Tone Ring Attachment Using Spring-Loaded Floating Pocket
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Solution Overview
Problem
The installation and maintenance of inductive tone rings in anti-lock brake systems, particularly on disc brake rotors, are hindered by difficult installation and replacement, thermal transfer issues causing warpage, and corrosion, due to the use of bolts and screws which can loosen or fail.
Innovation Solution
An improved method for attaching an inductive tone ring to a rotating part, such as a brake rotor, using a spring-loaded circular pocket with retaining ledges and locating tab assemblies that allow the tone ring to 'float' and reduce contact, eliminating the need for screws or bolts, thereby minimizing thermal transfer and corrosion.
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 fixed, but thermal transfer from the brake rotor to the tone ring causes dissimilar thermal expansion and warpage
Solution Approach 1:
The attachment method segments the connection between tone ring and rotor by using discrete retaining ledges and locating tabs instead of continuous rigid fastening. This allows the tone ring to be secured at specific points while maintaining thermal isolation across the interface.
Solution Approach 2:
The patent introduces an intermediary attachment mechanism (retaining ledges and locating tabs) that mediates between the need for secure fixation and thermal isolation. This intermediary structure provides mechanical support while minimizing direct thermal contact area between the brake rotor and tone ring.
2Stability of the object's composition
If the tone ring is rigidly constrained with screws or bolts, then the tone ring is securely attached, but warpage occurs at high temperatures
Solution Approach 1:
The attachment system transitions from a static rigid constraint to a dynamic floating mounting that allows the tone ring to adjust its position and orientation in response to thermal expansion. The retaining ledges and locating tabs provide guidance and support while permitting controlled movement that prevents warpage.
3Strength
If screws, bolts or press-fits are used to attach the tone ring, then the tone ring is securely fixed, but installation and replacement become difficult
Solution Approach 1:
The patent extracts the fastening elements (screws, bolts, press-fits) from the attachment system and replaces them with an integrated retaining ledge and locating tab structure that is formed as part of the rotor and tone ring respectively. This eliminates the need for separate fastening components and simplifies installation.
Solution Approach 2:
The retaining ledges and locating tabs are designed to automatically engage and secure the tone ring in the correct position during installation. The system is self-aligning and self-securing, eliminating the need for manual fastening operations with screws or bolts.
4Strength
If drilling or tapping of screw or bolt holes is performed, then secure attachment is achieved, but the process becomes more complex and time-consuming
Solution Approach 1:
The retaining ledges and locating tabs are pre-formed as integral features of the rotor and tone ring during manufacturing, rather than being created through secondary operations like drilling and tapping. This preliminary formation of attachment features eliminates complex post-manufacturing operations.
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
This method reduces thermal transfer and warpage, simplifies installation and replacement, and minimizes corrosion by allowing the tone ring to float within the rotor attachment, while eliminating the need for drilling or tapping holes, thus enhancing the reliability and longevity of the tone ring.
Implementation Method 1
A spring is located in the circular pocket. An anti-lock brake tone ring is received in the circular pocket adjacent the spring.
Implementation Method 2
The present application relates to a method and an assembly including an inductive tone ring attached to a rotating part for speed and position sensing purposes.
Data Source
AI summary
An attachment method an assembly for an induction sensing tone ring is provided comprisinga rotating part, the rotating part having a circular pocket.A spring is provided that is received in the rotating part circular pocket.A tone ring is received in the tone ring circular pocket on top of the spring.The rotating part has a plurality of retaining ledges, with each retaining ledge extending radially inward into the rotating part circular pocket from a wall of the rotating part forming the pocket. Each retaining ledge forms a retaining groove.The tone ring has a plurality of locating tab assemblies, each locating tab assembly being received in one of the retaining grooves of the brake rotor circular pocket.