Brake Carrier Rib Geometry for Lower Weight and Stress Peaks
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Solution Overview
Problem
Existing brake carriers for heavy commercial vehicles are heavy due to strength requirements and have limited installation space, leading to geometric design constraints that hinder weight and cost optimization.
Innovation Solution
A brake carrier design featuring a reinforcing rib with a contour line that rises steadily towards the center, reducing stress peaks and allowing for selective reduction in wall thicknesses, thereby optimizing weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the brake carrier is designed with sufficient wall thickness to meet strength requirements, then the structural strength is improved, but the weight increases
Solution Approach 1:
The brake carrier employs varying wall thicknesses in different regions, with thicker walls at the mounting flange and support horn areas where strength is critical, and thinner walls in less critical areas. This local differentiation optimizes the strength-to-weight ratio by concentrating material where it is most needed.
Solution Approach 2:
The brake carrier is divided into multiple functional regions with different wall thickness specifications. The mounting flange has a first wall thickness, the support horn area has a second wall thickness, and the brake disc surrounding area has a third wall thickness, allowing each segment to be optimized for its specific functional requirements.
2Weight of moving object
If the brake carrier weight is reduced for payload optimization, then the payload capacity is improved, but the structural strength may be compromised
Solution Approach 1:
The design uses non-uniform wall thickness distribution, maintaining adequate thickness only where structurally necessary while reducing it elsewhere, achieving weight reduction without compromising overall strength.
Solution Approach 2:
The patent introduces a third dimension (wall thickness variation) to the design, moving from a uniform thickness approach to a graduated thickness approach, enabling weight optimization while preserving strength through dimensional differentiation.
3Volume of moving object
If the installation space is increased to accommodate larger brake carrier geometry, then the design flexibility is improved, but the vehicle payload capacity worsens
Solution Approach 1:
The brake carrier utilizes varying wall thicknesses to achieve the required structural performance within a compact volume, eliminating the need for increased overall dimensions while maintaining strength requirements.
Data Source
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AI summary
The invention relates to a one-piece brake carrier for a disk brake of a vehicle having a brake disk, said brake carrier being produced by means of a primary shaping process, wherein the brake carrier has a frame-like disk-encompassing element and two hub sweeps (6) parallel to each other, which are oriented parallel to the brake disk, and wherein the brake carrier also has, at least on one side facing a fastening flange, a stiffening rib (2) protruding or raised from the brake carrier in the axial direction in relation to a brake disk rotational axis (19), wherein the stiffening rib (2) is designed as a continuous contour having a preferably continuously rising course from two outer ends to a central axis of symmetry.