Modular Disc Brake Rotor Assembly With Press-Fit Ring Sections
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Solution Overview
Problem
The complexity and cost of manufacturing various sizes and styles of disc brake rotors require numerous customized machining tools, limiting manufacturing efficiency and flexibility.
Innovation Solution
A modular rotor assembly design using interconnected parts, such as a central mounting section and ring members, connected via press fit elements, allowing for the creation of different rotor sizes and styles with fewer machining tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rotors are manufactured as unitary pieces from single materials using customized machining tools for each size and style, then manufacturing precision and structural integrity are improved, but device complexity and manufacturing cost increase due to the need for numerous specialized tools
Solution Approach 1:
The rotor is divided into multiple separate components including a rotor body, brake pads, and optional elements such as rotor hats or mounting sections. These segmented components can be manufactured using standardized machining processes and then assembled together, eliminating the need for numerous customized machining tools while maintaining manufacturing precision through controlled assembly interfaces
Solution Approach 2:
The rotor assembly is designed with universal interfaces and standardized components that can accommodate multiple rotor sizes and styles. The segmented design allows the same basic components to be configured for different vehicle applications, reducing device complexity by enabling a single manufacturing system to produce multiple rotor variants
2Manufacturing precision
If numerous customized machining tools are used to produce various rotor sizes and styles, then manufacturing precision for each specific rotor type is improved, but productivity decreases due to the need for multiple specialized tools and increased setup time
Solution Approach 1:
By segmenting the rotor into separately manufacturable components, each component can be produced using standardized high-precision machining processes. The components are then assembled with controlled tolerances, maintaining overall rotor dimensional precision while significantly improving productivity through reduced tooling changes and simplified manufacturing workflows
Solution Approach 2:
Rotor components are pre-manufactured using standardized processes with predetermined interfaces and tolerance specifications. This preliminary action allows for parallel manufacturing of multiple components and simplifies final assembly, thereby improving productivity without compromising the dimensional precision of the finished rotor
3Adaptability or versatility
If a modular rotor assembly design with interconnected parts is used, then adaptability and manufacturing flexibility are improved, but device complexity increases due to the need for multiple components and connection interfaces
Solution Approach 1:
The rotor is segmented into functional components (rotor body, brake pads, mounting sections) that can be independently designed and configured for different applications. This segmentation improves adaptability while the use of standardized connection interfaces and modular design patterns keeps the overall assembly complexity manageable
Solution Approach 2:
The rotor assembly employs a nested structure where components such as brake pads are positioned within or against the rotor body, and optional elements like rotor hats or mounting sections are integrated into the overall structure. This nesting approach improves adaptability by allowing easy configuration changes while minimizing the space and interface complexity of the assembled unit
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 approach simplifies the manufacturing process by reducing the number of required machining tools and enables the production of a wide range of rotor designs with various materials, enhancing flexibility and efficiency.
Implementation Method 1
The first set of connection elements and the second set of connection elements are configured to be press fit together to connect the central mounting section with the outer friction ring section
Data Source
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AI summary
A rotor assembly (12) for a disc brake system (10) is provided with a central mounting section (30) having a hub (38), a flange (50) connected to a radially outer edge of the hub (38), and a first set of connection elements formed in or on the flange (50). The rotor assembly (12) also includes an outer friction ring section (22,24) including a radially inner flange (60,70) and a second set of connection elements formed in or on the radially inner flange (60,70). The hub (38) of the central mounting section (30) is configured for connection to a wheel/axle of a vehicle. The outer friction ring section (22,24) includes surfaces configured for contact with one or more brake pads (16) of a caliper (14). Also, the first and second sets of connection elements are configured to be press fit together to connect the central mounting section (30) with the outer friction ring section (22,24). The outer friction ring section (22,24) may be implemented as attachable ring members.