Variable-Stiffness Brake Splines for Lower Stator Disc Stress
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Solution Overview
Problem
Existing brake systems experience high stress on stator discs due to dynamic loading during braking events, leading to reduced operating lifetime and potential need for additional components like stator inserts.
Innovation Solution
A brake assembly with a torque tube supporting splines of varying stiffness, where a compliant spline contacts the stator disc first, absorbing kinetic energy and reducing reaction forces, thereby minimizing stress on the stator disc.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If uniform stiffness splines are used, then the structure is simple and manufacturing is easy, but high dynamic loading occurs on the stator disc during braking
Solution Approach 1:
The patent applies local quality by varying the stiffness of individual splines based on their specific location and loading conditions. Different splines have different stiffness values, with softer splines positioned to contact first during braking events. This localized differentiation reduces dynamic loading on the stator disc while maintaining overall structural integrity.
Solution Approach 2:
The patent changes the physical parameter of spline stiffness across different spline locations. By adjusting the stiffness parameter of each spline individually, the system optimizes the contact sequence during braking, allowing gradual engagement that reduces impact forces on the stator disc.
2Reliability
If softer splines contact first, then dynamic loading is reduced, but the spline design becomes more complex
Solution Approach 1:
The patent implements local quality by assigning different material properties or geometric characteristics to specific splines based on their functional requirements. Softer splines are strategically positioned to engage first, while stiffer splines follow, creating a progressive contact pattern that extends stator disc life without requiring complete redesign of all components.
Solution Approach 2:
The patent segments the spline system into distinct groups with different stiffness characteristics. This segmentation allows each spline or spline group to be optimized for its specific role in the braking sequence, making the manufacturing process more manageable through modular design approaches.
3Stress or pressure
If multiple stiffness levels are used, then stress distribution is improved, but the number of components and assembly complexity increases
Solution Approach 1:
The patent applies local quality by varying spline stiffness at specific locations rather than using multiple component types throughout the entire system. This localized approach improves stress distribution on the stator disc while minimizing the number of different spline designs that must be manufactured and assembled.
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 solution reduces stress on stator discs, potentially increasing their operating lifetime, minimizing the need for inserts, and reducing brake disc material volume.
Implementation Method 1
The deflection and/or deformation of the first spline may reduce a dynamic loading (e.g., an impact loading) on the first spline and/or the second spline as the stator disc contacts the first spline and/or the second spline
Implementation Method 2
the first spline deflects and/or otherwise deforms before the stator contacts the second spline
Data Source
AI summary
In some examples, a brake assembly includes a torque tube supporting a plurality of splines including a first spline and a second spline. The first spline has a first stiffness and the second spline has a second stiffness greater than the first stiffness. The braking system is configured such that, during a braking event and/or other relative motion between the stator disc and the torque tube, the first spline contacts the stator disc prior to the second spline, such that the first spline deflects and/or otherwise deforms before the stator contacts the second spline.