Open Ring Connecting Element for Two-Piece Brake Disc Assembly
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Solution Overview
Problem
Current methods for connecting two-piece brake discs, such as screw connections and complex spring-based systems, are cumbersome and prone to errors during assembly, and irreversible connections make replacing defective parts difficult.
Innovation Solution
A connecting element in an open ring shape that securely fits onto the inner or outer lateral surface of the brake disc hub, using a bung and groove for a form-fitting connection, allowing for easy assembly and potential axial and radial securing without additional screws, and can snap into place during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screw connection is used to connect brake disc ring and brake disc hub, then the connection is secure, but the assembly effort is high and many individual parts are required
Solution Approach 1:
The patent merges multiple individual screw connections into a single integrated connecting element. This connecting element comprises a first part that connects to the brake disc hub and a second part that connects to the brake disc ring, eliminating the need for multiple separate screws and simplifying the assembly process while maintaining secure connection.
Solution Approach 2:
The connecting element is segmented into two functional parts: a first part for connection to the brake disc hub and a second part for connection to the brake disc ring. This segmentation allows the single element to fulfill multiple connection functions that previously required multiple separate fasteners.
2Strength
If spring-based connecting elements are used in grooves, then connection is achieved, but the assembly is complex requiring exact relative positioning
Solution Approach 1:
The connecting element incorporates elastic springs that can dynamically adapt to positioning tolerances. The springs allow the connecting element to flex and accommodate minor misalignments between the brake disc hub and brake disc ring during assembly, eliminating the need for exact relative positioning while maintaining secure connection.
Solution Approach 2:
The connecting element changes its physical parameters through elastic deformation of the springs during assembly. The springs compress or expand to accommodate positioning variations, allowing the connection to be made without precise alignment while still achieving the required connection strength.
3Device complexity
If irreversible connection by casting is used, then no further individual parts are needed, but defective parts cannot be replaced
Solution Approach 1:
The brake disc system is segmented into replaceable components: the brake disc ring, the brake disc hub, and the connecting element. This segmentation allows any defective component to be independently replaced without replacing the entire brake disc assembly, while still achieving a simplified connection without multiple individual parts.
Solution Approach 2:
The design allows defective components to be discarded and replaced individually. The connecting element can be removed and reused with a new brake disc ring or hub, enabling component recovery and reuse while maintaining the simplified single-element connection structure.
4Strength
If multiple screws are used for connection, then secure fastening is achieved, but the assembly time is increased
Solution Approach 1:
Multiple screw fastenings are merged into a single connecting element that can be installed in one operation. This connecting element simultaneously provides the fastening function of multiple screws while reducing the assembly time by eliminating the need to individually install and secure multiple separate fasteners.
Data Source
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AI summary
A connecting element (1) for connecting a brake disc ring (3) with a brake disc pot (2) to form a brake disc, wherein the connecting element is designed in an open ring shape, the connecting element in its intended state in the connection describes more than 180° of the ring shape, and wherein the connecting element (1) comprises at least one element (11) for securing the brake disc ring in an axial direction (B).