Stellate Insert Axle Brake Disc for Load and Ventilation
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Solution Overview
Problem
Assembled axle brake discs face challenges in withstanding high mechanical loads and maintaining effective internal ventilation due to the limitations of existing designs, particularly in rail vehicles, where high pad contact pressure forces and heat management are critical.
Innovation Solution
An assembled axle brake disc design featuring a hub with two friction rings and a stellate insert element with radially extending arms, which provides mechanical resilience and ventilation by using a solid steel structure and supporting bolts to absorb forces and enhance airflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solid connection between friction rings is used to withstand high mechanical loads, then mechanical resilience is improved, but internal ventilation is hindered due to high spatial filling
Solution Approach 1:
The connecting element is segmented into multiple radially extending arms that are spaced apart, creating channels for airflow between them. This segmentation allows the structure to maintain mechanical strength while enabling internal ventilation, resolving the contradiction between strength and ease of manufacture.
Solution Approach 2:
The connecting element has different local properties: the arms provide structural strength where needed, while the spaces between arms enable ventilation. This local differentiation allows simultaneous achievement of mechanical resilience and internal ventilation.
2Strength
If connecting elements are arranged between friction rings to absorb pad contact pressure forces, then mechanical load capacity is improved, but the complexity of the assembly increases
Solution Approach 1:
The connecting element combines multiple functions into a single integrated structure: it connects the friction rings to the hub, absorbs pad contact pressure forces through its radially extending arms, and enables internal ventilation through the spaces between arms. This merging reduces assembly complexity while maintaining mechanical load capacity.
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 design effectively absorbs high mechanical loads without significant elastic distortions and ensures good internal ventilation, improving the brake disc's mechanical resilience and heat management, allowing for efficient cooling and reduced spatial filling.
Implementation Method 1
the insert element can be built from a solid, preferably steel material body... the insert element can absorb pad contact pressure forces acting on the friction ring pair in an axially acting manner without significant elastic distortions
Implementation Method 2
the airflow is generated through the rotation of the axle brake disc around its axis of rotation... the brake disc can be cooled by heat convection between the friction rings
Implementation Method 3
an airflow is generated between the friction rings that for example axially flows onto the axle brake disc on the hub side and flows out radially on the outside
Implementation Method 4
pad contact pressure forces that are applied onto the friction ring pair by the brake linkage via the brake pads
Data Source
AI summary
The invention relates to an assembled undular brake disc having a hub and having two friction rings which are arranged parallel to and spaced apart from one another, which assembled undular brake disc can withstand high mechanical loads and permits good internal ventilation, wherein an insert element with arms extending radially outward in a stellate manner is arranged between the friction rings.