Segmented Rail Wheel Brake Disc Friction Ring Thermal Expansion
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Solution Overview
Problem
Existing rail vehicle brake discs face challenges in managing thermal expansion of friction rings, which can lead to unbalanced friction rings and reduced braking efficiency due to the lack of a simplified connection concept that allows for adequate thermal expansion.
Innovation Solution
A rail wheel brake disc design featuring a friction ring composed of multiple ring segments with guide means on one end face and receptacles on the other, allowing for thermal expansion while maintaining centering and balance, using a simplified structure with identical ring segments and integrated guide means for easy production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the friction ring is made as a single piece, then the structure is simpler, but thermal expansion causes unbalanced distortion and reduced braking efficiency
Solution Approach 1:
The friction ring is divided into multiple identical segment elements that are connected together. Each segment can expand independently during braking, preventing the unbalanced distortion that occurs in single-piece friction rings. The segments are joined through receptacles that accommodate thermal expansion while maintaining overall ring integrity and braking performance.
2Reliability
If the friction ring is segmented to allow thermal expansion, then braking efficiency is maintained, but the connection structure becomes more complex
Solution Approach 1:
Each segment element is designed as a universal, identical component that performs multiple functions: it provides friction surface area, accommodates thermal expansion through its connection to adjacent segments, and maintains structural integrity. The receptacles serve as both connection points and expansion accommodation features, simplifying the overall design compared to complex expansion joints.
Solution Approach 2:
All segment elements are made identical in structure and dimensions, creating a homogeneous assembly. This uniformity simplifies manufacturing and assembly while ensuring even thermal expansion distribution across the entire friction ring, preventing imbalance and maintaining braking efficiency.
3Strength
If traditional connection methods are used for segmented friction rings, then structural integrity is maintained, but production and assembly processes become more difficult
Solution Approach 1:
The segment elements are designed to be connected directly to adjacent segments through receptacles, merging the functions of connection and expansion accommodation into a single integrated structure. This eliminates the need for separate fasteners or complex joining mechanisms, simplifying both production and assembly while maintaining structural integrity during thermal expansion.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enables uniform thermal expansion of the friction ring without causing it to become unbalanced relative to the rail wheel, improving braking efficiency and simplifying production and assembly processes.
Implementation Method 1
The thermal energy causes the friction ring to thermally expand. This thermal expansion can lead to so-called shielding of the friction ring. In this context, it is known in the prior art to provide segmented friction rings in brake discs for rail vehicles. The segmented friction rings include multiple ring segments that can expand under thermal stress.
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
To provide a rail wheel for a rail vehicle comprising a brake disc with at least one friction ring, which has a simplified connection concept and allows thermal expansion of the at least one friction ring, a rail wheel for a rail vehicle comprising a brake disc is proposed, wherein the brake disc comprises at least one friction ring (11) with a friction surface (12), wherein the at least one friction ring (11) comprises at least two ring segments (13a, 13b, 13c, 13d), wherein each ring segment comprises a first end face (19a, 19b, 19c, 19d) and a second end face (20a, 20b, 20c, 20d), wherein at least one guide means (21) is arranged on the first end face of each ring segment and wherein at least one guide means receptacle (23) is arranged in the second end face of each ring segment, wherein each ring segment is arranged with its first end face on the second end face of an adjacent ring segment such thatthat the at least one guide means (21) of each ring segment is arranged in the at least one guide means receptacle (23) of the adjacent ring segment, wherein the at least one guide means of each ring segment is fixedly arranged on the first end face and wherein the at least one guide means of each ring segment is arranged with play in the at least one guide means receptacle of the second end face of the adjacent ring segment.