Assembled Axle Brake Disc with Support Bolts
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Solution Overview
Problem
Existing wave brake discs for rail vehicles face challenges in withstanding high mechanical loads and achieving effective heat dissipation, particularly due to the limitations of current designs in absorbing axially acting pad contact pressure forces and thermal expansion between ceramic or carbon friction rings and metallic hubs.
Innovation Solution
A built wave brake disc with a hub and two parallel, spaced friction rings made of steel, featuring rotationally symmetrical support bolts with a central section and end pins, connected via sliding blocks and screws, allowing for independent assembly and optimal material selection for mechanical and thermal loads, along with internal ventilation for enhanced heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If support bolts are arranged between friction rings to absorb high axially acting pad contact pressure forces, then mechanical strength is improved, but device complexity increases
Solution Approach 1:
The brake disc is divided into modular components: a hub, two friction rings, and multiple support bolts arranged between the friction rings. This segmentation allows each component to be optimized independently for its specific function while maintaining overall structural integrity under high mechanical loads
Solution Approach 2:
The invention employs composite material construction with friction rings made from ceramic or carbon materials mounted on a metallic hub. This composite approach enables the friction rings to withstand high contact pressure forces while the metallic hub provides structural support and heat dissipation
2Reliability
If complex connection geometries are used to avoid heat-induced stresses between ceramic or carbon friction rings and metallic hub, then thermal stress resistance is improved, but manufacturing complexity increases
Solution Approach 1:
Connection elements serve as intermediaries between the ceramic or carbon friction rings and the metallic hub. These intermediaries accommodate thermal expansion differences and prevent heat-induced stresses while simplifying the connection geometry and manufacturing process
Solution Approach 2:
The invention utilizes controlled thermal expansion parameters by designing connection geometries that allow for differential expansion between ceramic/carbon friction rings and the metallic hub. This parameter adjustment prevents thermal stress accumulation while maintaining structural integrity
3Temperature
If friction rings are made from ceramic or carbon materials, then heat dissipation is improved, but mechanical connection complexity increases
Solution Approach 1:
The brake disc is segmented into a metallic hub and separate ceramic or carbon friction rings connected through standardized support bolts and connection elements. This segmentation enables optimal heat dissipation properties of ceramic/carbon materials while using standardized connection components to reduce overall complexity
Solution Approach 2:
The support bolts and connection elements serve multiple functions: they mechanically connect the friction rings to the hub, absorb axial pad contact pressure forces, and accommodate thermal expansion differences. This multi-functionality reduces the number of separate components needed
4Temperature
If support bolts are optimized for heat dissipation through tangential ventilation, then thermal management is improved, but mechanical load-bearing capacity may be reduced
Solution Approach 1:
The support bolts are designed to perform multiple functions simultaneously: they provide mechanical connection between friction rings and hub, absorb axial pad contact pressure forces, and create tangential ventilation channels for heat dissipation. This multi-functionality ensures both load-bearing capacity and thermal management are maintained
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 provides a robust and adaptable wave brake disc capable of withstanding high mechanical loads and optimizing heat dissipation, with the ability to quickly replace friction rings and adjust geometry, while minimizing thermal stresses and weight, thus improving performance and durability.
Implementation Method 1
Support bolts can extend between the friction rings, which are designed to absorb axially acting lining contact pressure forces
Implementation Method 2
The brake disk can be cooled by heat convection through this air throughput, and the air flow is generated by the rotation of the shaft brake disk about its axis of rotation
Implementation Method 3
If a shaft brake disc has support bolts between the friction rings, these tend to produce tangential ventilation. Due to the rotation of the shaft brake disc, the surface of the support bolt is tangentially flowed, which means that heat is dissipated by convection
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to an assembled undular brake disc (1) having a hub (10) on which two friction rings (11, 12) which are produced from a steel material are arranged parallel to and spaced apart from one another, which assembled undular brake disc can withstand high mechanical loads and permits good internal ventilation, wherein supporting bolts (13) for absorbing an axially acting pad contact pressure force (14) are arranged between the friction rings (11, 12).