Ventilated Brake Disc Assembly Using a Co-Moulded Connection Ring
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Solution Overview
Problem
Existing disc brake assembly methods require complex and costly operations, such as hammering down protrusions into grooves, which can deform components and complicate production, and often necessitate postponing finishing operations until assembly, limiting production flexibility and increasing costs.
Innovation Solution
A disc brake disc design featuring a connection ring made by co-moulding with the braking band, allowing the bell to be connected via a shape coupling and interference fit, eliminating the need for direct attachment to the braking band during assembly and enabling complete finishing before assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bell is connected to the braking band by hammering protrusions into grooves, then secure locking is achieved, but the braking band and bell must be encapsulated to prevent deformation, complicating the production process
Solution Approach 1:
The invention divides the braking band into two separate components: the braking band itself and a connection ring. The connection ring is intimately connected to the braking band and provides the attachment interface for the bell. This segmentation allows the bell to be mounted on the connection ring without requiring encapsulation of the braking band, thus maintaining locking security while simplifying the production process.
Solution Approach 2:
The connection ring acts as an intermediary element between the braking band and the bell. It receives the protrusions from the bell during hammering operations while the braking band remains separate and unprotected. This intermediary structure absorbs the mechanical stresses of assembly without requiring encapsulation, resolving the contradiction between secure locking and production simplicity.
2Reliability
If hammering down operations are performed to lock the bell, then proper locking is achieved, but finishing operations must be postponed until after assembly, limiting production flexibility
Solution Approach 1:
By segmenting the braking band into the braking band and connection ring, the invention allows finishing operations to be completed on both components before assembly. The connection ring serves as the dedicated attachment interface, enabling the bell to be mounted after finishing without compromising the quality or appearance of the braking band surfaces.
Solution Approach 2:
The connection ring as an intermediary component is specifically designed to handle the mechanical attachment function. This allows the braking band to be fully finished beforehand, as the attachment operations occur on the connection ring rather than directly on the braking band, thereby maintaining production flexibility and finishing quality.
3Reliability
If through attachment seats are made directly in the braking band and bell, then secure connection is achieved, but the operation becomes excessively costly
Solution Approach 1:
The invention segments the attachment function from the braking band by introducing a connection ring. This allows attachment seats to be made only in the connection ring and bell, rather than in both the braking band and bell. The segmentation reduces the number of expensive through-seat operations required while maintaining secure connection through the intimate connection between the braking band and connection ring.
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 solution simplifies and economizes the production process by allowing separate component finishing and assembly without deforming the braking band, reducing operational complexity and costs, while ensuring secure locking and torque transmission between the bell and connection ring.
Implementation Method 1
The connection ring is made by co-moulding with the braking band
Implementation Method 2
the bell has an annular anchoring appendage provided externally with a plurality of protrusions designed to fit into said grooves in an interference fit
Implementation Method 3
The interaction commanded between the opposite brake pads and the opposite braking surfaces of the braking band determine a braking action as a result of friction
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a disc brake disc (1), in particular of the ventilated type, comprising a braking band (2) and a bell (20). The band (2) and the bell (20) are made separately from each other as separate components and are then connected together to make the disc (1). The bell (20) is coaxially connected to the braking band (2) at a central hole (3) of said braking band (2) coaxial to an axis Z of the disc (1) by means of a metal connection ring (10) which is circumferentially interposed between the braking band (2) and the bell (20) coaxially to the central hole (3) and is intimately connected to the braking band (2). The connection ring (10) is made by co-moulding with the braking band.