Aerodynamic Noise Reduction Member for Railroad Brake Disks

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Solution Overview

Problem

The existing brake disk designs for railroad vehicles, which incorporate integral plate, fin, and connecting portions to reduce aerodynamic noise, are prone to warpage due to uneven rigidity, leading to bending stress on bolts and complicating the design process.

Innovation Solution

An aerodynamic noise reduction member is introduced, featuring a plate-like support portion sandwiched between fins and a rotating member, with protruding portions that occlude between adjacent fins, allowing for separate attachment and reducing the risk of warpage by distributing stress evenly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-generated harmful factors

If the plate portion, fin portions, and connecting portion are integrally formed to reduce aerodynamic noise, then aerodynamic noise is reduced, but the plate portion is likely to warp due to uneven rigidity distribution

Engineering Contradiction:

Improveaerodynamic noiseVSAvoidplate portion warpage

Core Design Contradiction:

Object-generated harmful factorsVSStability of the object's composition

Solution Approach 1:

The brake disk is divided into separate components: the plate portion and the fin portions with connecting portions are formed as a separate noise reduction member that is attached to the plate portion, rather than being integrally formed. This segmentation allows each component to be optimized independently for its specific function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The noise reduction function is extracted from the structural plate portion by creating a separate attachable noise reduction member. This extraction allows the plate portion to maintain uniform rigidity for structural stability while the separate member provides aerodynamic noise reduction.

Inventive Principle:

Principle #2Taking out (Extraction)

2Object-generated harmful factors

If the plate portion, fin portions, and connecting portion are integrally formed, then aerodynamic noise is reduced, but the design becomes complicated due to warpage constraints

Engineering Contradiction:

Improveaerodynamic noiseVSAvoiddesign complexity

Core Design Contradiction:

Object-generated harmful factorsVSDevice complexity

Solution Approach 1:

By segmenting the brake disk into a plate portion and a separate noise reduction member, the design complexity is reduced. Each component can be designed and manufactured independently according to its specific requirements, simplifying the overall design process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The noise reduction member is designed and prepared as a separate component before attachment to the plate portion. This preliminary action allows for independent optimization and simplifies the final assembly process.

Inventive Principle:

Principle #10Preliminary action

3Object-generated harmful factors

If the plate portion, fin portions, and connecting portion are integrally formed, then aerodynamic noise is reduced, but manufacturing becomes more difficult due to warpage prevention requirements

Engineering Contradiction:

Improveaerodynamic noiseVSAvoidmanufacturing ease

Core Design Contradiction:

Object-generated harmful factorsVSEase of manufacture

Solution Approach 1:

The brake disk is segmented into separately manufacturable components: the plate portion and the noise reduction member with fins and connecting portions. This segmentation allows each component to be manufactured independently using optimal processes for each, avoiding the manufacturing difficulties of integral formation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The noise reduction function is extracted as a separate manufacturable component that can be produced independently and then attached to the plate portion, simplifying the manufacturing process.

Inventive Principle:

Principle #2Taking out (Extraction)

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 facilitates the creation of a railroad vehicle brake disk that effectively reduces aerodynamic noise while simplifying the design process by separating the noise reduction components from the brake disk, preventing warpage and maintaining structural integrity.

Implementation Method 1

each of the plurality of protruding portions partially occludes between adjacent ones of the fins in the circumferential direction... air flow is restrained and thus, aerodynamic noise is reduced

Methodology Applied

Scientific EffectAir flow restriction:

Implementation Method 2

The brake disk can be cooled by the air flow during braking

Methodology Applied

Scientific EffectConvection cooling: Convection

Data Source

PatentUS11480223B2Aerodynamic noise reduction member, railroad vehicle brake disk unit, railroad vehicle disk brake, railroad vehicle wheel, and railroad vehicle

Publication Date: 2022.10.25 NIPPON STEEL CORPORATION

AI summary

An aerodynamic noise reduction member 30 includes: a plate-like support portion 32 sandwiched between a plurality of fins 24 and 26 of a brake disk 20 and a rotating member 102 of a railroad vehicle; and a plurality of protruding portions 34 protruding from the support portion 32. Each of the plurality of protruding portions 34 is provided in such a manner that, in a state in which the support portion 32 is sandwiched between the plurality of fins 24 and 26 and the rotating member 102, each of the protruding portions 34 partially occludes between the fastening fin 24 and the anchoring fin 26 adjacent to each other in a circumferential direction of the brake disk 20.