Mechanically-keyed non-slip brake joints for torque stability
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Solution Overview
Problem
Existing brake joints in vehicle disc brakes experience slippage due to dynamic loading from electronic brake systems, leading to increased wear and torque fall-off, especially under high-force brake applications.
Innovation Solution
Mechanically-keyed non-slip brake joints are introduced, featuring a protrusion on the anchor bracket that mates with a complementary cavity on the mounting structure, transferring loads through keying features instead of fasteners, reducing slippage and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If electronically assisted brake systems are used to provide quicker and more powerful brake applications, then braking performance is improved, but the force experienced by the brake joint increases causing slippage and wear
Solution Approach 1:
The brake joint connection is segmented into two functional components: a fastener component that provides clamping force and a keying component that prevents slippage. The keying feature includes a protrusion on one part and a complementary cavity on the other part, creating distinct load transfer paths that separate normal force transmission from preventing relative motion.
Solution Approach 2:
The keying feature acts as an intermediary mechanical element between the fastener and the brake joint components. This intermediary protrusion-cavity interface mediates the load transfer by providing a positive mechanical interlock that prevents slippage while allowing the fastener to maintain clamping pressure.
2Device complexity
If traditional fastener-only connections are used in brake joints, then device complexity is low, but slippage occurs under dynamic loading causing torque fall-off
Solution Approach 1:
The connection mechanism is segmented into two distinct features: a fastener opening for receiving the fastener and a keying feature with protrusion and cavity. This segmentation allows each feature to perform its specific function - the fastener provides clamping while the keying feature prevents slippage - resulting in a relatively simple yet effective design.
3Ease of manufacture
If conventional brake joint designs are used, then manufacturing is simple, but increased wear occurs due to slippage under high-force applications
Solution Approach 1:
The joint design segments the load transfer function into two parts: the fastener handles clamping force application and the keying feature handles slippage prevention. This segmentation eliminates relative motion between contact surfaces, preventing wear while maintaining manufacturing simplicity through straightforward machining of the protrusion and cavity features.
Solution Approach 2:
The design changes the friction parameter from kinetic friction (slipping) to static friction (locked). By introducing the keying feature that prevents relative motion, the contact surfaces remain stationary relative to each other, eliminating wear that would otherwise occur under high-force dynamic loading conditions.
Data Source
AI summary
Methods, apparatus, and articles of manufacture are disclosed for mechanically-keyed non-slip brake joints. An example apparatus includes an anchor bracket having a first contact surface with a first fastener opening formed therethrough. A protrusion extends from the first contact surface. The apparatus also includes a mount having a second contact surface with a second fastener opening therethrough. A cavity is formed in the second contact surface. The anchor bracket is to be coupled to the mount such that protrusion matably engages the cavity.