Disc Brake Rotor Assembly With Spring Pins for Thermal Joint Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing disc brake rotor assemblies face issues with joint relaxation due to loss of clamping force over time, and splined connections are complex and expensive to manufacture, while also being sensitive to heat cycling.
Innovation Solution
A disc brake rotor assembly using a double shear configuration with spring pins that absorb torque and accommodate thermal expansion, allowing for even load distribution and simplified installation by utilizing partial keyways and bosses for secure attachment to the wheel hub.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If friction constrained disc brake assemblies use multiple fasteners to clamp the rotor to the wheel hub, then the rotor can withstand braking torque without slipping, but the clamping force is lost over time causing joint relaxation
Solution Approach 1:
The fastener includes a resilient portion that can elastically deform to accommodate dimensional variations and thermal expansion between the rotor and wheel hub. This dynamic compliance maintains consistent contact pressure and prevents joint relaxation, resolving the contradiction between initial torque resistance and long-term joint stability.
Solution Approach 2:
The fastener changes its physical state from rigid to compliant through the resilient portion that can expand and contract. This parameter change allows the fastener to adapt to thermal expansion and dimensional variations, maintaining reliable joint stability while持续 providing braking torque resistance.
2Stability of the object's composition
If splined connection is used between disc brake rotor and wheel hub, then rotation is prevented, but extensive machining operations and complex mating geometry are required
Solution Approach 1:
The connection interface is segmented into simplified keyway features rather than complex splined profiles. The resilient fastener segments the torque transmission function across multiple contact points, achieving rotational stability without requiring extensive machining of splined geometries on both the rotor and wheel hub.
Solution Approach 2:
The resilient fastener acts as an intermediary element between the rotor and wheel hub, providing rotational stability through its compliance and friction engagement. This eliminates the need for complex direct mating geometries like splines, significantly simplifying manufacturing while maintaining rotational stability.
3Stability of the object's composition
If splined joint design is used, then rotation prevention is achieved, but the design is more sensitive to heat cycling and expensive to manufacture
Solution Approach 1:
The resilient portion of the fastener is specifically designed to accommodate thermal expansion and contraction of the rotor and wheel hub during heat cycling. The elastic compliance absorbs thermal stresses, preventing the heat cycling sensitivity that plagues rigid splined joint designs while maintaining rotational stability.
Solution Approach 2:
The dynamic compliance of the resilient fastener allows it to adapt to thermal dimension changes in real-time during operation. This dynamic adjustment prevents stress concentration and fatigue failure that occur in rigid splined designs under heat cycling, while preserving rotational stability.
4Reliability
If double shear configuration is used with spring pins, then peak shear stress is reduced and durability is improved, but additional compliance mechanism is required
Solution Approach 1:
The fastener transitions from a rigid pin to a resilient pin that can elastically deform. This parameter change in flexibility allows the fastener to accommodate the double shear configuration's stress distribution while absorbing dimensional variations and thermal expansion, achieving improved durability without significantly increasing structural 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
The solution enhances the durability of the disc brake rotor-wheel hub joint by reducing peak shear stress and accommodating thermal changes, while simplifying the assembly process and reducing manufacturing complexity.
Implementation Method 1
The spring pins may also expand or contract to accommodate thermal expansion and contraction of the disc brake rotor.
Implementation Method 2
The spring pins provide compliance within the disc brake rotor-wheel hub joint by taking up dimensional variations and expanding or contracting during loading which more evenly distributes load and stress throughout the disc brake rotor-wheel hub joint.
Data Source
AI summary
In one aspect of the present disclosure, a disc brake rotor assembly is provided that includes a disc brake rotor and a wheel hub. One of the disc brake rotor and the wheel hub includes a plurality of pairs of partial keyways and the other of the disc brake rotor and the wheel hub includes intermediate partial keyways configured to fit intermediate the pairs of partial keyways to form keyways. The disc brake rotor assembly further includes a plurality of fasteners configured to be received in the keyways to secure the disc brake rotor and the wheel hub together.