Segmented Braking Nut Design Reduces Material Waste

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Solution Overview

Problem

The existing manufacturing process for vehicle braking system nuts is costly due to significant material losses and requires multiple operations, especially when the nuts are small and/or the piston diameter is large, resulting in disproportionate manufacturing costs compared to the forces they must withstand.

Innovation Solution

A method to manufacture a braking system nut by machining a hub and a separate ring, which are then rigidly attached, allowing for the use of inexpensive materials and reducing material losses, with the ring's dimensions chosen based on the stresses it will face, and the hub and ring made from materials with different hardness levels for secure assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the nut is made in one piece from a single block of material, then the structural integrity and strength are improved, but the material losses and manufacturing costs increase significantly

Engineering Contradiction:

Improvestructural integrityVSAvoidmaterial losses

Core Design Contradiction:

StrengthVSLoss of substance

Solution Approach 1:

The nut is divided into two separate elements: a hub and a ring. The hub is machined from a solid block to provide strength and house the tapped hole, while the ring is formed from a metal sheet and mounted on the hub to provide the braking surface. This segmentation reduces material waste while maintaining structural integrity through the rigid attachment of the two components.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If the nut is made in one piece from a single block of material, then the manufacturing process is simpler in terms of assembly, but the number of manufacturing operations and equipment requirements increase

Engineering Contradiction:

Improveassembly simplicityVSAvoidmanufacturing operations

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

3Device complexity

If the nut is made in one piece from a single block of material, then the design is more unified, but the adaptability to different screws and braking device models is reduced

Engineering Contradiction:

Improvedesign unityVSAvoidadaptability to different screws

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The hub and ring can be designed as universal components that can be used across different braking device models. The hub provides the threaded connection interface that can accommodate different screw sizes, while the ring can be adjusted or replaced to match different braking requirements, enhancing the adaptability of the nut assembly.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Volume of moving object

If the nut is small and/or the piston diameter is large, then the braking system is more compact, but the manufacturing cost becomes disproportionate to the forces withstood

Engineering Contradiction:

Improvenut sizeVSAvoidmanufacturing cost

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS11466763B2Low-cost nut for vehicle braking system

Publication Date: 2022.10.11 FOUND BRAKES FRANCE SAS

AI summary

A method for manufacturing a vehicle braking system including the steps of machining a hub so as to provide it with a nose and a tapped hole, mounting, on the nose of the hub, a ring having at least one relief extending in a direction perpendicular to a main axis of the ring, and rigidly attaching the ring to the hub such that the assembly, including the hub and the ring, forms a nut.