Brake Pad Module Attachment for Thermal Expansion Compliance
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Solution Overview
Problem
Existing brake pad assemblies for railway vehicles require significant production resources and are costly due to complex manufacturing processes, particularly in the connection between pad modules and the main plate, which fails to efficiently manage thermal expansion of the brake disc during braking.
Innovation Solution
A simplified connection method where a sleeve is inserted through the friction lining opening into a blind hole in the main plate, with a rivet inserted through a bore connecting the blind hole to the exterior, and a flange-type edge on the sleeve forms a stop for the rivet head, allowing for independent movement of pad modules to adapt to thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex connection structure with through-holes and multiple components is used to attach pad modules to the main plate, then the connection reliability is improved, but the manufacturing cost and production resources increase significantly
Solution Approach 1:
The connection structure is segmented into distinct functional zones: a blind hole for the sleeve to ensure reliable attachment, and a separate counterbore for the rivet to simplify installation. This segmentation allows each component to perform its specific function optimally while reducing overall manufacturing complexity.
Solution Approach 2:
The sleeve is nested within the blind hole of the main plate, and the rivet is nested within the counterbore. This nested arrangement ensures that connecting components are contained within the plate structure, providing reliable mechanical attachment while maintaining a compact and simple overall design.
2Ease of manufacture
If the sleeve extends entirely through the main plate as in prior art, then the connection structure is simpler, but the rivet cannot be properly installed to secure the pad module
Solution Approach 1:
The hole structure transitions from a single through-hole in prior art to a two-dimensional nested structure with a blind hole and a counterbore. This dimensional change allows the rivet to be properly installed and secured while maintaining ease of manufacture through standardized hole drilling and countersinking operations.
3Strength
If the diaphragm is supported on annular shoulders in the main plate as in prior art, then the structural support is improved, but the production cost and manufacturing complexity increase
Solution Approach 1:
The support function previously provided by separate annular shoulders is merged into the diaphragm's own structure. The diaphragm is designed with an annular shoulder that directly supports the pad module, eliminating the need for additional structural features in the main plate and reducing manufacturing complexity and cost.
Solution Approach 2:
The diaphragm is designed to be self-supporting with its own annular shoulder structure that provides the necessary support for the pad module. This self-service approach eliminates the need for external support structures in the main plate, simplifying both design and manufacturing.
Data Source
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AI summary
This brake pad assembly (1) for disk brakes, in particular in rail vehicles, comprises a main plate (2), pad modules (3) attached to the plate, which have a friction lining (9) and a backing plate (10), means (16) for attaching a respective pad module (3) to the plate (2), a plurality of bushes (7), each attachment means being arranged in a respective bush (7), which is inserted into orifices (11,6) provided facing each other in the backing plate (10) and in the main plate (2), through an opening (8) in the friction lining (9). According to the invention, the orifice for receiving the bush in the main plate is a blind hole (6), a bore (15) with a smaller diameter than that of the blind hole (6) being provided in the bottom of said blind hole, said bore (15) passing through the main plate (2), a rivet (16) being inserted into said bore inside the bush (7), said rivet linking the main plate (2) and the backing plate (10). The present invention therefore makes it possible to produce a brake pad assembly in which the link between the pad module and the main plate has a structure that is as simple as possible, while being reliable.