Brake Disc Connecting Clamp for Thermal Expansion and Vibration Control
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Solution Overview
Problem
Existing connecting means for brake disc assemblies are prone to noise, vibrations, and mechanical deterioration due to thermal expansion and vibrations, leading to hot spots and rattling effects, which compromise the integrity and acoustical properties of the brake disc.
Innovation Solution
A clamp with U-shaped design and planar contact surfaces is used to securely attach the brake disc ring to the bell, minimizing rattling effects and reducing wear by distributing force evenly, made from materials with high tensile strength and hardness like stainless steel, replacing traditional spring elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional spring elements are used as connecting means, then the brake disc assembly can accommodate thermal expansion, but the continual hammering effect due to vibrations causes the spring ends to cut into the bell surface, reducing resilient effect and increasing play
Solution Approach 1:
The invention extracts the harmful function of the spring element that causes cutting into the bell surface while retaining the necessary function of accommodating thermal expansion. The clamp design removes the spring element entirely and replaces it with a rigid clamping mechanism that eliminates the hammering effect and cutting problem while still allowing for thermal expansion through controlled clearance or elastic elements at specific locations.
Solution Approach 2:
The invention introduces wear-resistant inserts as intermediary elements between the clamp and the bell surface. These inserts prevent direct contact and cutting into the bell surface while transmitting the necessary forces, thus protecting the bell from damage caused by vibration-induced hammering effects.
2Temperature
If flat spring elements are used to provide resilient coupling, then thermal expansion can be accommodated, but the spring characteristic is too flat leading to excessive play and deterioration of mechanical properties
Solution Approach 1:
The invention changes the mechanical parameters of the connecting means by replacing the flat spring element with a clamp design that has different stiffness characteristics. The clamp provides controlled rigidity that maintains mechanical and acoustical stability while still accommodating thermal expansion through designed clearances or localized elastic elements, thus improving the overall stability of the brake disc assembly.
3Stability of the object's composition
If rigid connecting means are used to eliminate play, then mechanical stability is improved, but thermal expansion causes excessive mechanical tension and hot spots
Solution Approach 1:
The invention segments the connecting means into a rigid clamp portion for maintaining mechanical stability and a compliant portion (such as elastic elements or controlled clearances) for accommodating thermal expansion. This segmentation allows the system to maintain rigidity where needed while providing flexibility to handle thermal stresses, thus preventing hot spots and excessive mechanical tension.
4Reliability
If multiple wear-resistant inserts are used in the bell, then wear protection is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The invention makes the clamp design universal by integrating the wear protection function directly into the clamp structure or by using a standardized insert system that serves multiple purposes. The clamp itself is designed to distribute loads evenly and minimize wear, reducing or eliminating the need for separate wear-resistant inserts, thus maintaining reliability while simplifying the overall device complexity.
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 clamp provides a durable and noise-reduced coupling, minimizing vibrations and wear, while allowing for thermal expansion without excessive mechanical tension, thus enhancing the mechanical and acoustical properties of the brake disc assembly.
Implementation Method 1
The clamp... providing contact surfaces (118, 128) for contacting the bell (15)... distributing force evenly... reducing wear
Implementation Method 2
made from materials with high tensile strength and hardness like stainless steel... allowing for thermal expansion without excessive mechanical tension
Data Source
AI summary
A connecting means (100') for a brake disc assembly comprising a clamp having a central portion (101) and outer portion (110, 120) respectively arranged at opposite ends of the central portion. The first and second outer portions extend transversely to the central contact surface (104) and respectively provide a first and a second contact surface (118, 128) which, in an assembled state with a bell of a brake disc assembly, are configured to contact the bell of the brake disc assembly in order to provide for relative motion between the connecting means and the bell substantially only in a radial direction. The first and second contact surfaces are substantially planar and substantially parallel with respect to the central contact surface of the central portion.