Hub and Rotor Assembly Segmentation for Serviceability
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Solution Overview
Problem
Existing disc brake hub and rotor assemblies for heavy-duty vehicles are difficult to service due to their weight and require skilled technicians, leading to increased downtime and risk of damaging bearings and seals, while also exposing lubricant to excessive heat, which reduces their service life.
Innovation Solution
A three-piece or two-piece disc brake hub and rotor assembly design that allows the rotor to be removed without detaching the hub from the axle spindle, incorporating a flange portion that connects separately with both the rotor and hub, and features that facilitate cooling fluid flow to dissipate heat and reduce thermal stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the rotor and hub are made as a single integrated assembly, then the structural strength and rigidity are improved, but the weight increases making it difficult to handle and service
Solution Approach 1:
The rotor assembly is divided into separate components: the rotor disc and the hub are made separable through a removable flange connection. This allows the rotor to be serviced independently from the hub, reducing the weight that must be handled during maintenance while maintaining structural integrity during operation.
2Temperature
If the rotor is mounted on the hub with intimate contact, then the heat transfer from rotor to hub is improved, but the lubricant in the hub is exposed to excessive heat reducing its service life
Solution Approach 1:
A flange portion serves as an intermediary component between the rotor and hub. This flange provides a controlled thermal interface that allows necessary heat dissipation from the rotor while protecting the hub and its lubricant from excessive thermal exposure, thereby extending lubricant service life.
3Reliability
If the rotor and hub are removed as a single assembly, then the structural integrity is maintained, but the service time increases and productivity decreases
Solution Approach 1:
The rotor assembly is segmented into separable components (rotor disc and hub) connected through a flange. This segmentation enables the rotor to be removed and serviced independently from the hub, significantly reducing service time and vehicle downtime while maintaining structural integrity during normal operation.
4Strength
If the rotor is heavy requiring lift assist equipment, then the structural strength is sufficient, but the ease of operation during servicing is reduced
Solution Approach 1:
The rotor assembly is divided into separable components that can be handled independently. The rotor disc can be removed and serviced separately from the hub, eliminating the need for heavy lift assist equipment and making maintenance operations easier and safer for service technicians.
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 design simplifies servicing, reduces the risk of damage to components, extends the life of lubricants and seals, and minimizes heat transfer to the hub, thereby reducing downtime and maintenance costs.
Implementation Method 1
features that facilitate cooling fluid flow to dissipate heat
Implementation Method 2
The heat also creates a thermal gradient across, or conduction through, the components
Data Source
AI summary
A disc brake rotor and hub assembly for a heavy-duty vehicle. The disc brake rotor and hub assembly includes a hub portion. The hub portion is receivable on, and rotatable about, an axle spindle of a heavy-duty vehicle. A rotor portion includes a disc segment, a mounting segment and a cylindrical sleeve segment connecting the disc segment to the mounting segment. A flange portion connects with the rotor portion and separately with the hub portion. Optionally, the rotor portion connects directly to the hub portion. A smallest inner dimension of the rotor portion is greater than a largest outer dimension of the hub portion to facilitate removal of the rotor portion without removing the hub portion from the axle spindle.