Brake Disc Cover Offset Contact Surfaces Flapping Prevention
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Solution Overview
Problem
Disc brake covers are prone to undesirable flapping behavior due to dynamic and aerodynamic forces, especially when made of thin-walled materials, which can lead to vibration and instability during practical driving operations.
Innovation Solution
A cover design with offset contact surfaces for attachment to the carrier, where one surface is on one side and the other is on the opposite side, providing support both towards and away from the brake disc, and featuring resilient contact surfaces with a shortest mutual distance less than the carrier thickness, which prevents flapping and jamming on the carrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the cover is made of thin-walled material to reduce weight, then weight is reduced, but the cover exhibits flapping behavior and vibration under dynamic and aerodynamic forces
Solution Approach 1:
The attachment method transitions from single-sided to dual-sided attachment, utilizing the axial dimension to provide support from both directions. The offset contact surfaces are positioned at different axial locations, creating a three-dimensional attachment geometry that prevents flapping while maintaining thin-walled construction.
Solution Approach 2:
The contact surfaces are designed to be resilient rather than rigid, allowing dynamic adaptation to carrier thickness variations and operational forces. This resilience enables the thin-walled cover to maintain stable attachment without requiring increased wall thickness for rigidity.
2Device complexity
If single-sided attachment is used to simplify the design, then device complexity is reduced, but the cover exhibits flapping behavior under dynamic forces
Solution Approach 1:
The attachment structure is segmented into two separate contact surfaces positioned at different axial locations on opposite sides of the carrier. This segmentation provides stable attachment without requiring complex multi-component fastening systems, as each contact surface independently contributes to preventing flapping.
3Stability of the object's composition
If the contact surfaces are made resilient with short mutual distance to prevent flapping, then stability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The contact surfaces are designed with resilience, changing the physical state from rigid to elastic. This parameter change allows the system to accommodate manufacturing tolerances and carrier thickness variations through elastic deformation, reducing the stringency of manufacturing precision requirements while maintaining stable attachment.
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 design effectively counteracts the risk of flapping and vibration, ensuring a stable and secure attachment even with thin-walled materials, providing a flutter-free fastening against wind and vibration forces.
Implementation Method 1
the contact surfaces are resilient to one another, with the shortest mutual distance between them being less than the component thickness of the carrier in the support area in the de-energized state
Implementation Method 2
this design of the contact surfaces results in the cover jamming on the carrier, which additionally counteracts the risk of it being knocked back and forth
Data Source
Figure 1~2
Figure 3~4
AI summary
The cover (20) comprises contact surfaces (31,32) which are movable towards each other in an axial direction and stay opposite to each other at the carrier. One of these contact surfaces is supported from one side opposite the carrier and the other contact surface is supported from the other side. The contact surfaces are connected with each other with 180 degrees in one piece.