Land Vehicle Axle Through-Opening Design for Brake Carrier Screw Retention

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Solution Overview

Problem

Existing axle designs for land vehicles with disk brakes face issues with screw release due to transverse forces during braking and on poor road surfaces, leading to the need for larger screw dimensions that increase material consumption and space usage.

Innovation Solution

The first through-opening is designed with a smaller clearance width closer to the flange surface and a larger clearance width further away, reducing the lever arm of transverse forces and preventing screw release, allowing standard screws to be used without the need for complex fitting screws.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the screw dimensions are increased to prevent release due to transverse forces, then the reliability of the connection is improved, but the material consumption and constructional space increase

Engineering Contradiction:

Improveconnection reliabilityVSAvoidmaterial consumption

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The through-opening is designed with non-uniform clearance distribution: a first region with smaller clearance width near the flange surface and a second region with larger clearance width further away. This local differentiation allows the screw to be restrained against transverse forces near the support point while maintaining standard dimensions, thus improving connection reliability without increasing material consumption

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The through-opening is segmented into two distinct regions with different clearance characteristics. The first region (near the flange surface) provides interference fit for screw retention, while the second region (farther from the flange) provides clearance for assembly tolerance compensation. This segmentation enables standard screws to resist transverse forces effectively without requiring oversized dimensions

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If larger screw dimensions are used to counteract transverse forces, then the connection stability is improved, but the constructional space and manufacturing cost increase

Engineering Contradiction:

Improveconnection stabilityVSAvoidconstructional complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The through-opening features localized clearance variation rather than uniform enlargement. The smaller clearance in the first region near the flange surface provides stable screw retention against transverse forces, while the larger clearance in the second region accommodates assembly tolerances. This local quality differentiation maintains connection stability without requiring overall larger screw dimensions or complex fitting screws

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Instead of making the screw larger to resist transverse forces, the invention inverts the approach by designing the through-opening with non-uniform clearance. The opening itself is shaped to provide restraint where needed (near the flange) while allowing clearance elsewhere, thereby maintaining standard screw dimensions and reducing constructional complexity

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of operation

If a clearance fit is used in the through-opening, then the ease of mounting and dismantling is improved, but the positioning precision deteriorates

Engineering Contradiction:

Improvemounting easeVSAvoidpositioning precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The through-opening is divided into two functional regions: the first region with smaller clearance provides interference fit for precise screw positioning and retention, while the second region with larger clearance allows easy assembly by accommodating dimensional tolerances. This segmentation enables both precise positioning and ease of mounting/dismantling

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different clearance characteristics are applied locally within the same through-opening: tight clearance near the flange surface for positioning precision, and larger clearance farther away for assembly ease. This local quality differentiation resolves the contradiction between mounting ease and positioning precision

Inventive Principle:

Principle #3Local quality

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 effectively prevents screw release without increasing screw size, reducing material consumption and avoiding confusion between interference and clearance fits, while maintaining reliable brake carrier positioning.

Implementation Method 1

overcoming frictional forces. As a result, the screw may be released

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

the first through-opening serves for forming an interference fit

Methodology Applied

Scientific EffectInterference fit:

Data Source

PatentUS9994205B2Axis of a land vehicle, land vehicle with such a suspension and disk brake and brake support of such land vehicle

Publication Date: 2018.06.12 ZF CV SYST EURO BV

AI summary

A land vehicle with a disk brake, in particular a utility vehicle with a disk brake, has an axle with a first and a second flange surface for flanging a brake carrier of the disk brake. A first through-opening opens into the first flange surface and a second through-opening opens into the second flange surface. The first through-opening in a first region has a smaller clearance width than in a second region. The first region is located closer to the first flange surface than the second region.