Brake Disc Fastening Assembly With Floating Dust-Blocking Structure
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Solution Overview
Problem
Conventional brake disc assemblies face issues with loose fastening due to wheel rotation and vibration, leading to reduced braking effectiveness, and existing solutions like floating type disc assemblies are complex, costly, and prone to dust and foreign object ingress.
Innovation Solution
A brake disc assembly with a simplified structure using bolts, sleeves, spacers, and nuts that allow slight axial movement of the disc main body relative to the connecting seat, preventing foreign object ingress and using common specifications without additional certification, while maintaining effective fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a threaded rod with multiple positioning portions is used to allow axial sliding of the disc main body, then the floating effect is achieved, but the structure becomes complicated and manufacturing cost increases
Solution Approach 1:
The fastening member is divided into multiple functional components: a fastening body with threaded portion for securing, and a separate positioning portion with protrusions that engage with recesses in the disc main body. This segmentation allows the positioning function to be integrated into the fastening structure itself, eliminating the need for a complex threaded rod with multiple positioning portions while maintaining the floating effect.
Solution Approach 2:
The positioning portion is merged with the fastening body as an integrated structure. The protrusions on the positioning portion directly engage with corresponding recesses in the disc main body, combining the fastening and positioning functions into a single component. This merging simplifies the overall structure compared to using a separate threaded rod with multiple positioning portions.
2Reliability
If a threaded rod with multiple positioning portions is used to allow axial sliding, then the floating effect is achieved, but manufacturing cost increases due to certification requirements
Solution Approach 1:
The fastening body serves multiple functions: it provides threaded fastening through its threaded portion, positioning through its integrated positioning portion with protrusions, and structural support. This multi-functionality eliminates the need for separate certification of specialized threaded rods, allowing the use of standard fastening components that are easier and less costly to manufacture and certify.
Solution Approach 2:
The integrated fastening body with positioning portion can be manufactured as a standard, cost-effective component using conventional machining processes. Unlike specialized threaded rods requiring tensile strength certification, this design uses common fastening materials and processes, significantly reducing manufacturing and certification costs while maintaining the floating effect functionality.
3Reliability
If space is provided between the head portion and connecting seat for axial sliding, then the floating effect is achieved, but gaps are created that allow dust and foreign objects to enter
Solution Approach 1:
The fastening body is designed with an integrated positioning portion that dynamically adjusts to maintain optimal engagement. The protrusions on the positioning portion engage with recesses in the disc main body, allowing controlled axial movement while maintaining continuous contact. This dynamic engagement eliminates persistent gaps that would allow dust ingress, while still permitting the necessary floating effect for uneven brake pad wear compensation.
Solution Approach 2:
The positioning portion acts as an intermediary between the fastening body and the disc main body. Its protrusions engage with corresponding recesses to provide controlled axial movement while maintaining a sealed interface. This intermediary structure allows the floating effect to occur through controlled movement rather than through gaps, preventing dust and foreign objects from entering the fastening area.
4Device complexity
If direct screwing of bolts into threaded holes is used, then the structure is simple, but the fastening effect deteriorates due to loosening from rotation and vibration
Solution Approach 1:
The fastening member is segmented into a fastening body with threaded portion and an integrated positioning portion with protrusions. The positioning portion engages with recesses in the disc main body to prevent relative rotation and vibration-induced loosening, while the threaded portion provides secure fastening. This segmentation maintains relative structural simplicity while dramatically improving fastening reliability under rotational and vibrational conditions.
Data Source
AI summary
A brake disc assembly includes a disc main body having first through holes, a connecting seat having second through holes, and fastening devices each including a bolt, a nut, a spacer clamped between the disc main body and connecting seat and including a third through hole, and a sleeve including a fourth through hole. An insertion portion of the sleeve is disposed in the first, second and third through holes. The bolt includes a rod portion inserted through the fourth through hole and having a threaded section onto which the nut is screwed so that the disc main body, spacer, connecting seat and an abutment portion of the sleeve are clamped between a head portion of the bolt and the nut. The brake disc assembly has concise structure and low manufacturing cost, and provides slight floating effect of the disc main body while preventing foreign objects from entering therein.