Multi-part Brake Disc Segmentation for Wear Replacement
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Solution Overview
Problem
Brake disks for commercial vehicles require frequent replacement due to abrasive wear, leading to high maintenance costs and labor expenses.
Innovation Solution
A brake disk design featuring two friction rings and a carrier with bracing openings for clamping, allowing for easy disassembly and reassembly, reducing material and labor costs, and utilizing different materials for the rings and carrier for optimal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the brake disc is designed as a single integrated component, then the structure is simple and manufacturing is easy, but the entire brake disc must be replaced when friction surfaces wear out, leading to high maintenance costs and labor expenses
Solution Approach 1:
The brake disc is divided into separate functional components: friction rings with friction surfaces and a carrier body without friction surfaces. The friction rings are detachably connected to the carrier body via clamping means (screws, bolts, or rivets) passing through aligned bracing openings. This segmentation allows the friction rings to be replaced independently when worn, while the carrier body can be reused, significantly reducing maintenance costs and labor expenses compared to replacing the entire integrated brake disc.
2Ease of repair
If the brake disc is designed with replaceable friction rings, then maintenance costs are reduced, but the device complexity increases due to multiple components and assembly requirements
Solution Approach 1:
The brake disc is divided into separate functional components: friction rings with friction surfaces and a carrier body without friction surfaces. The friction rings are detachably connected to the carrier body via clamping means (screws, bolts, or rivets) passing through aligned bracing openings. This segmentation allows the friction rings to be replaced independently when worn, while the carrier body can be reused, significantly reducing maintenance costs and labor expenses compared to replacing the entire integrated brake disc.
Solution Approach 2:
The carrier body is designed with bracing openings that serve multiple functions: they provide structural reinforcement, enable alignment of friction rings during assembly, and allow passage of clamping means for secure attachment. This multi-functionality reduces the need for separate alignment features or complex fastening mechanisms, thereby limiting the increase in device complexity while achieving replaceable friction rings.
3Ease of operation
If bracing openings are provided in friction rings, then clamping means can be inserted to secure rings to carrier, but the friction ring strength is reduced due to material removal
Solution Approach 1:
The brake disc is divided into separate functional components: friction rings with friction surfaces and a carrier body without friction surfaces. The friction rings are detachably connected to the carrier body via clamping means (screws, bolts, or rivets) passing through aligned bracing openings. This segmentation allows the friction rings to be replaced independently when worn, while the carrier body can be reused, significantly reducing maintenance costs and labor expenses compared to replacing the entire integrated brake disc.
Solution Approach 2:
The bracing openings are strategically positioned in the friction rings at locations that minimize impact on the friction surfaces and overall structural integrity. The openings are sized and shaped to provide sufficient clearance for clamping means while removing the minimum necessary material. Reinforcement features may be provided around the openings to locally strengthen the friction rings, compensating for the material removed and maintaining adequate strength for operational loads.
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 design minimizes maintenance needs, reduces costs, and enhances the brake disk's stability and cooling efficiency while maintaining effective torque transmission and vibration damping.
Implementation Method 1
The first friction ring (4) has a first friction surface (8) and the second friction ring (6) has a second friction surface (9), each of which is designed to come into contact with a brake lining
Implementation Method 2
the clamping openings being designed to receive clamping means (14) in order to clamp the first friction ring (4) with the second friction ring (6) in the direction of the axis of rotation (A)
Implementation Method 3
the carrier (2) being connected to the first friction ring (4) and the second friction ring (6) in such a way that a torque can be transmitted about the axis of rotation (A) between the carrier (2) and the friction rings (4; 6)
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a brake disc (1) comprising a first friction ring, a second friction ring, and a carrier (2), wherein: the brake disc (1) is designed to rotate about an axis of rotation (A); the carrier (2) has a connection portion (22), by means of which the carrier (2) can be fixed to a further element; the first friction ring (4) has a first friction surface (8) and the second friction ring (6) has a second friction surface (10) which are each designed to come into contact with a brake lining; the first friction ring (4) has a plurality of clamping openings (12) and the second friction ring (6) has a plurality of clamping openings (13); the clamping openings (12) in the first friction ring (4) are each aligned with a clamping opening (13) in the second friction ring (6); the clamping openings (12, 13) are designed to receive clamping means (14) in order to clamp the first friction ring (4) to the second friction ring (6) in the direction of the axis of rotation (A); and the carrier (2) is connected to the first friction ring (4) and the second friction ring (6) in such a way that a torque about the axis of rotation (A) can be transferred between the carrier (2) and the friction rings (4, 6).