Multi-piece Rotor with Adaptor for Electric Wheel End Drive
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Solution Overview
Problem
In electric motor-driven trucks, the ideal placement of electric motors next to the wheel hub poses challenges for efficient braking systems, as existing multi-piece brake rotors require complex assembly and maintenance, and the rotor's shorter lifespan necessitates easy removal and replacement without disassembling the hub or motor, while also considering ground clearance and cooling.
Innovation Solution
A brake disc arrangement with multiple rotor assembly pieces and an adaptor allows for secure mounting to the wheel hub, enabling easy removal and replacement of the rotor without disassembling the hub or motor, while maintaining efficient cooling through slotted designs for weight reduction and ventilation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the electric motor is placed immediately next to the wheel hub, then system efficiency is improved, but the brake system becomes more complex and difficult to maintain
Solution Approach 1:
The brake rotor is divided into multiple separable pieces (first rotor piece, second rotor piece, third rotor piece) that can be independently removed and reassembled. This segmentation allows maintenance of the brake system without removing the electric motor from its optimal position next to the wheel hub, thus maintaining system efficiency while reducing maintenance complexity.
Solution Approach 2:
An adaptor is introduced as an intermediary component between the wheel hub and the rotor assembly. The adaptor provides a mounting interface that allows the rotor pieces to be secured to the hub while accommodating the electric motor housing, thereby enabling the motor to be positioned next to the hub without complicating the brake system architecture.
2Strength
If the rotor is designed as a single piece, then structural strength is improved, but removal and replacement becomes difficult without disassembling the hub or motor
Solution Approach 1:
The rotor is segmented into multiple pieces (first rotor piece with engagement portion, second rotor piece, third rotor piece) connected by fasteners. This segmentation maintains the structural integrity and strength of the complete rotor assembly while enabling individual pieces to be removed and replaced independently without disassembling the hub or motor, significantly improving ease of repair.
Solution Approach 2:
The rotor pieces are pre-assembled with fasteners and connection features that allow for quick assembly and disassembly. The engagement portion with friction pad contact surfaces is pre-configured on the first rotor piece, enabling the rotor assembly to be rapidly installed or removed as a unit while maintaining structural strength during operation.
3Force
If a larger diameter rotor is used, then braking performance is improved, but ground clearance concerns arise
Solution Approach 1:
The rotor assembly is configured to extend along the rotor assembly axis between the engagement portion and the attachment base, utilizing the axial dimension rather than solely increasing radial diameter. This allows the rotor to achieve sufficient braking force through optimized surface area and friction pad engagement while maintaining a compact radial profile that avoids ground clearance issues.
Solution Approach 2:
The rotor pieces are designed with localized friction surfaces and engagement portions that concentrate braking force where needed. The intermediate section and attachment base provide structural support without requiring increased overall diameter, allowing high braking force to be achieved through optimized local geometry rather than increasing the rotor's external dimensions.
4Reliability
If the rotor life is extended to match the hub or motor, then system reliability is improved, but the rotor cannot be easily refurbished or replaced
Solution Approach 1:
The rotor is segmented into multiple replaceable pieces secured by fasteners, allowing the rotor assembly to be removed and refurbished or replaced independently of the hub and motor. This segmentation maintains system reliability by enabling timely rotor maintenance while preserving the longevity of the hub and motor components.
Solution Approach 2:
The rotor pieces can be removed, refurbished, or replaced as needed without discarding the entire brake system or the expensive hub and motor components. The separable design allows recovery and reuse of the hub, motor, and adaptor while the rotor pieces can be independently maintained, extending the overall system lifecycle and improving cost-effective reliability.
Data Source
AI summary
A brake disc arrangement to be located at an end of an axle of a vehicle driven by an electric motor includes a rotor assembly having multiple rotor assembly pieces joined together with fasteners, as well as an adaptor. The pieces mentioned include rotor sections defining an engagement portion having surfaces to be contacted by friction pads. The rotor assembly also includes an attachment base and an intermediate section, surrounding a rotor assembly axis of rotation, extending along the rotor assembly axis of rotation between the engagement portion and the attachment base. When assembled, the adaptor extends between a wheel hub base and the attachment base of the rotor assembly so that the rotor assembly is securable to the wheel hub. The adaptor defines an internal volume within which a housing for the electric motor and at least a portion of the wheel hub are receivable.