Segmented Rivetless Wear Liner for Torque Transfer and Low Waste
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Solution Overview
Problem
Current aircraft braking systems face issues with torque transfer problems and increased part count due to the use of single piece wear liners, which can lead to warping and wasteful manufacturing, as well as higher costs and overhaul times.
Innovation Solution
The implementation of segmented wear liners for friction disks, where each segment includes a tenon that couples to mortises on the friction disk core without the need for fasteners, forming an annular structure that reduces waste and part count, and allows for easier replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single piece wear liner is used, then the structure is simple, but it experiences warping and causes manufacturing waste
Solution Approach 1:
The wear liner is divided into multiple segments (typically three) that are assembled around the friction disk core. Each segment is manufactured separately as a flat annular component, avoiding the warping issues of large single-piece liners while maintaining structural integrity through the segmented design with interlocking features.
2Reliability
If rivets are used to fasten wear liners to the core, then the connection is secure, but the part count increases thus increasing cost, manufacture time, and overhaul time
Solution Approach 1:
The attachment features (tenons and mortises) are integrated directly into the wear liner segments and friction disk core structure. The tenons on the inner diameter edge of each segment interlock with corresponding mortises on the core, eliminating the need for separate rivets or fasteners while maintaining secure mechanical attachment.
3Shape
If the center of the disk is removed after forming a single piece wear liner, then the annular shape is achieved, but the center disk is wasted
Solution Approach 1:
Instead of forming a complete annular liner and removing the center (which wastes material), the liner is segmented into multiple flat annular components. These segments can be manufactured more efficiently with less material waste, and the center portion of each segment can be utilized in the design, eliminating the need to remove and discard a central disk portion.
4Reliability
If a flange is used to attach the liner to the core, then the attachment is achieved, but torque transfer problems occur particularly when the liner is worn
Solution Approach 1:
The tenon-mortise interlocking mechanism is built into the design from the beginning, providing inherent torque transfer capability. The tenons on the wear liner segments engage with mortises on the core, creating a positive mechanical connection that maintains torque transfer effectiveness throughout the wear liner's service life, unlike flange attachments that rely on friction and can become problematic as the liner wears.
Data Source
AI summary
A friction disk includes a friction disk core having an inner diameter edge, an outer diameter edge, and a first surface with multiple mortises extending radially across the first surface, each of the multiple mortises having a different dimension at the inner diameter edge than at the outer diameter edge. The friction disk further includes a first wear liner having two wear liner segments each including a wear surface and a non-wear surface having a tenon with a complimentary shape to each of the multiple mortises, the tenon being configured to be received by a corresponding mortise of the multiple mortises to couple the wear liner segments to the friction disk core to form an annular liner.