Carbon-Ceramic Brake Disc Assembly with Serrated Bushing Connection
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Solution Overview
Problem
The manufacturing of conventional carbon-ceramic brake disc assemblies is hindered by the need for precise mechanical machining processes, which are costly and difficult to achieve high accuracy and precision, particularly in the connection between the hat part and the carbon-ceramic brake disc.
Innovation Solution
A carbon-ceramic brake disc assembly with a hat part and connection unit featuring serrations on the bushing that penetrate into the hat part's internal surface, allowing for a firm connection without the need for precise mechanical machining, using a harder stainless steel for the bushing to prevent turning and a simpler assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precise mechanical machining processes are used to manufacture the hat part and connection unit, then connection precision and firmness are improved, but manufacturing cost increases and manufacturing complexity increases
Solution Approach 1:
The bushing is pre-formed with an irregular cross-section (D-shaped or oval-shaped) that complements the corresponding hole shape in the hat part. This preliminary shaping allows the components to self-align and self-lock during assembly, eliminating the need for post-assembly machining operations and achieving precise connection without increased manufacturing cost
Solution Approach 2:
The bushing and hat part hole are designed with asymmetric irregular cross-sections rather than circular shapes. This asymmetry ensures that the components fit together in a specific orientation, preventing rotation and achieving firm connection. The asymmetric design is achieved through standard forming processes rather than precision machining, reducing manufacturing complexity
2Reliability
If precise mechanical machining processes are used to manufacture the hat part and connection unit, then connection firmness is improved, but device complexity increases
Solution Approach 1:
The irregular cross-sectional shape of the bushing is pre-formed during the manufacturing process itself, rather than requiring subsequent machining operations. This preliminary action ensures that the connection geometry is built-in from the start, simplifying the overall manufacturing process while guaranteeing connection firmness through the interlocking asymmetric shapes
Solution Approach 2:
The asymmetric irregular cross-section design enables the bushing and hat part to self-align and self-lock during assembly without requiring additional guidance features or complex machining operations. The components automatically achieve the correct orientation and firm connection through their complementary shapes, reducing device complexity
3Stability of the object's composition
If a D-shaped head bushing is used to fit into a U-shaped recess, then the bushing is prevented from turning and connection stability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The design transitions from requiring high-precision machining of D-shaped and U-shaped features to using standard forming processes that create irregular cross-sectional shapes. The key parameter change is in the tolerance requirements - the focus shifts from achieving exact geometric shapes to ensuring complementary fit between mating parts, which can be achieved with standard manufacturing tolerances
Solution Approach 2:
The irregular cross-sectional geometry is established during the primary forming operation rather than requiring subsequent precision machining. This preliminary action embeds the anti-rotation feature directly into the component geometry, achieving connection stability without imposing stringent precision requirements on secondary operations
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 solution simplifies the configuration and reduces costs by enabling a firm connection between the hat part and the carbon-ceramic brake disc, while also reducing the weight of the bushing by 40% and providing additional stability through the nut and bolt mechanism.
Implementation Method 1
serrations protruding the outer surface of the body along the length of the body, with the serrations being penetrated into the internal surface of the second hole in the hat part when forced to be inserted into the second hole in the hat part
Implementation Method 2
Each of the cool channels 113 is pierced through a core body of the carbon- ceramic brake disc 110 in the radial direction, from the first axis hole 111 to the outer circumferential edge thereof (or vice versa). Outside air, introduced into the cool channels, cools down the carbon- ceramic brake disc 110 while in use.
Data Source
Figure 1~3
Figure 4~5
AI summary
There is provided a carbon-ceramic brake disc assembly (200) including a carbon-ceramic brake disc (210) having a first axis hole (211) in the center thereof, and a plurality of first holes (212) around the first axis hole (211), a hat part (220) having a second axis hole (221) in the center thereof, and a plurality of second holes (222) around the second axis hole (221); and a connection unit (230) connecting the carbon-ceramic brake disc (210) and the hat part (220), including bushings (231), each of which includes a head (231 a), a body (231b) connecting to the head, and serrations (231c) protruding the outer surface of the body (231b) along the length of the body (231b), with a threaded hole (231d) pierced through the head (231a) and body (231b), lengthwise, the body (231b) being inserted into the first hole (212) in the carbon-ceramic brake disc (210), and the serrations (231c) being penetrated into the internal surface of the second hole (222) in the hat part (220) when forced to be inserted into the second hole (222) in the hat part (220), and a bolt (232) being inserted into the threaded hole (231d) in the head (231a) and body (231b) of the bushing (231). According to the present invention, both configurations of the hat part (220) and the bushing (231) are made simple at low cost. And penetration of the serrations (231c) of the bushing (231) into the hole (222) in the hat part (220) permits a firm connection between the hat part (220) and the carbon-ceramic disc (210).