Recessed Stator Clip Geometry for Stable Brake Spline Contact
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Solution Overview
Problem
Existing stator clips in brake assemblies, particularly in aircraft brake assemblies, face issues of dynamic instability and reduced braking performance due to sharp edges contacting torque plate splines, leading to instability and drag under extreme loading conditions.
Innovation Solution
A stator disk assembly design featuring lugs with notches for stator clips that do not protrude beyond the lug end walls, allowing splines to engage the stator disk without contacting the clips, thereby reducing dynamic instability and enhancing braking performance.
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 instability occurs due to sharp edges contacting torque plate splines
Solution Approach 1:
The stator clip edges are rounded to match the radius of the torque plate splines, eliminating sharp edges that cause dynamic instability. This curvature allows the clips to maintain structural strength while reducing contact instability during operation.
Solution Approach 2:
The stator clips are designed with different edge treatments: rounded edges on the loading side that contact torque plate splines, and sharp edges on the braking side that contact carbon disks. This local differentiation optimizes both structural strength and dynamic stability.
2Strength
If stator clips extend proud of the carbon disk face, then structural strength is improved, but braking performance is reduced due to stator clip drag on torque plate spline
Solution Approach 1:
Rounded clip edges reduce friction and drag on the torque plate splines during rotation, minimizing energy loss while maintaining the structural strength provided by the proud extension of the clips.
3Ease of manufacture
If stator clips are formed from sheet metal with sharp edges, then manufacturing ease is improved, but dynamic instability and braking performance are worsened
Solution Approach 1:
The stator clips are manufactured with selective edge treatments: rounded edges on the torque plate contact side and sharp edges on the carbon disk contact side. This local differentiation can be achieved through stamping or rolling processes that maintain manufacturing simplicity while improving dynamic stability.
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 lug of this pair. The stator clip are configured such that a spline of a torque plate 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; until crushing of the stator disk). 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.