Brake Disc Drive Insert Bridge Structure for Fastener-Free Load Distribution
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Solution Overview
Problem
Existing wheel brake systems face challenges in distributing mechanical stresses across brake discs, leading to wear and potential failure due to the use of rivets and other fasteners that can fatigue under cyclic vibrations and stress, compromising the attachment and surface integrity of the brake disc.
Innovation Solution
A drive insert system comprising a first and second insert member and a bridge member that securely attaches to the brake disc without fasteners, distributing load and reducing wear by sliding over the disc surfaces and extending between the members to limit movement and absorb forces during braking operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rivets and fasteners are used to attach the drive insert to the brake disc, then the drive insert can be securely fixed to the brake disc, but the fasteners will fatigue under cyclic vibrations and stress, compromising the attachment and surface integrity of the brake disc
Solution Approach 1:
The invention extracts and eliminates the fasteners (rivets, bolts, welds) from the attachment system. The drive insert is secured to the brake disc through interference fits, keyways, and splines that are integral to the insert design itself, removing the separate fastening components that were causing fatigue and reliability issues.
Solution Approach 2:
The attachment function is merged into the drive insert structure itself. The insert includes integrated features such as interference fit surfaces, keyways, and splines that combine the functions of both the drive insert and the fastening mechanism, eliminating the need for separate fasteners.
2Strength
If fasteners are used to secure the drive insert, then the insert can be firmly attached to the brake disc, but the fasteners create stress concentration points and potential failure points under cyclic loading
Solution Approach 1:
The invention removes the fasteners that create stress concentration points. By eliminating rivets, bolts, and welds, the design removes the discrete stress concentration locations that would initiate fatigue cracks under cyclic loading conditions.
Solution Approach 2:
The drive insert employs different local attachment mechanisms (interference fit in one region, keyway engagement in another, spline engagement in a third) that distribute stresses more evenly across the insert-brake disc interface, avoiding the localized stress concentrations created by discrete fasteners.
3Device complexity
If a simple single-piece insert design is used, then the structure is simpler and easier to manufacture, but it cannot effectively distribute mechanical stresses or limit movement in multiple directions
Solution Approach 1:
The drive insert is divided into multiple functional segments or components (such as the insert body, keyway features, spline elements, and interference fit surfaces) that work together to distribute and manage mechanical stresses in multiple directions, providing both complexity for stress management and relative simplicity for 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
The drive insert system effectively distributes mechanical stresses and reduces wear on the brake disc, enhancing the structural integrity and longevity of the brake system by eliminating the need for fasteners and minimizing the impact of cyclic vibrations.
Implementation Method 1
A bridge member is configured to extend from the first insert member to the second insert member when the first insert member is positioned over the first surface and the second insert member is positioned over the second surface, wherein the bridge member is configured to limit movement of the first insert member and the second insert member in a tangential direction of the brake disc
Implementation Method 2
The first insert member is configured to be slidable over the first surface in a first direction substantially tangential to the brake disc. The second insert member is configured to be slidable over the second surface in a second direction substantially opposite the first direction
Data Source
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AI summary
A drive insert for a drive slot of a brake disc includes a first insert member (382) configured to cover a first surface of the drive slot, a second insert member (383) configured to cover a second surface of the drive slot, and a bridge member (384) configured to extend between the first insert member (382) and the second insert member (383). The bridge member (384) is configured to limit movement of the first insert member (382) and the second insert member (383) in a tangential direction of the brake disc when the bridge member (384) extends from the first insert member (382) to the second insert member (383). The bridge member (384) is configured to be in compression between the first insert member (382) and the second insert member (383).