Cast Brake Disc With Integrated Sliding Elements
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Solution Overview
Problem
Current brake disc production methods are costly and inefficient, particularly for internally ventilated designs, due to high material usage and manufacturing complexity, which limits their cost-effectiveness and service life.
Innovation Solution
A brake disc design featuring a friction ring with an inner toothed ring and a materially separated neck, connected by an outer toothed ring with cast-in U-shaped sliding elements that allow radial movement, enabling simpler production and reduced material usage by casting the sliding elements directly into the brake disc mold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sliding elements are formed as sleeves with pins and multiple connection elements are used to establish a stable connection between the friction ring and the neck, then the connection stability is improved, but the manufacturing cost and material usage increase significantly
Solution Approach 1:
The patent combines multiple separate connection elements (sleeves and pins) into a single integrated casting structure. The sliding element is formed as one piece during the casting process, eliminating the need for multiple separate components and their associated assembly steps, thereby reducing manufacturing cost while maintaining connection stability.
Solution Approach 2:
The sliding element serves multiple functions simultaneously: it acts as a connection element between the friction ring and neck, provides radial movement capability, and serves as a structural support. This multi-functionality eliminates the need for separate components for each function, reducing overall manufacturing complexity and cost.
2Reliability
If an high number of connection elements (pins and sleeves) are used to ensure stable connection, then the connection reliability is improved, but the device complexity and manufacturing outlay increase
Solution Approach 1:
Multiple connection elements are merged into a single integrated sliding element that is cast as one piece. This reduces the number of discrete components from multiple sleeves and pins to a single unified structure, simplifying the device while maintaining the necessary connection stability through the casting's inherent structural integrity.
3Reliability
If the friction ring is materially separated from the neck with sliding elements, then thermal stress cracks are prevented, but the production cost increases due to complex manufacturing processes
Solution Approach 1:
The sliding element is designed to automatically accommodate thermal expansion and contraction through its radial movement capability. The casting process itself creates the material separation and sliding mechanism in one operation, allowing the structure to self-regulate thermal stresses without requiring complex additional manufacturing steps or components.
4Productivity
If sliding elements are cast in during the casting process, then production time is reduced and manufacturing is simplified, but the precision of sliding element positioning may be compromised
Solution Approach 1:
The sliding elements are prepared in advance as separate components with precise dimensions and geometries before being inserted into the casting mold. This preliminary preparation ensures that the sliding elements have the required precision, which is then maintained during the casting process as they are positioned and cast in place, combining the benefits of pre-manufacturing precision with the efficiency of integrated casting.
Data Source
AI summary
A brake disc, in particular an internally ventilated brake disc, implemented as a casting includes a friction ring having an inner toothed rim and a neck materially separated therefrom and retained against rotation by an outer toothed rim. The neck is connecting to a wheel hub. Cast-in sliding elements are provided between the teeth to allow for a radial displacement of the friction ring relative to the neck. Each sliding element has a U-shape, the opposite legs thereof being disposed between the radially and axially oriented side faces of the associated teeth facing each other, wherein a web connecting the legs extends radially.