Disc Brake Anchor Bracket Cast Window Machining

Solution Overview

Problem

The existing anchor brackets for vehicle disc brake assemblies require extensive machining of rotor channels post-casting, increasing production complexity and cost.

Innovation Solution

The anchor bracket is designed with cast windows that limit and localize machining, allowing for the creation of rotor channels directly from the as-cast condition, reducing the need for extensive post-casting machining.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the anchor bracket is cast with traditional methods, then the structural integrity is maintained, but extensive machining of rotor channels is required post-casting, increasing production complexity and cost

Engineering Contradiction:

Improveproduction complexityVSAvoidmachining precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by incorporating pre-formed rotor channel cavities directly into the anchor bracket during the casting process. These pre-formed cavities are created using removable inserts or cores placed in the mold before casting, allowing the rotor channels to be partially formed before final machining. This preliminary formation of the rotor channels reduces the amount of post-casting machining required, thereby decreasing production complexity while maintaining the necessary precision for rotor clearance and brake function.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If extensive machining is performed on rotor channels, then the required precision and clearance are achieved, but production time and cost increase

Engineering Contradiction:

Improverotor channel precisionVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent applies preliminary action by incorporating pre-formed rotor channel cavities directly into the anchor bracket during the casting process. These pre-formed cavities are created using removable inserts or cores placed in the mold before casting, allowing the rotor channels to be partially formed before final machining. This preliminary formation of the rotor channels reduces the amount of post-casting machining required, thereby decreasing production complexity while maintaining the necessary precision for rotor clearance and brake function.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If the anchor bracket design is simplified for easier manufacturing, then production cost decreases, but the structural integrity required for brake torque transmission may be compromised

Engineering Contradiction:

Improvemanufacturing easeVSAvoidstructural integrity

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent applies segmentation by dividing the anchor bracket into modular components, including separate arms, tie rods, and pre-formed rotor channel cavities. This modular design allows each component to be optimized independently - the rotor channels are pre-formed with appropriate geometry for structural strength, while the overall bracket design maintains necessary load-bearing capabilities for brake torque transmission. The segmented approach enables easier manufacturing of individual components while preserving the structural integrity of the complete assembly.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS10422393B2Anchor bracket for use in a disc brake assembly, disc brake assembly including such an anchor bracket and method for producing such an anchor bracket

Publication Date: 2019.09.24 KELSEY HAYES CO

AI summary

An anchor bracket for use in a disc brake assembly comprises first and second arms, first and second windows, and first and second rotor channels. The first arm has a first rotor notch and the second arm has a second rotor notch. The first window is cast in the first arm and the second window is cast in the second arm. The first rotor channel is machined from the first rotor notch to the first window and the second rotor channel is machined from the second rotor notch to the second window.