Brake Disc Assembly Pin Joint for Higher Torque Transfer
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Solution Overview
Problem
Existing brake disk assemblies face challenges in transmitting torque effectively between the friction ring and the brake disk chamber, leading to potential damage from high mechanical stresses and instability in the connection.
Innovation Solution
Incorporating a wall element with additional radial openings aligned with the connector rings' openings, which increases the contact area for the fixing pin, distributing the mechanical force and enhancing the stability of the connection by providing an additional contact point for force transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single radial opening is used for the fixing pin, then the device complexity is reduced, but the torque transmission capability and connection stability deteriorate
Solution Approach 1:
The connector ring is segmented into multiple radial openings (first radial opening and second radial opening) instead of using a single opening. This segmentation allows the fixing pin to create multiple contact points with the brake disk chamber, distributing mechanical forces and improving connection stability while maintaining a relatively simple overall structure.
Solution Approach 2:
The solution transitions from a single-point contact (one radial opening) to a multi-point contact system (multiple radial openings arranged radially). This dimensional change in the contact interface increases the overall contact face area, enabling better torque transmission and force distribution without significantly increasing structural complexity.
2Power
If the contact area for the fixing pin is increased, then the torque transmission capability improves, but the device complexity increases
Solution Approach 1:
The contact area is segmented into multiple discrete contact zones created by the first and second radial openings. Each opening provides a contact face between the fixing pin and the brake disk chamber wall, collectively increasing the total contact area for torque transmission while keeping each individual opening simple in structure.
Solution Approach 2:
The contact interface is extended from a single radial plane to multiple radial planes by adding the second radial opening. This increases the overall contact face area available for force transmission, enhancing torque capability without requiring a proportional increase in structural complexity.
3Device complexity
If the mechanical force is concentrated in a single contact point, then the device complexity is reduced, but the risk of damage to the brake disk chamber increases
Solution Approach 1:
The mechanical force from the fixing pin is segmented and distributed across multiple contact points created by the first and second radial openings. This segmentation prevents stress concentration at a single location, reducing the risk of damage to the brake disk chamber while maintaining a simple fixing pin configuration.
Solution Approach 2:
The force distribution is extended from a single-point contact to a multi-point contact system arranged radially. This increases the overall contact face area, distributing the mechanical stress across a larger area and reducing peak stress values that could cause damage.
Data Source
AI summary
A brake disc assembly includes a friction ring made of a first material and a brake disc chamber made of a second material and which is secured to the friction ring. The brake disc chamber has a first connection ring with multiple first radial openings, and the friction ring has a second connection ring with multiple second radial openings. The connection rings are coaxial such that at least some of the first and second radial openings are flush with one another. A fixing pin lies in at least some of the flush radial openings to connect the connection rings. The first connection ring has at least one wall element with at least one additional radial opening paired with the circumference of the first connection ring such that the additional radial opening is flush with one of the first radial openings. The fixing pin also lies in the additional radial opening.