Brake Disc Segmented Connecting Elements
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Solution Overview
Problem
Existing brake discs for commercial vehicles face issues with heat-related expansion and warping due to differential thermal expansion between friction rings and brake disc chambers, leading to assembly challenges and limited variability in using friction rings for different vehicle axles.
Innovation Solution
A brake disc design featuring a friction ring with detachable connecting elements that extend from the inner circumference to the axis of rotation, allowing for easy assembly and disassembly, and enabling connection with various connecting elements, which facilitates the use of friction rings of a specific size and type on different vehicle axles, and allows for modular combinations of connecting elements and friction rings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the friction ring is directly fastened to the hub or brake disc chamber, then the assembly is structurally stable, but the different heat-related expansion of the friction rings compared to the brake disc chambers results in shielding or general warping of the brake disc
Solution Approach 1:
The connection between the friction ring and hub is segmented into multiple discrete connecting elements distributed around the circumference. This segmentation allows each connecting element to independently accommodate thermal expansion differences, preventing the cumulative warping effects that would occur with a rigid direct connection.
Solution Approach 2:
The connecting elements are designed with dynamic characteristics that allow them to adapt to thermal expansion. The connecting elements can accommodate dimensional changes through their fastening mechanism, allowing the friction ring to expand radially under heat without transferring this expansion to the hub, thus preventing warping while maintaining structural stability.
2Device complexity
If the friction ring is directly fastened to the hub, then the assembly is simple, but servicing requires complete disassembly and the friction ring cannot be reused with different vehicle axles
Solution Approach 1:
The connection system is divided into separable components: the friction ring with its coupling parts and the hub with corresponding receiving elements. This segmentation enables the friction ring to be easily detached and reattached to different hubs for different vehicle axles, greatly improving serviceability while maintaining simple assembly through standardized coupling mechanisms.
Solution Approach 2:
The coupling parts on the friction ring are designed with universal characteristics that allow them to interface with different hub configurations. The standardized coupling mechanism enables the same friction ring to be used with different vehicle axles and hub designs, providing multi-functionality and ease of repair without requiring complex customizations.
3Strength
If the friction ring is directly fastened to the hub, then the structure is rigid, but the friction ring cannot expand radially during braking due to heat
Solution Approach 1:
The connecting elements incorporate dynamic characteristics that allow the friction ring to expand radially during braking while maintaining structural rigidity. The connection allows controlled movement and expansion in the radial direction through the fastening mechanism, accommodating thermal growth without compromising the overall structural strength and stability of the brake disc assembly.
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 simplifies assembly, enhances variability, and allows for the reuse of connecting elements with new friction rings, promoting radial expansion during braking and improved heat transport, while preventing corrosion and facilitating maintenance.
Implementation Method 1
The connecting elements are designed in such a way that they allow an expansion of the friction ring in the radial direction as a result of heating during a braking process
Implementation Method 2
In order to dissipate the frictional energy generated during this braking process, it is known to ventilate the inside of the friction rings
Data Source
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AI summary
A brake disc for a disc brake of a commercial vehicle has a friction ring (2) and at least one connecting element (3) extending axially from an inner circumference of the friction ring (2) to an axis of rotation of the brake disc (1) for fastening the brake disc to a wheel axle, wherein the connecting element (3) is detachably connected to the friction ring (2) via connecting elements (4), wherein at least one coupling part (5) projecting radially towards the axis of rotation of the brake disc is formed on the inner circumference (11) of the friction ring (2), with at least one recess (6) being formed, wherein the connecting elements (4) are received in the recesses (6) of the at least one coupling part (5) and in receptacles (7) of the connecting element (3).