Segmented Rivetless Wear Liner for Aircraft Brake Torque Transfer
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Solution Overview
Problem
Current aircraft brake systems face issues with torque transfer problems, warping, and increased part count and cost due to the use of single-piece wear liners and fasteners in friction disk assemblies, leading to inefficiencies in manufacturing and maintenance.
Innovation Solution
The implementation of segmented wear liners with tenon and mortise dovetail shapes that couple to the friction disk core without fasteners, reducing waste and part count, and allowing for easier replacement and manufacturing efficiency.
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 creates manufacturing waste
Solution Approach 1:
The wear liner is divided into multiple segments that can be independently manufactured and assembled. Each segment is formed separately without requiring removal of the center disk, eliminating warping issues associated with single-piece construction and reducing manufacturing waste.
2Reliability
If rivets are used to fasten wear liners to the reusable core, then the connection is secure, but it increases part count, cost, and manufacture time
Solution Approach 1:
The wear liner segments are integrally formed with the reusable core through a press-fit arrangement where the segment's outer surface directly contacts and fits within the core's inner surface. This eliminates the need for separate fasteners like rivets, reducing part count while maintaining secure connection.
3Ease of manufacture
If the center disk is removed from a formed disk to create a wear liner, then the manufacturing process is straightforward, but the center disk is wasted
Solution Approach 1:
Instead of forming a complete disk and removing the center, the wear liner is manufactured as separate annular segments. This allows the material to be optimally utilized for the friction surface area only, eliminating waste of the center disk material while maintaining manufacturing simplicity.
4Ease of manufacture
If a flange is used to attach the liner to the core, then the attachment is possible, but torque transfer problems occur particularly when the liner is worn
Solution Approach 1:
The flange is eliminated by creating a direct press-fit interface between the wear liner segment's outer surface and the reusable core's inner surface. This integral connection provides superior torque transfer compared to flange attachments, especially when the liner is worn, as there is no separate attachment interface that can fail.
Data Source
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Figure 2B
AI summary
A friction disk (140) includes a friction disk core (149) having an inner diameter edge, an outer diameter edge, and a first surface with multiple mortises extending radially across the first surface. The friction disk further includes a first wear liner (150) 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 of each wear liner segment 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.