Anti-lock Brake Rotor Tone Ring Cartridge with Shaft Guide
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Solution Overview
Problem
Anti-lock brake rotor sensors face issues due to heat buildup and space constraints in brake flange locations, and semi-float shaft configurations require solutions for blind installation and lubricant flow without interfering with inboard sensors, while accommodating full float, semi-float, and independent shaft systems.
Innovation Solution
A rotor tone ring cartridge design with a shaft guide and anti-lock brake sensor assembly that includes a sensor mount and tone ring cartridge, allowing for blind installation and free lubricant flow, while maintaining sensor functionality and avoiding interference with inboard sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the sensor is located in or adjacent the brake flange, then the sensor is easily accessible, but heat buildup adversely affects the sensor and space is insufficient
Solution Approach 1:
The sensor is extracted from the brake flange location and repositioned to the shaft housing. This removes the sensor from the high-temperature environment generated by brake operations while maintaining its functional accessibility through the shaft housing interface.
2Temperature
If the sensor is moved inboard of the brake flange, then heat and space issues are resolved, but the shaft assembly becomes more complex
Solution Approach 1:
The shaft housing is designed to serve multiple functions: it houses the sensor, provides a mounting interface for the tone ring cartridge, and maintains structural integrity of the axle assembly. This multi-functionality reduces the need for additional separate components.
3Ease of manufacture
If the ABS rotor is pressed into the shaft housing prior to bearing and seal installation, then the ABS rotor can be installed in semi-float configurations, but shaft end float and lubricant flow are restricted
Solution Approach 1:
The shaft housing is designed with dynamic characteristics that allow the shaft to float axially within specified limits. This dynamic capability enables the shaft to accommodate thermal expansion and assembly variations while maintaining proper bearing clearance and lubricant flow paths.
4Productivity
If the shaft is installed in a blind fashion, then installation is simplified, but the installer cannot see the shaft end connection to the differential spline
Solution Approach 1:
Visual indicators such as colored alignment marks or contrasting paint are applied to the shaft and shaft housing interface. These visual cues enable the installer to detect proper alignment and insertion depth of the shaft into the differential spline during blind installation.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
An anti-lock brake rotor tone ring cartridge (72) has an inner piece (66) and an outer piece (68). The outer piece (68) fits at least partially within the inner piece (66) so as to prevent the axial movement of the inner piece (66). A tone ring (130) is located on the inner piece.