Additive Wheel Suspension With Integrated Brake Caliper Cooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing motor-vehicle wheel suspension devices are heavy, costly, and inefficient in cooling the braking system, leading to increased noise and vibrations, especially on uneven surfaces.
Innovation Solution
A suspension device formed using additive manufacturing technology, where the brake caliper and support member are integrated into a single piece, combined with a single-piece brake disc cover, incorporating an air intake and radial openings for improved cooling and reduced component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional multi-component suspension devices are used, then structural robustness is maintained, but weight increases and manufacturing cost increases
Solution Approach 1:
The patent combines the brake caliper and support member into a single integrated component formed by additive manufacturing, eliminating the need for separate fastening members and reducing the total number of parts. This merging of components directly reduces weight while maintaining structural integrity through the monolithic construction.
2Temperature
If traditional braking systems are used, then basic braking function is provided, but cooling efficiency is insufficient leading to increased noise and vibrations
Solution Approach 1:
The brake disc cover incorporates a porous structure with multiple openings that facilitate air flow through the braking system. This porous design enables efficient cooling of the brake disc and caliper, reducing temperature buildup that would otherwise cause thermal expansion, noise, and vibrations during braking operations.
3Ease of manufacture
If conventional manufacturing methods are used, then traditional component production is maintained, but manufacturing cost increases and production efficiency decreases
Solution Approach 1:
The patent replaces traditional mechanical manufacturing methods (casting, machining, assembly) with additive manufacturing technology. This substitution enables complex geometries to be produced directly from digital models in a single process step, eliminating multiple manufacturing stages, reducing tooling costs, and improving production efficiency while lowering overall manufacturing costs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a lighter, cheaper, and more effective suspension system that reduces noise and vibrations, enhances cooling, and maintains structural robustness, thereby improving the overall performance of the braking system.
Implementation Method 1
additive manufacturing technology, in which an energy source is used, such as a laser or plasma beam, to selectively melt layers of powders or wires of metal material or plastic material
Implementation Method 2
peripheral portion, at least partially surrounding the brake disc, having a plurality of openings arranged radially in succession along the peripheral portion
Data Source
AI summary
A suspension device of a motor-vehicle wheel includes a support member of the motor-vehicle wheel connectable to the motor-vehicle structure by means of one or more suspension members, a brake disc connected in rotation with the motor-vehicle wheel, a brake caliper associated with the brake disc and a brake disc cover. The brake caliper is formed in a single piece with the support member of the motor-vehicle wheel by means of additive manufacturing technology.