Internally Ventilated Brake Disk Cooling Channel Segmentation
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Solution Overview
Problem
Existing internally ventilated brake disks face challenges in efficiently dissipating frictional heat during high-speed braking, leading to brake fading and potential damage, despite efforts to enhance cooling through radial cooling channels and web configurations.
Innovation Solution
The design features radially arranged webs connecting friction disks, forming identically sized cooling channels that subdivide into multiple flow channels, with shorter webs centrally located to increase cooling surface area and reduce flow separation, and a rivet connection between the friction disk and hub to minimize thermal expansion differences and enhance centering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the webs are made relatively short to achieve low frequency and flexible web configuration, then the vibration frequency is reduced and flexibility is improved, but the distance over which the air stream is carried is reduced and cooling effect is weakened
Solution Approach 1:
The brake disk is segmented into multiple radially arranged webs that divide the cooling channels into multiple flow channels. This segmentation allows the air stream to be distributed across multiple paths, increasing the effective cooling surface area while maintaining manageable web lengths for manufacturing flexibility.
Solution Approach 2:
The cooling channels are configured to extend not only radially but also circumferentially, creating a three-dimensional cooling network. This multi-dimensional approach increases the cooling surface area without requiring excessively long radial web spans, thus maintaining manufacturing feasibility.
2Temperature
If the webs are thickened to achieve higher frequency and increased stiffness, then the vibration frequency and stiffness are improved, but the weight and overall width of the brake disk increase
Solution Approach 1:
The webs are designed with non-uniform thickness distribution, being thicker near the inner circumference where structural support is needed for high-frequency vibration resistance, and thinner toward the outer circumference where cooling surface area is prioritized. This local quality variation optimizes both stiffness and weight.
Solution Approach 2:
The brake disk employs a composite structure combining metallic friction rings with integrated cooling channels and webs. This composite design allows optimization of each component's properties - the friction rings provide structural integrity while the webbed structures provide cooling efficiency - without uniformly increasing the entire disk's weight.
3Temperature
If radial cooling channels and webs are added to enhance heat dissipation, then the cooling performance is improved, but the device complexity and structural complexity increase
Solution Approach 1:
The cooling channels are merged directly into the brake disk's structural webs, eliminating the need for separate cooling components. The webs serve dual functions as both structural elements and cooling channel boundaries, simplifying the overall device while enhancing cooling performance.
Solution Approach 2:
The radially arranged webs perform multiple functions simultaneously: they provide structural support for vibration resistance, define the cooling channel geometry, and serve as mounting surfaces for friction pads. This multi-functionality reduces the need for additional components, thereby reducing overall device complexity.
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 configuration significantly enhances cooling performance, reduces noise, and allows for effective heat dissipation, maintaining braking efficiency and reducing the risk of brake fading, especially during high-speed and downhill driving.
Implementation Method 1
This gives rise, while the brake disk is rotating, to a centrifugal force which causes a continuous draft of air in the outward direction from the hub, through the radial cooling openings.
Implementation Method 2
The frictional heat which occurs on the friction elements of a wheel brake during braking operation has to be dissipated outward to the surroundings... This assists the dissipation of heat.
Data Source
AI summary
An internally ventilated brake disk for a disk brake, includes two friction disks, which are arranged adjacent to each other and which are connected to each other by radially extending, regularly arranged webs. The webs extend from an outer peripheral edge to an inner peripheral edge of the friction disks and the friction disks are connected by the webs in such a way that intermediate spaces thereof form cooling channels of equal size, through which cooling air can flow and which are divided by further, shorter webs in such a way that at least one shorter web is located centrally between the webs in a radial region closer to the inner peripheral edge of the friction disks. Outward from the shorter web in the radial direction, the cooling channels are divided into at least three flow channels in that, in each cooling channel, two first further shorter webs are arranged at an offset to each shorter web radially outwardly and in the peripheral direction. The friction disk directed toward a brake disk hub is extended radially inward from each of the shorter webs and is provided with a bore in the axial direction at the height of a collar of the brake disk hub, which bore is used to hold a rivet, which fastens the friction disk to the brake disk hub.