Reduced-Size Torque Plate for Heavy-Duty Brake Systems
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Solution Overview
Problem
Existing torque plates for heavy-duty vehicles are too large and heavy, increasing costs and reducing fuel efficiency, while maintaining strength and performance is crucial for optimal brake system operation, especially with reduced-diameter brake rotors, and they often require post-weld processing that adds expense and complexity.
Innovation Solution
A reduced-size torque plate design featuring an axle ring, radially extending bodies, and optimized bolt openings, forged from steel to minimize weight and cost, with integrated ABS sensor and splash guard mounting bosses, allowing for square alignment without post-weld machining, ensuring structural integrity and efficient brake operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional large-size torque plates are used, then strength and performance are maintained, but weight and cost increase
Solution Approach 1:
The torque plate is divided into multiple functional segments: a central hub portion, radial arms extending outward, and mounting flanges at the ends of the arms. This segmentation allows material to be concentrated where structural strength is needed (hub and arm roots) while reducing material in less critical areas, achieving weight reduction without compromising overall strength.
Solution Approach 2:
Different regions of the torque plate are given different thicknesses and structural characteristics based on their functional requirements. The hub portion has greater thickness for strength, the arms have optimized thickness for torque transmission, and the mounting flanges have specific geometries for bolt attachment. This local differentiation maintains strength where needed while reducing weight overall.
2Reliability
If traditional large-size torque plates are used, then performance is maintained, but cost increases
Solution Approach 1:
The segmented design allows the torque plate to be manufactured as a single integrated component using modern forging or casting processes, eliminating the need for expensive post-weld machining operations. The geometry is optimized for direct manufacturing, reducing production steps and associated costs while maintaining brake system performance.
Solution Approach 2:
The torque plate geometry parameters (arm length, flange positioning, bolt hole locations) are optimized to work with reduced-diameter brake rotors, allowing the use of smaller, less expensive components throughout the brake assembly while maintaining stopping performance through improved force distribution.
3Weight of moving object
If reduced-diameter brake rotors are used, then weight and cost are reduced, but torque plate compatibility becomes problematic
Solution Approach 1:
The torque plate design incorporates universal mounting features and standardized flange geometries that can accommodate various brake rotor sizes, including reduced-diameter rotors. The radial arm structure and flange positioning are designed to work with different rotor configurations, making the torque plate adaptable to multiple brake system configurations.
Solution Approach 2:
The torque plate parameters (particularly flange radius, arm length, and bolt hole positioning) are specifically optimized for reduced-diameter rotors, creating a new compatibility standard that enables the entire brake assembly to be downsized while maintaining proper alignment and braking performance.
4Manufacturing precision
If traditional torque plates requiring post-weld processing are used, then alignment precision is achieved, but manufacturing complexity increases
Solution Approach 1:
The torque plate is designed with pre-formed mounting surfaces and integrated alignment features that are created during the primary forging or casting process. This preliminary formation of critical surfaces eliminates the need for subsequent welding and machining operations, achieving the required alignment precision through the initial manufacturing step alone.
Solution Approach 2:
Multiple manufacturing operations that were previously separate (forming, welding, machining alignment surfaces) are merged into a single integrated manufacturing process. The torque plate geometry is designed to achieve final dimensions and alignment through one forming operation, combining multiple steps into one and reducing overall manufacturing complexity.
Data Source
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AI summary
A torque plate for heavy-duty vehicles includes a reduced size and structural features that enable the torque plate to be used in conjunction with a reduced diameter brake rotor. The torque plate is rigidly attached to an axle of the heavy-duty vehicle. The torque plate includes an axle ring that is formed with a thickness and an opening for receiving the axle, in which the axle ring engages an outer diameter of the axle. Each one of a pair of bodies is formed with a thickness and extends radially outwardly in opposite directions from the axle ring. Each body thickness is less than the axle ring thickness. Each one of a pair of carrier mounting bosses extends radially outwardly from a respective one of the bodies. The torque plate also includes a pair of anti-lock braking system sensor mounting bosses, and a pair of splash guard mounting bosses.