Floating Motorcycle Disc Brake With Torque-Decoupled Hub
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Solution Overview
Problem
Current floating disc brake systems for motorcycles are heavy due to the need to withstand braking torque, leading to increased wear and dynamic issues like vibrations and uncontrolled brake pad movement, caused by wheel deformations and the high radial distance between the hub and disc.
Innovation Solution
A disc brake system with a supporting crown and a floating connection system that allows axial mobility between the crown and brake disc, connected to the wheel via a fixing system that limits the transmission of braking torque through the hub, reducing the weight and stress on the hub while maintaining rotational integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the hub is structurally configured to transmit and withstand the braking torque, then the braking torque is effectively transmitted to the ground, but the overall weight of the rotary unit increases
Solution Approach 1:
The braking system is segmented into two functional parts: the crown (support) that transmits braking torque to the hub, and the brake disc that rotates with the wheel. The connection system with radial play allows the brake disc to be mechanically separated from the hub for torque transmission purposes, enabling the hub to be lighter while still handling braking forces through the crown.
Solution Approach 2:
The crown acts as an intermediary element between the brake disc and the hub. It receives the braking torque from the brake disc through the connection system and transmits it to the hub, which then discharges it to the ground. This intermediary allows the hub to be optimized for weight while the crown handles the torque transmission function.
2Strength
If the support is keyed on the hub with high radial distance, then the braking torque transmission is effective, but the disc is significantly influenced by bending deformations of the wheel
Solution Approach 1:
The connection system between the brake disc and crown incorporates radial play (floating connection), allowing the brake disc to dynamically adjust its position relative to the crown. This dynamic adjustment compensates for wheel bending deformations during braking, maintaining stable contact between the brake pads and disc surface while still transmitting braking torque effectively.
Solution Approach 2:
The radial play in the connection system changes the positional parameters of the brake disc relative to the crown during operation. This parameter change allows the disc to self-align and compensate for deformations, reducing gradual wear and dynamic problems like vibrations and uncontrolled pad movement.
3Reliability
If the connection system is floating with axial clearance, then the disc can self-align with the gripper to compensate for deformations, but the complexity of the connection system increases
Solution Approach 1:
The connection system is segmented into multiple connection points angularly distributed around the axis of the support. This segmentation allows the brake disc to float axially while maintaining rotational alignment, providing deformation compensation without requiring a single complex universal joint.
Solution Approach 2:
The floating connection system with radial play serves multiple functions simultaneously: it allows axial floating for self-alignment, transmits braking torque through the crown to the hub, and compensates for wheel bending deformations. This multi-functionality reduces the need for additional separate mechanisms.
Data Source
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AI summary
Described is a floating disc brake (1) for a motorcycle, by means of which there is a lightening of the hub (62) of the wheel on which the disc brake (1) operates, and therefore a lightening of the wheel (6) and of the motorcycle.