Brake Plate Interlocking Joint to Reduce Noise and Vibration
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Solution Overview
Problem
Existing brake assemblies in vehicles suffer from high component complexity, noise, and vibration issues due to rivet joints, which are prone to damage and wear under high vibrational stresses during braking.
Innovation Solution
A brake assembly design that connects a brake plate with hub plates using an interlocking joint formed by extending extrusions of the hub plates through holes in the brake plate, eliminating the need for additional components and enhancing structural strength and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rivet joints are used to join brake plate with hub plates, then the assembly is structurally connected, but the number of components increases and design complexity complicates
Solution Approach 1:
The hub plate and brake plate are merged into a single integrated component through plastic deformation joining. The brake plate material is plasticized and forced into the hub plate's recesses, creating a unified structure that eliminates rivets, nuts, bolts, and other fastening components while maintaining strong structural connection.
Solution Approach 2:
The joining function previously performed by separate rivet components is extracted and integrated directly into the hub plate structure. The hub plate is designed with built-in recesses that receive and lock the brake plate material, removing the need for external fastening elements.
2Reliability
If rivet joints are used to connect brake plate with hub plates, then the assembly is joined, but noise and vibration issues increase under braking vibrations
Solution Approach 1:
The separate rivet joint system is merged into an integrated plastic deformation joint where the brake plate material itself becomes the connecting element. This monolithic connection eliminates the interface between separate components that generates noise and vibration, creating a silent and stable joint under braking conditions.
Solution Approach 2:
The joint utilizes composite construction where the brake plate material is plasticized and combined with the hub plate material in a metallurgical or mechanical composite structure. This composite joint provides superior vibration damping and noise reduction compared to traditional rivet connections.
3Reliability
If numerous components are used in rivet joint assembly, then the brake plate can be joined with hub plates, but the assembly process becomes more complex
Solution Approach 1:
The complex multi-step assembly process involving multiple components is extracted and replaced by a single integrated forming operation. The hub plate is manufactured with built-in joining features, and the brake plate is directly formed into the hub plate in one operation, eliminating sequential assembly steps.
Solution Approach 2:
The joining features (recesses and locking structures) are preliminarily formed into the hub plate during its manufacturing process. This preliminary preparation enables the brake plate to be directly joined without requiring additional assembly operations, simplifying the overall manufacturing process while maintaining joint strength.
Data Source
Figure 1
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AI summary
A brake assembly (10) comprises a brake plate (2) mountable on a shaft with the support of a first hub plate (6) and a second hub plate (8), wherein the brake plate (2) is placed between the first hub plate (6) and the second hub plate (8), wherein the brake plate (2) is configured with a plurality of holes (12), wherein at least the first hub plate (6) has plurality of extrusions (14) having a spread (16) at the end of each of the extrusions (14) and at least the second hub plate (8) has a plurality of holes (18), wherein the first hub plate (6), the second hub plate (8) and the brake plate (2) are connected by a joint (20), wherein the joint (20) is defined by extending at least one of the extrusions (14) of the first hub plate (6) through at least one of the holes (12) of the brake plate (2), and at least one of the holes (18) of the second hub plate (8) receives the spread (16) of the first hub plate (6).