured to undergo a threshold linear deformation (e.g., causing a displacement D2) in the torque tube 31. Figure 5 When the linear deformation of the bearing surface 92 encounters the disk stack 42, the bearing surface 92 may be an example of the bearing surface 82 and may be configured relative to the disk stack 42 in the same manner as discussed for the bearing surface 82 and the disk stack 42.

[0074] The exemplary wheel assembly described herein may include any suitable number of mechanical stops. Figure 9A portion of an assembly 70 with multiple mechanical stops, including mechanical stops 102, 104, and 106, is schematically shown. The assembly 70 is shown in a direction viewed along axis A. That is, Figure 9 The image shows a wheel 10 with its axis A perpendicular to the page. Mechanical stops 102, 104, and 106 are examples of mechanical stops 74, 80, and / or 84, respectively. Figure 9 The inner surface 16, wheel hub 19, inner bead seat 20, and multiple rotor drive keys 24 engaging with the inner surface 16 are further shown. For clarity, Figure 9 The braking system 40 is omitted. Mechanical stops 102, 104, and 106 are positioned around axis A within the wheel well 17 of wheel 10.

[0075] Each of the mechanical stops 102, 104, and 106 can be configured to apply a reaction force (e.g., reaction force F3) to the disk stack 42 when the mechanical stop 102, 104, or 106 encounters the disk stack 42. Figure 5 Mechanical stops 102, 104, 106 may be configured about axis A to distribute the applied reaction force across the disk stack 42 (e.g., to reduce stress on the disk stack 42 and / or eliminate concentration on portions of the disk stack). For example, mechanical stops 102, 104, 106 may be configured to apply reaction forces at one or more locations on rotor disks 43, 44, 45 and / or stator disks 47, 48. Mechanical stops 102, 104, 106 may be configured to apply reaction forces substantially around the periphery of rotor disks 43, 44, 45 and / or stator disks 47, 48. Assembly 70 may include mechanical stops sufficient to cause one or more of the mechanical stops to encounter the disk stack 42 when actuator 39 compresses the disk stack 42 (e.g., when actuator 39 causes torque tube 31 to undergo threshold linear deformation). Figure 3 , Figure 5 , Figure 6 Any number of mechanical stops arranged in any manner.

[0076] Each of the mechanical stops 102, 104, and 106 can be radially displaced from axis A. For example, Figure 9A mechanical stop 102 is shown that is radially displaced by a radius R from axis A. Each of the mechanical stops 102, 104, 106 can be radially displaced from axis A by a separate radius centered on axis A. The separate radius can define different displacements for each mechanical stop and / or substantially similar displacements for one or more mechanical stops. In the example, mechanical stops 102, 104, 106 are positioned together with wheel wells 17 to define a substantially circumferential pattern about axis A. Mechanical stops 102, 104, 106 can be spaced uniformly or non-uniformly about axis A. Mechanical stops 102, 104, 106 can be spaced such that the spacing distance (e.g., arc length) between adjacent mechanical stops is substantially equal about axis A. Mechanical stops 102, 104, 106 can be spaced such that the spacing distance (e.g., arc length) between adjacent mechanical stops varies about axis A. The spacing and / or arc length can be defined in a position substantially perpendicular to axis A.

[0077] In the example, each mechanical stop 102, 104, 106 is configured to reside substantially between adjacent rotor drive keys in a plurality of rotor drive keys 24. For example, Figure 9 A mechanical stop 102 is shown, substantially positioned between rotor drive key 25 and adjacent rotor drive key 15. The mechanical stop 102 may be configured to be closer to rotor drive key 15 than to rotor drive key 25, farther from rotor drive key 15 than to rotor drive key 25, or substantially equidistant from both rotor drive keys 25 and 15. In some examples, the mechanical stop 102 may extend substantially from rotor drive key 25 to rotor drive key 15, such that the mechanical stop 102 is configured to exert a reaction force on the disk stack 42 over a larger area (e.g., to reduce stress on the disk stack 42).

[0078] Component 70 may include any suitable number of mechanical stops between adjacent rotor drive keys (e.g., rotor drive key 25 and rotor drive key 15), and the mechanical stops may be arranged in any pattern relative to the adjacent rotor drive keys. For example, a first mechanical stop and a second mechanical stop may be located between rotor drive key 25 and rotor drive key 15, wherein the first mechanical stop is closer to rotor drive key 25 than to rotor drive key 15, and the second mechanical stop is closer to rotor drive key 15 than to rotor drive key 25.

[0079] The mechanical stops described herein, including mechanical stops 74, 80, 84, 102, 104, and 106, as well as the wheel 10 and brake system 40 and their components, may be made of any suitable material. For example, the material may be any material having suitable strength for the intended use of the mechanical stops 74, 80, 84, 102, 104, and 106, the wheel 10, the brake system 40, and their components. In some examples, the material includes metals or metal alloys. For example, the material may include nickel alloys or steel alloys. As an example, the material may include stainless steel.

[0080] Mechanical stops 74, 80, 84, 102, 104, 106, wheels 10, brake systems 40, and their components can be formed using any suitable technique. Mechanical stops 74, 80, 84, 102, 104, 106, wheels 10, brake systems 40, and their components can be produced by bar forging, casting, manufacturing, additive manufacturing (e.g., 3D printing), extrusion, stretching, or using other suitable methods. In some examples, mechanical stops 74, 80, 84, 102, 104, 106, wheels 10, brake systems 40, and their components can be machined to define the configuration described herein. In other examples, mechanical stops 74, 80, 84, 102, 104, 106, wheels 10, brake systems 40, and their components can be formed without substantially any machining.

[0081] In some examples, wheel 10 may be finished from near-net-shaped forged aluminum and includes axial components and / or wheel rims for assembling brake system 40 and / or mechanical stops 74, 80, 84, 102, 104, 106 onto wheel 10. In other examples, wheel 10 may be manufactured in a different manner. In still other examples, wheel 10 may be obtained rather than manufactured. Wheel 10 may be made of any suitable material. In some examples, wheel 10 comprises metal or metal alloy. For example, wheel 10 may comprise aluminum, nickel alloy, steel alloy (e.g., stainless steel), titanium, carbon composite, or magnesium.

[0082] The brake discs described herein, including rotor discs 43, 44, 45 and stator discs 47, 48, can be manufactured from any suitable material. In some examples, the brake discs described herein can be made of metal or metal alloys (such as steel alloys). In some examples, the brake discs can be manufactured using ceramic materials such as ceramic composites. In some examples, the brake discs can be manufactured using carbon-carbon composite materials. In some examples, the brake discs can be manufactured using carbon-carbon composite materials with high thermal stability, high wear resistance, and / or stable frictional properties. The brake discs may include carbon materials having multiple carbon fibers and dense material. The carbon fibers may be arranged as a single layer or multiple layers in woven or nonwoven fabrics.

[0083] Figure 10 This is a flowchart illustrating an exemplary technique for compressing a stack of discs using an actuator. Although the technique is described with reference to the specific exemplary wheels 10, brake system 40, and mechanical stops 74, 80, 84, 102, 104, 106 described herein, the technique may be used with other components in other examples.

[0084] The technique involves using an actuator 39 to compress the disc stack 42 (1002). The braking system 40 can be configured such that compression of the disc stack 42 by the actuator 39 causes engagement of the friction surfaces of the rotor discs 43, 44, 45 and the stator discs 47, 48, thereby reducing and / or substantially preventing rotation of the wheel 10. The rotor discs 43, 44, 45 and the stator discs 47, 48 can be configured to translate in a direction substantially parallel to the axis A of the wheel 10 as the actuator 39 compresses the disc stack 42. The actuator 39 can be configured to apply a compressive force F to the disc stack 42 to compress it. In an example, the actuator 39 includes an actuator body 52 and a piston 54 configured to translate relative to the actuator body 52 to cause compression of the disc stack 42. The actuator 39 can be configured to cause the piston 54 to translate relative to the actuator body 52 using a pressurized hydraulic fluid supply source, one or more electric motors, or some other suitable method.

[0085] Actuator 39 may be configured to compress disk stack 42 against back plate 50 using a compressive force F. Back plate 50 may be configured to transmit at least a portion of the compressive force F to torque tube 31. Torque tube 31 may be configured to apply a reaction force to back plate 50 in response to the compressive force F. Torque tube 31 may be configured such that under certain conditions (e.g., high thermal load), torque tube 31 deforms linearly as it applies a reaction force to back plate 50.

[0086] Mechanical stops 74, 80, 84, 102, 104, and 106 are used to limit the linear displacement (1004) of the disk stack 42. For example, when the actuator 39 compresses the disk stack 42, the disk stack 42 may encounter the mechanical stops 74, 80, 84, 102, 104, and 106, at least in part, due to the tension of the torque tube 31 in a direction parallel to axis A. The mechanical stops 74, 80, 84, 102, 104, and 106 can be configured to apply a reaction force F3 to the disk stack 42 when the mechanical stops 74, 80, 84, 102, 104, and 106 encounter the disk stack 42. Figure 5Mechanical stops 74, 80, 84, 102, 104, and 106 can be configured to reduce the reaction force exerted by the torque tube 31 on the back plate 50 when the mechanical stops 74, 80, 84, 102, 104, and 106 apply a reaction force F3. Therefore, mechanical stops 74, 80, 84, 102, 104, and 106 are configured to limit the linear displacement of the disk stack 42 when they encounter it. Mechanical stops 74, 80, 84, 102, 104, and 106 can be configured to limit and / or substantially stop the linear deformation of the torque tube 31 when they encounter the disk stack 42.

[0087] Component 70 can be configured such that when actuator 39 compresses disk stack 42, disk stack 42 encounters back plate 50 before encountering mechanical stops 74, 80, 84, 102, 104, 106. In some examples, component 70 defines a first length L1 between actuator 39 and mechanical stops 74 and a second length L2 between actuator 39 and back plate 50, wherein the first length L1 is greater than the second length L2. In examples, the first length L1 and the second length L2 may be substantially parallel to axis A. Component 70 can be configured such that the threshold linear deformation of torque tube 31 caused by compression F from actuator 39 substantially causes disk stack 42 to encounter mechanical stops 74, 80, 84, 102, 104, 106.

[0088] A portion of the reaction force F3 applied by the mechanical stops 74, 80, 84, 102, 104, 106 is transmitted to the wheel 10. The wheel 10 may be configured to substantially restrict the movement of the mechanical stops 74, 80, 84, 102, 104, 106 when the reaction force F3 is applied. The wheel 10 may be configured to apply force to the mechanical stops 74, 80, 84, 102, 104, 106 in response to the reaction force F3 applied by the mechanical stops 74, 80, 84, 102, 104, 106 to the disk stack 42. In some examples, the mechanical stops 74, 80, 84, 102, 104, 106 are elongated pins supported and / or defined by the wheel 10. In some examples, mechanical stops 74, 80, 84, 102, 104, and 106 are steps or flanges supported and / or defined by the wheel 10. In some examples, mechanical stops 74, 80, 84, 102, 104, and 106 are supported by wheel components 86 of the wheel 10. The wheel component 86 may be a rotor drive key 25, 15 among a plurality of rotor drive keys 24 coupled to the inner surface 16 of the wheel 10.

[0089] This disclosure includes the following embodiments.

[0090] Example 1: An assembly comprising: a wheel configured to rotate about a wheel axis; a braking system comprising: a disc stack including a rotor disc and a stator disc, wherein the rotor disc is rotatably coupled to the wheel, and wherein the wheel is configured to rotate relative to the stator disc; and an actuator defining an actuator housing and configured to compress the disc stack, wherein the braking system is configured to compress the disc stack by limiting linear movement of the disc stack by applying a reaction force to the disc stack when the actuator compresses the disc stack, and wherein a portion of the braking system is configured to deform linearly when the braking system applies the reaction force; and a mechanical stop configured such that the linear deformation of the portion of the braking system causes the mechanical stop to reduce the reaction force applied by the braking system when it encounters the braking system, such that the mechanical stop limits linear displacement of the disc stack relative to the actuator housing.

[0091] Example 2: The component according to Example 1, wherein the mechanical stop is configured to encounter the disc stack when the mechanical stop encounters the brake system.

[0092] Example 3: The component according to Example 1 or 2, wherein the mechanical stop is configured to transmit at least a portion of the reaction force to the wheel.

[0093] Example 4: The component according to any one of Examples 1-3, wherein the mechanical stop is rotatably connected to the wheel.

[0094] Example 5: The component according to any one of Examples 1-4, wherein the mechanical stop is configured to maintain displacement between the braking system and the wheel.

[0095] Example 6: The component according to Example 5, wherein the braking system includes a torque tube, wherein the wheel is configured to rotate relative to the torque tube, and wherein the mechanical stop is configured to maintain displacement between the torque tube and the wheel.

[0096] Example 7: The component according to any one of Examples 1-6 further includes: a wheel component attached to the wheel, wherein the wheel component includes the mechanical stop.

[0097] Example 8: The component according to Example 7, wherein the wheel component is a rotor drive key.

[0098] Example 9: The component according to any one of Examples 1-8, wherein the mechanical stop includes a support surface defined by the inner surface of the wheel, wherein the support surface is configured to encounter the brake disc stack.

[0099] Example 10: The component according to any one of Examples 1-9 further includes: a back plate configured to encounter the disc stack when the actuator compresses the disc stack, wherein the wheel is configured to rotate relative to the back plate, and wherein the back plate is configured to move in the axial direction of the wheel when the portion of the braking system deforms linearly.

[0100] Example 11: The component according to any one of Examples 1-10, wherein the brake system includes a torque tube configured to apply a portion of the reaction force, and wherein the mechanical stop is configured to reduce the portion of the reaction force applied by the torque tube when the mechanical stop encounters the brake system and the actuator compresses the disc stack, such that the mechanical stop reduces the reaction force applied by the brake system and limits the linear displacement of the disc stack relative to the actuator housing.

[0101] Example 12: The component according to any one of Examples 1-11, wherein: the actuator is configured to compress the disk stack using a compressive force, the actuator defines a first length between the actuator and the mechanical stop in the absence of the compressive force, the actuator defines a second length between the actuator and the back plate in the absence of the compressive force, the first length and the second length are measured in a parallel direction, and the first length is greater than the second length.

[0102] Example 13: The component according to any one of Examples 1-12, wherein the mechanical stop is configured to be rotatably coupled to the portion of the wheel when encountering the stack of discs.

[0103] Example 14: The component according to any one of Examples 1-13, wherein the mechanical stop is configured to encounter a portion of the disk stack, and wherein the wheel is configured to rotate relative to that portion of the disk stack.

[0104] Example 15: The component according to any one of Examples 1-14, wherein the mechanical stop is configured to encounter a drive insert located in the drive slot of the rotor disk.

[0105] Example 16: An assembly comprising: a wheel configured to rotate about a wheel axis; a braking system comprising: a disc stack; a torque tube configured to engage the disc stack; a backplate attached to the torque tube, wherein the backplate is configured to restrict movement of the disc stack in a direction parallel to the wheel axis; and an actuator configured to compress the disc stack against the backplate using a compressive force, wherein the backplate is configured to apply a reaction force to the disc stack when the actuator compresses the disc stack; and a mechanical stop configured to encounter the disc stack, wherein: the mechanical stop... The stop is configured to reduce the reaction force when the mechanical stop encounters the disc stack, and the mechanical stop is configured to restrict the movement of the disc stack in a direction parallel to the wheel axis when the mechanical stop encounters the disc stack, such that the mechanical stop restricts the linear displacement of the disc stack relative to the actuator; the actuator defines a first length between the actuator and the mechanical stop in the absence of the compressive force, and the actuator defines a second length between the actuator and the backplate in the absence of the compressive force, the first length and the second length being measured in a direction parallel to the wheel axis, and the first length being greater than the second length.

[0106] Example 17: The component according to Example 16, wherein the mechanical stop is rotatably coupled to the wheel, and wherein the mechanical stop is configured to encounter the portion of the disc stack that is rotatably coupled to the wheel.

[0107] Example 18: The component according to Example 16 or 17, wherein the mechanical stop is configured to transmit at least a portion of the reaction force to the wheel when the mechanical stop encounters the disc stack.

[0108] Example 19: A method comprising: using an actuator of a brake system to compress a disc stack of the brake system, wherein the disc stack includes a rotor disc rotatably coupled to a wheel and a stator disc, wherein the wheel is configured to rotate about the stator disc, wherein the brake system applies a reaction force to the disc stack when the actuator compresses the disc stack; and limiting the movement of the disc stack by means of reducing the reaction force applied by the brake system by causing the brake system to encounter a mechanical stop through the compression of the disc stack by the actuator.

[0109] Example 20: The method according to Example 19, wherein the mechanical stop rotates substantially synchronously with the rotor disk, the method further comprising: causing the mechanical stop to contact the brake system by bringing the rotor disk and the mechanical stop into contact.

[0110] Various examples have been described. These and other examples are within the scope of the following claims.

Claims

1. A component comprising: A wheel, the wheel being configured to rotate about a wheel axis; A braking system, the braking system comprising: A disk stack, the disk stack including a rotor disk and a stator disk, wherein the rotor disk is rotatably coupled to the wheel, and wherein the wheel is configured to rotate relative to the stator disk; and An actuator, defining an actuator housing and configured to compress the disk stack, The braking system is configured to compress the disk stack by limiting its linear movement through a reaction force applied to the disk stack when the actuator compresses it. A portion of the braking system is configured to undergo linear deformation when the reaction force is applied by the braking system; and A mechanical stop rotatably coupled to the wheel is configured to reduce the reaction force exerted by the braking system when the mechanical stop encounters the braking system due to the linear deformation of the portion of the braking system, thereby limiting the linear displacement of the disc stack relative to the actuator housing.

2. The component according to claim 1, wherein, The mechanical stop is configured to encounter the disc stack when it encounters the braking system.

3. The component according to claim 1 or claim 2, wherein, The mechanical stop is configured to transmit at least a portion of the reaction force to the wheel.

4. The component according to claim 1 or claim 2, wherein, The mechanical stop includes a support surface defined by the inner surface of the wheel, wherein the support surface is configured to encounter the disc stack.

5. The component according to claim 1 or claim 2, wherein, The mechanical stop is configured to maintain displacement between the braking system and the wheel.

6. The component according to claim 5, wherein, The braking system includes a torque tube, wherein the wheel is configured to rotate relative to the torque tube, and wherein the mechanical stop is configured to maintain displacement between the torque tube and the wheel.

7. The component according to claim 1 or claim 2, further comprising: A wheel assembly attached to the wheel, wherein the wheel assembly includes the mechanical stop.

8. The component according to claim 1 or claim 2, further comprising: A backplate, configured to encounter the disk stack when the actuator compresses the disk stack, wherein: The actuator is configured to use compressive force to compress the disk stack. The actuator defines a first length between the actuator and the mechanical stop when the compressive force is absent. The actuator defines a second length between the actuator and the backplate in the absence of the compressive force, the first length and the second length being measured in a parallel direction, and The first length is greater than the second length.

9. A method comprising: An actuator of a braking system is used to compress the disc stack of the braking system, wherein the disc stack includes a rotor disc and a stator disc rotatably coupled to a wheel, wherein the wheel is configured to rotate about a wheel axis, wherein the braking system applies a reaction force to the disc stack when the actuator compresses the disc stack, and wherein a mechanical stop is configured to rotate substantially synchronously with the wheel. as well as The movement of the disc stack is limited by reducing the reaction force applied by the braking system through the compression of the disc stack by the actuator, causing the braking system to encounter the mechanical stop.

10. The method of claim 9, further comprising: The mechanical stop is brought into contact with the braking system by contacting the rotor disc.

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