Brake Stator Clip Geometry to Reduce Torque Plate Spline Drag

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Solution Overview

Problem

Standard stator clips in aircraft brake assemblies, formed from sheet metal, lead to dynamic instability and reduced braking performance due to their configuration, which results in stator clip drag on the torque plate spline, especially under extreme loading conditions.

Innovation Solution

A stator disk assembly design featuring lugs with recesses and stator clips that do not protrude beyond the lug sidewalls, allowing the torque plate splines to engage the stator disk without contacting the clips, thereby reducing drag and enhancing stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If stator clips extend proud of the carbon disk face to take all loading, then structural capability is improved, but dynamic instability occurs due to sharp edges contacting torque plate splines

Engineering Contradiction:

Improvestructural capabilityVSAvoiddynamic stability

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The stator clip is designed with a rounded leading edge instead of a sharp edge, creating a localized quality change at the contact point. This rounded geometry eliminates the dynamic instability caused by sharp edges while maintaining the load-bearing function of the clip extending proud of the carbon disk face.

Inventive Principle:

Principle #3Local quality

2Strength

If stator clips are formed from sheet metal to provide structural reinforcement, then strength is improved, but stator clip drag on torque plate spline increases leading to reduced braking performance

Engineering Contradiction:

Improvestructural reinforcementVSAvoidbraking performance

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

The stator clip geometry is modified by rounding the leading edge and optimizing the profile shape. These parameter changes reduce the drag on the torque plate spline while maintaining the sheet metal construction and structural reinforcement benefits, thereby improving braking performance at high landing energies.

Inventive Principle:

Principle #35Parameter changes

3Force

If stator clips protrude beyond lug sidewalls to engage torque plate splines, then load bearing capacity is improved, but metal-to-metal contact between clips and splines causes dynamic instability

Engineering Contradiction:

Improveload bearing capacityVSAvoiddynamic stability

Core Design Contradiction:

ForceVSStability of the object's composition

Solution Approach 1:

Instead of having the stator clip engage the torque plate spline directly with a sharp edge, the design inverts the engagement approach by using a rounded leading edge that contacts the spline surface gradually. This reversal of the contact mechanism eliminates metal-to-metal impact and dynamic instability while maintaining load bearing capacity.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentEP4283152A1Stator clip for brake assembly

Publication Date: 2023.11.29 GOODRICH CORP

Figure 1A
Figure 1B
Figure 2A

AI summary

A stator disk assembly (270) for a brake assembly is disclosed. The stator disk assembly includes at least a pair lugs (236) with a recess disposed therebetween, along with a separate stator clip (280) that is separately mounted on each of the lugs. The stator clips are configured such that a spline of a torque plate barrel (114) that is disposed in the recess will contact only the stator disk and not either of the stator clips in at least certain conditions (e.g., during a braking operation). For instance, each of the two ends of each stator clip may be recessed back from the adjacent-most sidewall of the lug on which the stator clip is mounted.