Brake Dust Shield Axial Offset Structure to Prevent Rotor Contact
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Solution Overview
Problem
Brake dust shields in wheel assemblies often bend during manufacturing, leading to unwanted noise due to contact with the brake rotor. There is a need for a brake dust shield design that prevents contact between the brake dust shield and the brake rotor, enhancing robustness and reducing noise.
Innovation Solution
The brake dust shield design features a central body portion radially centered along the wheel axis and a peripheral body portion with a positive axial offset surface. This design ensures that the brake dust shield is axially offset from the brake rotor, preventing contact and noise, even if the shield bends during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brake dust shield is designed with conventional flat structure, then manufacturing is simple, but the shield bends during manufacturing causing contact with brake rotor and unwanted noise
Solution Approach 1:
The brake dust shield transitions from a conventional flat two-dimensional structure to a three-dimensional structure with axial offset. The peripheral body portion is positioned in a second plane spaced apart from the first plane along the wheel axis, creating a positive axial offset that provides robustness against bending while maintaining manufacturing feasibility.
2Reliability
If brake dust shield is made more robust to prevent bending, then contact with brake rotor is prevented, but the design becomes more complex
Solution Approach 1:
The brake dust shield is segmented into a central body portion and a peripheral body portion. The central body portion remains in a first plane substantially perpendicular to the wheel axis for simple manufacturing, while the peripheral body portion is positioned in a second plane spaced apart along the wheel axis to provide robustness and prevent contact with the brake rotor.
3Object-affected harmful factors
If brake dust shield contacts brake rotor due to bending, then noise is generated, but preventing contact requires complex design
Solution Approach 1:
The brake dust shield is pre-designed with a positive axial offset in its nominal, unbent state. The peripheral body portion is positioned axially offset from the central body portion in a direction extending away from the brake rotor, creating preliminary clearance that prevents contact even when bending occurs during manufacturing or installation.
4Reliability
If brake dust shield is designed with axial offset, then contact with brake rotor is prevented, but manufacturing precision requirements increase
Solution Approach 1:
The axial offset is built into the design of the brake dust shield during manufacturing, with the peripheral body portion positioned in a second plane spaced apart from the first plane along the wheel axis. This preliminary positioning ensures that even with normal manufacturing tolerances and bending, the shield maintains clearance from the brake rotor without requiring excessive precision.
Data Source
AI summary
A brake dust shield for a wheel assembly for a vehicle may be provided. A brake dust shield may include a central body portion that may be radially centered along a wheel axis in a first plane substantially perpendicular to the wheel axis, and a peripheral body portion that may be positioned radially outward from the central body portion disposed at least in part in a second plane spaced apart from the first plane along the wheel axis. The central body portion may be operably coupled to the wheel assembly via a knuckle of the wheel assembly, and the peripheral body portion may include a positive axial offset surface that may be axially offset from the first plane in a direction extending away from the brake rotor.