Recessed Stator Clip Geometry for Stable Aircraft Braking
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Solution Overview
Problem
Existing brake assemblies, particularly those in aircraft, face dynamic instability and reduced braking performance at high landing energies due to the design of stator clips, which protrude and cause drag on the torque plate spline.
Innovation Solution
A stator disk assembly design where stator clips are mounted on lugs of the stator disk without protruding beyond the lug sidewalls, allowing the torque plate splines to engage directly with the stator disk without initial contact with the stator clips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If stator clips extend proud of the carbon disk face to take all loading, then structural strength is improved, but dynamic stability deteriorates due to sharp edges contacting torque plate splines
Solution Approach 1:
The stator clip is designed with a rounded leading edge instead of a sharp edge, creating a localized quality change at the contact point. This rounded geometry eliminates the harmful sharp edge while maintaining the overall structural integrity and load-bearing function of the clip.
Solution Approach 2:
The stator clip is positioned to engage the torque plate spline before the brake assembly undergoes extreme loading conditions. The preliminary engagement with a rounded edge prevents dynamic instability from developing during operation, preparing the system to handle subsequent high-stress events smoothly.
2Force
If stator clips protrude to interface with torque plate spline, then load-bearing capability is improved, but braking performance deteriorates due to stator clip drag
Solution Approach 1:
The geometry parameter of the stator clip edge is changed from sharp to rounded. This parameter change reduces the drag force exerted by the stator clip on the torque plate spline during rotation, thereby improving braking performance while maintaining adequate load-bearing capability through the rounded contact interface.
3Strength
If stator clips are formed from sheet metal to provide structural reinforcement, then strength is improved, but harmful factors increase due to sharp edges causing dynamic instability
Solution Approach 1:
Only the leading edge of the stator clip is modified to be rounded, while the rest of the sheet metal structure maintains its original form for structural reinforcement. This localized quality change eliminates the harmful sharp edge effect while preserving the overall strength-providing function of the sheet metal construction.
Data Source
AI summary
A stator disk assembly for a brake assembly is disclosed. The stator disk assembly includes at least a pair lugs with a recess disposed therebetween, along with a separate stator clip that is separately mounted on each of the lugs. The stator clips are configured such that a spline of a torque plate barrel that is disposed in the recess will contact only the stator disk and not either of the stator clips in at least certain conditions (e.g., during a braking operation). For instance, each of the two ends of each stator clip may be recessed back from the adjacent-most sidewall of the lug on which the stator clip is mounted.