Segmented Brake Disc With Sinusoidal Ribs
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Solution Overview
Problem
One-piece brake discs for railway rolling stock deform due to high braking temperatures, leading to premature wear of linings, security concerns, and difficulties in handling and installation, as they warp during manufacturing and service, and existing radial ribs fail to control these deformations effectively.
Innovation Solution
A brake disc made of composite material with stiffening elements comprising regular radial and concentric ribs forming a continuous sinusoidal shape, segmented into multiple parts for improved handling and stability, with interconnected 'tenon-mortise' connections and internal blind housings for secure assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If one-piece brake discs are used, then structural simplicity is achieved, but deformation occurs due to high braking temperatures
Solution Approach 1:
The brake disc is divided into multiple segments (typically three) that are assembled together using tenon-mortise connections. This segmentation allows the disc to accommodate thermal expansion and deformation more effectively while maintaining structural integrity, resolving the contradiction between simplicity and stability.
Solution Approach 2:
The invention introduces a new dimensional aspect by adding radial ribs and concentric ribs that create a three-dimensional stiffening structure. These ribs extend in multiple directions (radial and concentric) to provide enhanced structural support against thermal deformation, transforming the simple flat disc structure into a multi-dimensional stiffened structure.
2Strength
If radial ribs are added to stiffen the disc, then structural rigidity improves, but deformation control remains insufficient
Solution Approach 1:
The invention combines radial ribs and concentric ribs into an integrated stiffening structure. The radial ribs provide support in the radial direction while concentric ribs provide support in the circumferential direction, and their interconnection creates a synergistic effect that significantly improves deformation control beyond what radial ribs alone can achieve.
Solution Approach 2:
By adding concentric ribs as a second dimensional element to the existing radial ribs, the invention creates a multi-directional stiffening network. This multi-dimensional rib structure provides comprehensive support against thermal deformation in multiple directions simultaneously, resolving the insufficient deformation control problem.
3Strength
If one-piece discs with large dimensions are manufactured, then structural integrity is achieved, but warping occurs during manufacturing and service
Solution Approach 1:
Dividing the large-dimensional disc into smaller segments facilitates manufacturing with better precision control for each segment. The segmented approach allows each piece to be manufactured with less warping, and the assembly process maintains structural integrity while avoiding the warping problems of large one-piece manufacturing.
Solution Approach 2:
The segmented structure with flexible connections allows the disc to dynamically adapt to thermal stresses during service. The structure can flex and adjust locally without developing the warping that occurs in rigid one-piece discs, maintaining manufacturing precision over time despite thermal cycling.
4Ease of manufacture
If one-piece brake discs are used, then manufacturing process is simplified, but weight increases significantly
Solution Approach 1:
The segmented design allows each segment to be manufactured separately using lighter materials and thinner sections, reducing overall weight. The segmentation enables optimization of each component's mass while maintaining structural integrity through the assembly and stiffening ribs, resolving the weight penalty of one-piece construction.
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
The solution effectively controls deformations caused by braking heat, reduces wear on linings, enhances security, and simplifies handling and installation by maintaining interchangeability with existing equipment.
Implementation Method 1
the very high temperature of these during braking at high speed (approximately 900°), causes the deformation of the discs which tend to deform by forming a re-entrant cone
Data Source
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AI summary
The invention relates to a brake disk for railway rolling equipment intended to be secured to a wheel to be braked and to engage, during braking, with a composite material lining that is mounted onto a movable jaw and capable of being placed in contact with the disk via a control means. The brake disk is characterized in that the disk is divided into three identical parts that each comprise, on the inner surface (6) thereof opposite the braking surface, stiffening elements made of ribs (8) that are regularly directed in a radial direction and a concentric direction at the same time relative to the axis of the wheel so as to control the changes in the shape of said disk due to the braking heat.