Brake Disc Hub Connection Tolerance Compensation

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Solution Overview

Problem

Existing brake disc/hub connections face issues with tolerance compensation and operational reliability due to production-related tolerances and fatigue fractures caused by varying load conditions during braking, leading to reduced service life.

Innovation Solution

A brake disc/hub connection design featuring deformable radial and axial sleeves with screw bolts and spring elements allows for even loading and thermal expansion compensation, ensuring secure engagement without play and enhancing operational reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If intermediate elements with two legs at acute angles are provided to compensate for production tolerances, then tolerance compensation is improved, but torque transmission is impaired due to compression of the elastic intermediate elements

Engineering Contradiction:

Improvetolerance compensationVSAvoidtorque transmission

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

The intermediate element is designed with a deformable wall structure that allows dynamic adaptation. The wall can deform radially and axially to compensate for manufacturing tolerances while maintaining sufficient rigidity for torque transmission. This dynamic deformability resolves the contradiction by allowing the structure to be rigid enough for torque transmission yet flexible enough for tolerance compensation.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The intermediate element's wall thickness and material properties are optimized to achieve the right balance between rigidity and deformability. By carefully controlling the geometric parameters of the wall structure, the element can transmit torque effectively while still deforming to accommodate manufacturing tolerances in the support elements and drivers.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If intermediate elements are provided to allow brake disc dismantling and prevent crack formation, then operational reliability is improved, but fatigue fracture occurs due to frequent load changes during braking operations

Engineering Contradiction:

Improvecrack preventionVSAvoidservice life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The intermediate element employs a thin-walled tubular structure that provides flexibility to absorb load variations during braking operations. This flexible shell design allows the intermediate element to deform elastically under frequent loading cycles, preventing stress concentration and fatigue fracture while maintaining its function in preventing crack formation.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The deformable wall structure of the intermediate element acts as a cushioning element that anticipates and absorbs the effects of frequent load changes during braking. By being pre-designed to deform radially and axially, it protects against fatigue fracture before it can occur, thereby extending service life while maintaining reliability.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Temperature

If the brake disc is designed as a separate component from the hub, then thermal expansion is accommodated, but production-related tolerances lead to uneven loading of support elements and drivers

Engineering Contradiction:

Improvethermal expansion compensationVSAvoidloading uniformity

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The intermediate element serves as a mediator between the hub's driver and the brake disc's support element. It absorbs the effects of manufacturing tolerances through its deformable wall structure, ensuring uniform loading distribution while allowing the brake disc to expand thermally independently as a separate component from the hub.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 design effectively compensates for production tolerances and thermal expansions, ensuring even loading and improved service life and operational reliability by preventing micro-twisting and fatigue fractures.

Implementation Method 1

the sleeve is designed to be deformable radially and axially

Methodology Applied

Scientific EffectDeformation: Deformation

Implementation Method 2

A thermally induced expansion of the brake disk in the axial direction can be compensated for by a spring element

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentEP2028387B1Brake discs/collar connection

Publication Date: 2012.02.01 KNORR BREMSE SYSTEME FUER NUTZFAHIZEUGE GMBH

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AI summary

The brake disk-hub connection has a brake disk (1) with multiple evenly distributed supporting elements (3) on an inner circumference. The supporting elements correspond with the attachments provided on an outer circumference of a hub (2) for anti-twist protection. Each attachment is formed as a pin (5) extending parallel to the central axis of the brake disk, which is firmly connected with the hub. An intermediate element consists of a bushing (6) supported on the pin, which abuts, free of play, on the respective supporting element in the circumferential direction of the brake disk.