Braking Axle Structure With Curvilinear Coaxial Coupling
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Solution Overview
Problem
Current braking axle structures face challenges in achieving precise coaxiality between the braking unit and the axle body due to rough geometrical tolerances and deformation caused by welding, leading to geometric errors and reduced braking efficiency.
Innovation Solution
The braking axle structure employs curvilinear surfaces on the axle body and load-bearing structure for precise coaxial coupling, with welds limited to specific zones to minimize deformation, ensuring perfect concentricity, planarity, and perpendicularity, and using a mechanical turning process to achieve optimal alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to fix the braking unit to the axle body, then the braking unit is firmly constrained to the axle body, but geometric errors occur due to deformation during welding and cooling
Solution Approach 1:
The patent applies preliminary action by performing mechanical turning on the curvilinear surfaces before welding to establish precise coaxial alignment. This pre-alignment ensures that the braking unit and axle body are perfectly coaxial before the welding process begins, so that even when deformation occurs during welding and cooling, the pre-established geometric precision is maintained.
Solution Approach 2:
The patent uses curvilinear surfaces (curved surfaces) instead of flat surfaces for the connection between the braking unit and axle body. These curvilinear surfaces are mechanically turned to achieve perfect coaxiality, and their curved geometry provides better contact and alignment during welding, reducing geometric errors caused by thermal deformation.
2Ease of manufacture
If clearance is left between the axle body and brake structure for positioning, then positioning is easier, but cooling deformation alters precision of concentricity and planarity
Solution Approach 1:
The patent eliminates the need for clearance and centring tools by performing preliminary mechanical turning on the curvilinear surfaces to achieve perfect coaxial alignment directly during manufacturing. This pre-established precision eliminates the need for post-positioning operations and prevents cooling deformation from affecting concentricity.
Solution Approach 2:
The patent replaces the traditional mechanical centring system (clearance + centring tools) with a mechanically turned curvilinear surface system. Instead of using clearance and external centring tools to achieve alignment, the curvilinear surfaces themselves are precision-turned to provide inherent coaxial alignment, eliminating the need for the traditional centring mechanism.
3Ease of operation
If ample clearance is used with centring tools, then positioning is simplified, but geometric errors persist after welding cooling
Solution Approach 1:
The patent performs preliminary mechanical turning on the curvilinear surfaces to establish perfect coaxial and perpendicular alignment before welding. This pre-established geometric precision ensures that the braking unit maintains perfect alignment with the axle body even after welding cooling, eliminating the need for complex positioning operations and centring tools.
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
This solution ensures maximum braking efficiency with reduced geometric errors and increased resistance to twisting moments, maintaining performance and cost-effectiveness while preventing deformations during cooling.
Implementation Method 1
connection means (15) for their mutual precise coaxial coupling, respectively on first curvilinear surfaces (16) on the flange and on second curvilinear surfaces (17) on the axle body, able to withstand the thermal expansion generated by the welding (8)
Implementation Method 2
a load-bearing structure 7 of the braking unit 6 and related accessories (not shown) which is constrained to the axle body through a welding 8
Data Source
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AI summary
The braking axle structure for vehicles comprises an axle body (2) having, on each end or spindle (3), a wheel hub (4) provided with the related drum (5) of the brake unit (6) and a load-bearing structure (7) of said brake unit and the related accessories which is constrained to the axle body (2) through welding, the axle body (2) and the load-bearing structure (7) having connection means (15) for their mutual precise coaxial coupling on first and second curvilinear surfaces (16, 17) and able to withstand the thermal expansion generated by the welding.