Brake Rotor Runout Jig With Eccentric Compensation Alignment
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Solution Overview
Problem
Existing methods for machining brake rotors fail to accurately compensate for runout and concentricity issues caused by the axle or interface, leading to vibrations when brakes are applied, as they require removal and machining of the rotor on a lathe, which does not address inherent inaccuracies in the spindle.
Innovation Solution
A rotor runout and concentricity jig that adjusts for runout and concentricity using two disks and eccentric tubes, allowing for precise compensation within 0.020 inches, with disassembly for cleaning and incremental adjustments, and detents for precise positioning to mimic spindle characteristics, enabling accurate machining of the rotor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the rotor is removed from the axle and machined on a lathe, then the rotor surface can be turned to provide a flat surface, but the inherent runout and concentricity issues caused by the axle or interface between the axle and rotor are not addressed
Solution Approach 1:
The patent introduces a runout compensator as an intermediary device between the rotor and the lathe spindle. This compensator includes a face surface that contacts the rotor and can be adjusted to offset the runout and concentricity errors introduced by the axle or rotor interface, thereby eliminating brake vibrations while maintaining manufacturing efficiency
Solution Approach 2:
The runout compensator allows for parameter changes in the positioning of the rotor relative to the lathe spindle. By adjusting the angle and position of the face surface that contacts the rotor, the system can compensate for measured runout and concentricity errors, transforming the machining parameters to achieve the desired rotational accuracy
2Manufacturing precision
If a runout compensator is used to angle the face surface, then runout can be compensated, but the device complexity increases with additional members and adjustment mechanisms
Solution Approach 1:
The runout compensator is designed to perform multiple functions within a single integrated structure. It not only compensates for runout but also provides positioning, alignment, and support for the rotor during machining. This multi-functionality reduces the need for separate adjustment mechanisms and simplifies the overall device complexity
Data Source
AI summary
Improvements in a rotor runout and concentricity jig that mimics the runout and/or concentricity of an axle of a vehicle that can be transferred to a rotor. The jig uses discs with high and low points and/or two eccentric tubes. The parts can be adjusted from in-phase to out of phase to duplicate the characteristics of the axle. The adjustments have incremental detents that correspond with the imperfections of the axle to rotor. The position of the rotor is marked on the axle and the rotor to ensure that the rotor is placed onto the axle in the exact same location. The axle and the rotor are cleaned, reinstalled and measured for runout and concentricity. The rotor is then removed and inaccuracies for runout and/or concentricity are transferred to the jig for machining the rotor.