Axle-Mounted Brake Disk Rib Structure for Lower Mass and Better Cooling
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Solution Overview
Problem
Conventional axle-mounted brake disks for rail vehicles are excessively heavy due to their mass, which hinders performance and increases production costs, while maintaining the same performance capacity is a challenge.
Innovation Solution
The brake disk design features ribs with varying cross-sections, where some ribs are optimized for mechanical support and others for thermal energy dissipation, allowing for a larger cooling surface area and reduced mass by increasing the packing density of ribs and enlarging the cooling channel area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If ribs are made with uniform cross-section optimized for mechanical support, then mechanical strength is sufficient, but mass is excessive and cooling capacity is insufficient
Solution Approach 1:
The patent applies local quality by differentiating rib cross-sections based on their specific functions: ribs in the cooling channel area have reduced cross-sections optimized for heat dissipation, while ribs in load-bearing areas maintain larger cross-sections for mechanical strength. This localized differentiation reduces overall mass while preserving cooling capacity and structural integrity.
Solution Approach 2:
The patent segments the rib structure into functionally distinct groups: load-bearing ribs with larger cross-sections and cooling ribs with smaller cross-sections. This segmentation allows each rib group to be optimized independently for its specific function, enabling mass reduction in non-critical areas while maintaining performance in critical areas.
2Weight of moving object
If rib cross-sections are reduced to decrease mass, then mass reduction is achieved, but mechanical load absorption capacity is compromised
Solution Approach 1:
The patent ensures mechanical strength by maintaining larger rib cross-sections in load-bearing regions where mechanical loads are transmitted to the axle, while reducing cross-sections only in regions dedicated to cooling functions. This localized quality differentiation preserves load absorption capacity while enabling mass reduction elsewhere.
Solution Approach 2:
The patent segments ribs into load-bearing and cooling functions, ensuring that load-bearing ribs maintain sufficient cross-sections for mechanical strength while cooling ribs can have reduced cross-sections. This functional segmentation prevents compromise of mechanical strength while achieving mass reduction.
3Temperature
If conventional uniform rib design is used, then manufacturing is simple, but cooling surface area is insufficient
Solution Approach 1:
The patent increases cooling surface area by reducing rib cross-sections specifically in the cooling channel regions, creating more extensive cooling passages without significantly complicating the overall manufacturing process. The differentiation is localized to cooling areas, keeping the design relatively simple while enhancing thermal performance.
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
This design results in a 30% mass reduction, enhancing cooling capacity and reducing unsprung mass, thereby increasing payload and improving rail vehicle performance without compromising mechanical load absorption.
Implementation Method 1
at least one cross-section of a first subset of ribs, which are configured as supporting elements transmitting pressure forces
Implementation Method 2
at least one cross-section of a second subset of ribs, serving to dissipate thermal energy
Data Source
AI summary
The invention relates to an axle-mounted brake disk for a rail vehicle, comprising two friction rings which are arranged in parallel and at a distance from each other and are interconnected by a plurality of ribs extending in the direction of the rotational axis of the friction rings, where at least some of the ribs are embodied with different cross-sections from each other, where the cross-sections of a first subset of the ribs, embodied as supporting elements transmitting pressure forces, do not fall below a minimum cross-section, defined by the stability required in relation to the mechanical load during a brake process, and the cross-section of a second subset of the ribs, used to radiate thermal energy, falls below the minimum cross-section.