Track Wheel Friction Ring Assembly for Simpler Brake Cooling
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Solution Overview
Problem
Existing friction ring bodies for rail wheel brakes are complex and costly to produce, requiring intricate molding processes and often necessitate materials that are difficult to coordinate for welding, limiting material selection and increasing production costs.
Innovation Solution
The friction ring bodies are designed using a two-dimensional manufacturing process with separately formed connecting bodies that are non-positively connected to the friction ring, allowing for the use of different metallic materials and enabling secure attachment to the wheel web through a pin locking mechanism, which prevents rotation and allows for radial expansion during braking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If friction ring bodies are produced using traditional casting processes with cooling fins and projections, then the friction rings can be cooled during braking, but the molding process becomes technically complex and production costs increase
Solution Approach 1:
The friction ring body is divided into a friction ring component and separate connecting bodies that are inserted into openings. This segmentation allows the friction ring to be produced as a simple flat component without complex molding, while the connecting bodies provide the necessary structural functions including cooling fin integration.
Solution Approach 2:
The connecting bodies are extracted as separate components from the friction ring proper. These connecting bodies are inserted into openings in the friction ring and secured by pin locking mechanisms, allowing the friction ring itself to be manufactured as a simple flat component while the connecting bodies provide cooling and attachment functions.
2Adaptability or versatility
If separate connecting bodies are used to attach the friction ring to the wheel web, then material selection flexibility increases, but the device complexity increases due to additional components and assembly steps
Solution Approach 1:
The connecting bodies serve multiple functions: they attach the friction ring to the wheel web, provide cooling fins, and enable pin locking to prevent rotation. This multi-functionality reduces the need for separate components and simplifies the overall device while maintaining material selection flexibility.
Solution Approach 2:
The connecting bodies are inserted into openings in the friction ring, creating a nested structure where the connecting bodies are contained within the friction ring body. This nesting approach consolidates multiple functions into integrated components rather than requiring separate attached parts.
3Strength
If through screws are used to screw the friction ring bodies against the wheel web, then secure attachment is achieved, but the original molding process becomes more complex and production costs increase
Solution Approach 1:
The attachment mechanism is segmented into separate connecting bodies that are inserted into openings rather than being integrated into the friction ring molding. This allows the friction ring to be manufactured as a simple flat component while the connecting bodies provide the attachment function through pin locking mechanisms.
Solution Approach 2:
The attachment and cooling functions are extracted into separate connecting bodies that are inserted into the friction ring. These connecting bodies are secured by pin locking and can be attached to the wheel web without requiring complex integrated molding features.
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 design simplifies production, increases material selection flexibility, and ensures reliable attachment and cooling of the friction ring, maintaining consistent braking performance without radial tension or assembly issues.
Implementation Method 1
The separately formed connecting bodies or at least some of the connecting bodies are non-positively connected to the friction ring, with the connecting bodies non-positively connected to the friction ring each being pressed with an oversize into a corresponding opening in the friction ring.
Implementation Method 2
The connecting bodies are secured against rotation relative to the friction ring by means of a positive locking element, the positive locking element being a pin.
Implementation Method 3
enabling secure attachment to the wheel web through a pin locking mechanism, which prevents rotation and allows for radial expansion during braking
Data Source
Figure 1~3
Figure 4~5
Figure 6~9
AI summary
In order to provide a development of friction ring elements for a friction ring set for arranging on the wheel web of a track wheel in order to form a track wheel brake, wherein the friction ring elements can be simply and cost-effectively produced and can be easily fitted with linking elements, a friction ring element (10) is proposed for a friction ring set (200) for arranging on the wheel web (2) of a track wheel (1) for a railway vehicle in order to form a track wheel brake (100), wherein the friction ring element (10) has a friction ring (11) and multiple linking elements (12, 13) designed as separate components and arranged on the friction ring (11), and wherein at least some of the linking elements (12, 13) are force-lockingly connected to the friction ring (11).