Rotor Drive Key Assembly with Insert for Wheel Boss
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Solution Overview
Problem
Existing wheel brake systems for vehicles face challenges in securely attaching rotor drive keys to the wheel, leading to potential loosening due to heat cycling, vibration, and lack of radial clearance, which can compromise braking performance and increase maintenance costs.
Innovation Solution
A rotor drive key assembly that includes a rotor drive key and an insert configured to mate with the wheel boss, providing mechanical connection and limiting movement in radial, axial, and tangential directions, with a fastener securing the assembly to prevent relative motion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a rotor drive key is directly attached to the wheel, then the structure is simple, but the attachment becomes loose due to heat cycling and vibration
Solution Approach 1:
The patent introduces an insert as an intermediary component between the rotor drive key and the wheel boss. This insert acts as a mediator that absorbs thermal expansion and contraction forces, preventing direct stress transmission to the rotor drive key attachment. The insert includes features like a radial clearance gap and expansion chamber that allow it to flex and accommodate thermal cycling, thereby maintaining reliable attachment despite temperature variations.
Solution Approach 2:
The attachment structure is segmented into three distinct components: the wheel boss, the insert, and the rotor drive key. This segmentation allows each component to be optimized independently - the insert can be designed with specific compliance features (radial clearance, expansion chamber) to handle thermal and vibrational stresses, while the rotor drive key maintains a simple secure attachment form.
2Reliability
If radial clearance is reduced to prevent loosening, then attachment stability improves, but manufacturing precision requirements increase
Solution Approach 1:
Instead of eliminating radial clearance entirely (which would demand excessive manufacturing precision), the patent employs partial clearance - a small controlled gap between the insert and wheel boss. This partial clearance is sufficient to accommodate thermal expansion and prevent loosening, while remaining small enough to maintain stable attachment. The radial clearance serves as a compliance feature that absorbs dimensional variations without compromising reliability.
3Reliability
If multiple fasteners are used to secure the rotor drive key, then attachment reliability improves, but device complexity increases
Solution Approach 1:
The insert serves as a mediator that consolidates multiple attachment functions into a single component. Rather than using multiple fasteners to directly secure the rotor drive key to the wheel boss, the insert intermediates the connection, providing compliance and stress absorption. This reduces the number of fasteners needed while improving overall attachment reliability through the insert's compliance features.
Data Source
AI summary
In some examples, a rotor drive key assembly configured to be positioned on a wheel includes an insert and a rotor drive key. The insert is configured to mate with a wheel boss of the wheel and mechanically connect the rotor drive key with the wheel boss. The rotor drive key is configured to mate with the insert such that the insert limits movement of the rotor drive key relative to the wheel boss in at least a radial direction of the wheel. In some examples, the rotor drive key includes a tab having a tab aperture configured to receive a fastener extending in an axial direction of the wheel and engaging the wheel boss.