Magnet Wheel Hub Connection Using Leaf Spring Clamping
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Solution Overview
Problem
The connection between the magnet wheel and the wheel hub or brake disc is prone to detachment due to different thermal expansions, leading to impaired functionality of the anti-lock braking system, especially under high thermal stresses, and requires additional assembly efforts and manufacturing precautions.
Innovation Solution
A secure connection is achieved by using connecting lugs with recesses on the magnet wheel, which are arranged at specific angular distances and interact with the wheel hub's drivers, allowing for axial and rotational securing without additional assembly or manufacturing measures, utilizing leaf springs for clamping and screws for fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the magnet wheel is fixed by press connection or in a borehole, then the assembly is simplified, but the connection becomes unreliable under thermal stress due to different thermal expansions
Solution Approach 1:
The leaf spring is designed as a dynamic securing element that can flex and adapt to thermal expansions. The spring continuously applies clamping force to the connecting lug, maintaining secure connection despite dimensional changes in the magnet wheel and wheel hub during thermal cycles.
Solution Approach 2:
The securing system uses a spring with adjustable preload that can compensate for thermal expansion differences. The elastic properties of the spring allow it to maintain constant contact pressure on the connecting lug throughout temperature variations, ensuring reliable connection.
2Reliability
If additional threaded holes are made in the wheel hub for fastening, then the connection reliability is improved, but the manufacturing complexity and costs increase
Solution Approach 1:
The connecting lug integrates multiple functions into a single component: it provides both the mechanical connection interface and the mounting feature for the leaf spring. The lug is formed as an integral part of the magnet wheel, eliminating the need for separate fastening elements and additional holes in the wheel hub.
Solution Approach 2:
The connecting lug serves multiple purposes: it secures the magnet wheel to the wheel hub, provides a mounting point for the leaf spring, and maintains the functional relationship between the magnet wheel and brake disc. This multi-functional design eliminates the need for dedicated fastening features.
3Reliability
If the magnet wheel is securely fastened with additional fastening elements, then the connection reliability is improved, but the disassembly and replacement complexity increases
Solution Approach 1:
The securing system is divided into separable components: the leaf spring can be independently removed from the connecting lug by loosening the single screw, without affecting the magnet wheel itself. This segmentation allows easy replacement of the leaf spring while keeping the magnet wheel installed.
Solution Approach 2:
The leaf spring is pre-configured with a single screw fastening mechanism that allows quick release. The spring itself acts as a preliminary securing element that can be easily detached, facilitating rapid maintenance and replacement operations.
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 a reliable and long-lasting connection under high thermal stresses, reduces costs, simplifies assembly and disassembly, and maintains the functionality of the anti-lock braking system without the need for special measures or additional manufacturing steps.
Implementation Method 1
supporting elements, which are designed as leaf springs and are each fastened on the one hand to a driver by screwing and on the other hand rest under spring pressure on the adjacent support elements of the brake disc
Implementation Method 2
the frictional heat generated during braking, which prevents the system from functioning reliably over the long term
Implementation Method 3
the different degrees of thermal expansion of the magnet wheel and the wheel hub or brake disc poses the risk of detachment
Data Source
Figure 1
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Figure 3
AI summary
An arrangement of a brake disk (1) on a wheel hub (2), in particular of a utility vehicle, having multiple support elements (8), which are distributed on the inner circumference of the brake disk (1), and which correspond to drivers (6) disposed on the outer circumference of the wheel hub (2) in the meaning of a twist lock, and having securing elements (9) which press against both the drivers (6) and also adjacent support elements (8) to axially secure the brake disk (1), and a rotor (3), which is disposed in the attachment area of the brake disk (1) on the wheel hub (2), is implemented so that the rotor (3) has attachment parts, for the axial and twist-locked fixing, which each engage behind one of the securing elements (9).