Ventilated Brake Disc Assembly With Spot-Welded Cooling Channels
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Solution Overview
Problem
Existing ventilated disc brake systems face issues with heat dispersion and mechanical resistance, leading to deformation, corrosion, and uneven wear, particularly in high-performance applications, and are costly and labor-intensive to produce.
Innovation Solution
A braking band and disc brake system where two plates are welded to a ventilation spacer using capacitive spot welding at discreet points, avoiding direct contact with braking surfaces and minimizing structural discontinuities, allowing for efficient heat dissipation and improved mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If brazing is used to join plates, then production volume can be increased, but mechanical resistance and corrosion resistance deteriorate
Solution Approach 1:
The patent changes the joining method from brazing to welding, fundamentally altering the connection parameter. Welding provides superior mechanical strength and corrosion resistance compared to brazing, while maintaining high production volumes through automated welding processes. This parameter change resolves the contradiction by selecting a joining method that excels in both productivity and strength.
Solution Approach 2:
The patent employs composite construction with plates of different materials (e.g., stainless steel and cast iron) joined by welding. This allows optimization of each plate's material properties while the welding joint provides strong, corrosion-resistant connection, achieving both high productivity and mechanical resistance that brazing cannot provide.
2Strength
If welding is used to join plates, then mechanical resistance improves, but production cost and labor intensity increase
Solution Approach 1:
The patent replaces manual or semi-automatic welding operations with automated welding systems. This substitution maintains the high mechanical resistance benefits of welding while dramatically reducing labor intensity and production costs through automation, resolving the contradiction between strength and ease of manufacture.
Solution Approach 2:
The patent optimizes welding parameters (current, voltage, speed, pattern) to achieve maximum joint strength with minimum material consumption and processing time. This parameter optimization reduces both material waste and energy consumption, lowering production costs while maintaining superior mechanical resistance.
3Strength
If heat treatment processes are extended, then mechanical characteristics improve, but production time and cost increase
Solution Approach 1:
The patent performs preliminary heat treatment of plates before welding, pre-optimizing their mechanical characteristics. This preliminary action reduces or eliminates the need for extended post-weld heat treatment, achieving the required mechanical properties while significantly reducing total production time and cost.
Solution Approach 2:
The patent uses controlled cooling rates and optimized heat treatment parameters after welding to achieve the desired mechanical characteristics more quickly. By precisely controlling temperature-time parameters, the patent attains optimal mechanical properties with shorter heat treatment cycles, reducing production time while maintaining strength.
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 solution enhances braking comfort, maintains high cooling efficiency, extends disc life, and reduces production costs while providing lightweight, corrosion-resistant discs with uniform wear.
Implementation Method 1
collegati mediante punti di saldatura a scintilla capacitiva
Implementation Method 2
saldatura a scintilla capacitiva
Implementation Method 3
delimit ventilation channels for cooling the disc, crossed by airflows according to a centrifugal direction during the rotary motion of the disc itself
Implementation Method 4
the friction between the pads of the brake calipers and the braking surfaces of the braking band generates a high amount of heat
Data Source
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AI summary
A method for manufacturing a brake disc (1), comprising the steps of: - providing at least one sheet of predefined thickness; - blanking a first disc-shaped portion (2) in at least one sheet adapted to make a first plate (3) of a ventilated braking band (4); - blanking a second disc-shaped portion (5) in at least one sheet adapted to make a second plate (6) of said ventilated braking band (4); - blanking a third portion (7) in at least one sheet adapted to make at least one ventilation spacer (8) for said ventilated braking band (4); - drawing said third portion (7) by shaping, along a circular path along said third portion (7), first and second protrusions (9, 10), forming opposite first and second recesses (11, 12) adapted to make ventilation channels (13) for said ventilated braking band (4); - connecting said first disc-shaped portion (2) adapted to make a first plate (3) to said first protrusions (9) by means of discontinuous weld spots (14); - connecting said second disc-shaped portion (5) adapted to make a second plate (6) to said second protrusions (10) by means of discontinuous weld spots (14). A system for manufacturing a disc brake disc capable of carrying out the manufacturing steps indicated above. A disc for disc brake manufactured according to the manufacturing steps indicated above.