Inductive Tone Ring Floating Attachment for Disc Brake Rotor
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Solution Overview
Problem
The installation and maintenance of inductive tone rings in disc brake assemblies are hindered by difficult installation and replacement, thermal transfer issues leading to warpage, and corrosion, particularly due to the use of bolts and screws which can loosen or fail, and the dissimilar thermal expansion between the brake rotor and tone ring.
Innovation Solution
An improved attachment method for an inductive tone ring using a brake rotor with a circular pocket and protruding members featuring retaining grooves, where the tone ring 'floats' within the rotor, reducing contact areas and eliminating the need for screws or bolts, allowing for easier installation and reducing corrosion by minimizing thermal transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the tone ring is rigidly mounted to the rotor with screws or bolts, then the tone ring is securely attached, but thermal transfer from the brake rotor to the tone ring causes dissimilar thermal expansion and warpage
Solution Approach 1:
The attachment system is segmented into multiple discrete retaining tabs distributed around the tone ring, each providing localized attachment points. This segmentation reduces continuous thermal contact areas while maintaining secure attachment through distributed retention points.
Solution Approach 2:
The retaining tabs act as intermediary elements between the tone ring and brake rotor, providing mechanical retention while minimizing direct thermal contact. The tabs create isolated contact points rather than continuous thermal pathways, reducing heat transfer to the tone ring.
2Stability of the object's composition
If the tone ring is rigidly constrained to the rotor, then the attachment is secure, but the ring cannot float and warping occurs at high temperatures
Solution Approach 1:
The attachment system transitions from a static rigid constraint to a dynamic floating arrangement where the tone ring can move independently within the rotor. The retaining tabs provide guidance and retention while allowing thermal expansion and contraction without rigid constraint, enabling the ring to 'float' and accommodate temperature-induced dimensional changes.
3Strength
If screws and bolts are used to attach the tone ring, then secure attachment is achieved, but installation and replacement become difficult and time-consuming
Solution Approach 1:
The complex fastening system of screws and bolts is extracted and replaced with a simpler retaining tab mechanism. This extraction eliminates the need for threading, tightening, and alignment operations, reducing installation complexity while maintaining adequate attachment strength through the distributed tab structure.
Solution Approach 2:
The retaining tabs are integrally formed with the tone ring, making the attachment system self-contained and self-retaining. The tabs automatically engage with the rotor bore features during installation without requiring separate fastening operations, enabling simple snap-fit or press-fit installation and removal.
4Strength
If the tone ring is attached with multiple fasteners, then secure attachment is achieved, but drilling and tapping of holes in the rotor is required
Solution Approach 1:
The complex hole-drilling and tapping operations are extracted from the installation process by using retaining tabs that engage with pre-formed rotor bore features. This eliminates the need for secondary machining operations, reducing device complexity and installation steps while maintaining attachment integrity.
5Strength
If the tone ring has extensive contact areas with the rotor, then secure attachment is achieved, but thermal transfer and corrosion increase
Solution Approach 1:
The attachment system uses localized retaining tabs at specific circumferential positions rather than extensive continuous contact. This local quality approach concentrates attachment strength at discrete points while minimizing overall contact area, thereby reducing thermal transfer pathways and corrosion exposure areas between the tone ring and rotor.
Data Source
Figure 1
Figure 2~3
AI summary
An assembly (10) for an induction sensing tone ring (20) is provided. A brake rotor (12) includes a circular pocket. A tone ring (12) is received in the circular pocket of the brake rotor. The brake rotor has a plurality of locating tabs (17), with each locating tab having a slope surface (19). The tone ring has a plurality of retaining tabs (31), with each retaining tab (31) being received between two locating tabs (17) of the brake rotor. A retaining ring is fitted in each locating tab slope surface of the brake rotor to press fit against the retaining tabs of the tone ring.