Brake Rotor Tone Ring Assembly Protrusion Recess Mounting
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Solution Overview
Problem
Existing wheel end assemblies with brake rotors and tone rings face challenges in securely mounting the tone ring to prevent rotational and axial movement, which can lead to misalignment and reduced braking efficiency.
Innovation Solution
The wheel end assembly incorporates a brake rotor with an inner surface that includes protrusions to engage with the tone ring's recesses, and a socket to receive the tone ring's mounting feature, inhibiting rotational and axial movement, thereby ensuring secure mounting and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the tone ring is mounted on the brake rotor without protrusions and sockets, then the assembly is simpler, but the tone ring experiences rotational and axial movement leading to misalignment
Solution Approach 1:
The mounting structure is segmented into multiple functional elements: protrusions on the brake rotor, corresponding recesses on the tone ring, and a socket with mounting feature. This segmentation allows each element to perform a specific function (rotational constraint, axial constraint, and combined positioning) thereby achieving reliable alignment without requiring a single complex mounting mechanism
Solution Approach 2:
The mounting feature is received within the socket, creating a nested arrangement where the tone ring's mounting feature fits into the brake rotor's socket. This nesting provides both axial and radial positioning, effectively preventing axial movement while maintaining structural compactness
2Stability of the object's composition
If the tone ring is secured to the brake rotor with protrusions engaging recesses, then rotational movement is restricted, but the mounting structure becomes more complex
Solution Approach 1:
The protrusions and recesses feature asymmetric geometries that are specifically designed to engage with each other in a fixed rotational orientation. The non-circular cross-sections of the protrusions and corresponding recesses prevent rotational movement while the asymmetric shapes provide inherent alignment, eliminating the need for additional rotational locking mechanisms
Solution Approach 2:
The mounting system transitions from two-dimensional surface contact to three-dimensional volumetric engagement. The protrusions extend into the brake rotor opening and engage the recesses in multiple dimensions, providing rotational constraint through spatial interference rather than relying solely on surface friction or simple mechanical keys
3Reliability
If the socket receives the mounting feature to inhibit axial movement, then the tone ring positioning is improved, but the brake rotor structure becomes more complex
Solution Approach 1:
The socket serves multiple functions simultaneously: it provides axial positioning by receiving the mounting feature, radial support through its cylindrical geometry, and structural integration with the brake rotor. This multi-functionality eliminates the need for separate axial locating features, end stops, or additional fastening elements, thereby achieving reliable axial positioning without proportionally increasing structural complexity
Data Source
AI summary
A wheel end assembly includes a brake rotor that is rotatable about an axis and a tone ring that is secured to the brake rotor. The brake rotor includes a protrusion that extends into a brake rotor opening. The tone ring includes a recess that receives the protrusion to restrict rotational movement of the tone ring with respect to the brake rotor.