Brake Disc Refinement Layer Positioning for Precise Recoating
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Solution Overview
Problem
Brake discs made of grey cast iron or centrifugally cast materials suffer from limited longevity due to abrasion and corrosion, leading to environmental pollution and increased exhaust emissions, as they require premature replacement and have insufficient friction hardness for controlled braking.
Innovation Solution
A workpiece with a refinement layer applied to the treatment surface, featuring a precise reference mark for accurate measurement and coating, allowing for a thin, hard material layer that enhances friction hardness and corrosion resistance while minimizing material usage, and enabling precise reprocessing and quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a refinement layer is applied to the support body to increase friction hardness and corrosion resistance, then the longevity and performance of the brake disc is improved, but the mass of the brake disc increases leading to higher fuel requirements and exhaust emissions
Solution Approach 1:
The patent applies parameter changes by transitioning from conventional coating methods to HVOF (High Velocity Oxygen Fuel) spraying, which fundamentally changes the deposition parameters including particle velocity, temperature, and impact energy. This enables the formation of a dense, adherent refinement layer with optimized thickness and material properties, achieving the required friction hardness and corrosion resistance with minimal material usage.
Solution Approach 2:
The patent implements local quality by applying the refinement layer selectively only to the friction surface areas of the brake disc that require enhanced properties, rather than coating the entire component. This localized application minimizes the total material used and the associated mass increase, while still providing the necessary performance enhancement at critical locations.
2Reliability
If a thicker refinement layer is applied to ensure sufficient friction hardness and corrosion protection, then the reliability and durability of the brake disc is improved, but the material usage and production cost increase
Solution Approach 1:
The HVOF process parameters (particle velocity, temperature, spray distance, coating thickness control) are precisely adjusted to achieve optimal layer formation. This allows for the application of thin, dense refinement layers that provide sufficient corrosion protection and friction hardness without excessive material consumption, optimizing the balance between reliability and material usage.
Solution Approach 2:
The patent replaces conventional mechanical or thermal coating methods with HVOF spraying, which uses a controlled combustion process to accelerate coating particles to high velocities. This substitution enables more efficient material deposition with better adhesion and density, reducing the total material quantity needed to achieve the required protective properties.
3Ease of manufacture
If conventional coating methods are used to apply the refinement layer, then the process is simpler and more established, but the precision and uniformity of the coating application is insufficient leading to quality variations
Solution Approach 1:
The patent replaces conventional coating equipment with HVOF spraying apparatus, which uses a controlled combustion chamber to generate high-velocity oxygen-fuel jet. This mechanical/thermal substitution provides superior control over particle delivery, resulting in more uniform and precise coating application while maintaining process feasibility through established HVOF technology.
Solution Approach 2:
The patent implements feedback control in the HVOF coating process by monitoring and adjusting process parameters such as spray distance, coating thickness, and particle velocity in real-time. This feedback mechanism ensures consistent coating quality and uniformity across different brake disc components, addressing the precision issues of conventional methods.
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 solution extends the service life of brake discs, reduces environmental impact by minimizing material usage and emissions, and ensures consistent quality through precise application and reprocessing of the refinement layer, thereby improving braking performance and reducing waste.
Implementation Method 1
the refinement layer is applied by an HVOF process
Data Source
AI summary
The invention relates to a workpiece to be coated with a finishing layer. The workpiece has a support body with a treatment surface, wherein the finishing layer is applied or can be applied onto the treatment surface. The workpiece is primarily characterized in that the workpiece is provided with a reference mark to which a stationary coordinate system that is highly precise relative to the workpiece can be repeatedly assigned. By virtue of the aforementioned workpiece and the corresponding reference mark, a finishing layer can be applied onto the workpiece in a highly precise manner, and the finishing layer can be reprocessed.