Brake Disc Connecting Elements Using Hydroforming
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Solution Overview
Problem
Existing brake disc assemblies for land vehicles face challenges in operational reliability and production complexity, leading to increased costs and the risk of manufacturing defects due to complex casting processes and temperature fluctuations.
Innovation Solution
A brake disc assembly design featuring a friction ring, connection adapter, and connecting elements with a contour that allows for a two-state configuration, enabling the connecting element to expand and form a positive or non-positive connection without the need for casting, using hydroforming or hydromechanical deep drawing, allowing for separate manufacturing of the friction ring and adapter and enabling the use of non-cast materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional connecting elements are arranged between the friction ring and the connection adapter with complex manufacturing process, then the connecting reliability is improved, but the production costs increase and the risk of manufacturing defects increases
Solution Approach 1:
The brake disc assembly is divided into separate components (friction ring, connection adapter, connecting elements) that can be manufactured independently and then assembled. This segmentation allows each component to be optimized for its specific manufacturing process while maintaining overall reliability through controlled assembly procedures.
Solution Approach 2:
The connecting elements are pre-positioned in recesses of the friction ring and connection adapter before final assembly. This preliminary positioning ensures correct alignment and reduces the risk of manufacturing defects during the final assembly process, while still providing reliable connection.
2Reliability
If the friction ring is cast onto the connection adapter to allow radial expansion, then the operational reliability under temperature fluctuations is improved, but the manufacturing complexity and production costs increase
Solution Approach 1:
The connection between the friction ring and connection adapter is designed to be dynamically adaptable through the two-state connecting elements. In the first state, connecting elements are arranged in recesses allowing for assembly flexibility. In the second state, connecting elements expand radially to form positive connections, accommodating temperature-induced expansions while maintaining structural integrity.
Solution Approach 2:
The connecting elements undergo parameter changes by transitioning between two states: a first state for assembly where they fit in recesses, and a second state during operation where they expand radially to form secure connections. This parameter change allows the system to adapt to temperature fluctuations without complex manufacturing processes.
3Strength
If the connecting element outer diameter is enlarged in the second state compared to the first state, then the connection strength is improved, but the manufacturing process complexity increases
Solution Approach 1:
The connecting elements are designed with dynamic geometry that allows them to transition between two states: a first state with a smaller outer diameter for easy assembly into recesses, and a second state with an enlarged outer diameter that forms strong positive connections. This dynamic size change provides both ease of assembly and strong connection without requiring complex manufacturing processes.
Solution Approach 2:
The outer diameter parameter of the connecting elements is designed to change between two distinct states. In the first state, the smaller diameter allows for simple assembly into the recesses formed in the friction ring and connection adapter. In the second state, the enlarged diameter creates interference fits or positive mechanical connections, achieving high connection strength through a controlled parameter transition rather than complex manufacturing.
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 enhances operational reliability, simplifies the production process, reduces costs, and offers greater flexibility in material selection while minimizing the risk of temperature-related distortions and manufacturing errors.
Implementation Method 1
using hydroforming or hydromechanical deep drawing
Implementation Method 2
using hydroforming or hydromechanical deep drawing
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
A brake disc arrangement for disc brakes, particularly for land vehicles, comprising a friction ring, a mounting adapter for mounting the brake disc arrangement on a wheel hub, at least one connecting element for connecting the friction ring and the mounting adapter, and at least one contour having a friction ring-side and an adapter-side contour region, in which the contour is shaped along a longitudinal axis by means of recesses in the friction ring and the mounting adapter running perpendicular to a rotational axis of the brake disc arrangement, wherein the connecting element can be brought from a first state into a second state, wherein the connecting element in the first state is designed such that it can be arranged inside the contour and wherein the outer diameter of the connecting element in the second state is enlarged relative to the first state perpendicular to the longitudinal axis, at least in sections, in such a manner that the connecting element is connected to the friction ring-side and/or the adapter-side contour region by form fit and/or friction fit.