Half Cap Wear Clip Deformation for Ductile Brake Torque Load Sharing

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Solution Overview

Problem

Conventional aircraft brake assemblies with riveted rotor clips lack the ability to deform under excessive loads, leading to brittle failure and reduced ultimate strength as an assembly, which is not practical due to regulated criteria exceeding the individual strengths of the clips.

Innovation Solution

The introduction of a half cap wear clip with a deformable feature that permanently deforms in response to load thresholds, allowing for load redistribution and achieving a ductile failure mode similar to floating clips, enabling the use of riveted rotor clips in all carbon brake disc designs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional riveted rotor clips are used, then the brake assembly structure is simple and easy to manufacture, but the clips lack the ability to deform under excessive loads leading to brittle failure and reduced ultimate strength

Engineering Contradiction:

Improveultimate strength of brake assemblyVSAvoidstructure of wear clip

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The wear clip's material properties are changed by introducing a deformable feature with controlled yield strength lower than the main body material. This allows the clip to undergo plastic deformation at the deformable feature when load exceeds a threshold, transforming the failure mode from brittle to ductile and enabling load redistribution across multiple clips, thereby increasing the ultimate strength of the brake assembly.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The wear clip is segmented into a rigid body portion and a deformable feature portion. The deformable feature acts as a distinct segment that can independently deform under excessive load, allowing the main body to maintain structural integrity while the deformable segment absorbs energy through controlled deformation, preventing catastrophic brittle failure.

Inventive Principle:

Principle #1Segmentation

2Reliability

If conventional riveted rotor clips are used, then the manufacturing process is simple, but the clips exhibit brittle failure mode under excessive loads

Engineering Contradiction:

Improvefailure mode of wear clipVSAvoidmanufacturing process of wear clip

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The material parameters of the wear clip are modified by creating a deformable feature with different mechanical properties (lower yield strength) than the main body. This parameter change enables the clip to transition from brittle failure to ductile failure mode, improving reliability by allowing progressive deformation and load redistribution before final failure.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The deformable feature is introduced as a localized region with distinct material or geometric properties different from the main body. This local quality change allows the specific region to deform plastically under excessive load while the rest of the clip maintains its structural integrity, achieving ductile failure mode without requiring complete redesign of the entire clip.

Inventive Principle:

Principle #3Local quality

3Force

If conventional riveted rotor clips are used, then the assembly structure is straightforward, but the individual clip strengths are insufficient to meet regulated brake torque criteria

Engineering Contradiction:

Improvebrake torque capacityVSAvoidindividual clip strength

Core Design Contradiction:

ForceVSStrength

Solution Approach 1:

The wear clip is designed with dynamic deformation capability through the deformable feature. When brake torque exceeds design limits, the deformable feature dynamically adjusts by deforming and redistributing loads to adjacent clips, enabling the assembly to handle forces beyond the static strength limits of individual clips, thereby meeting regulated brake torque criteria.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The deformable feature acts as a mechanical feedback mechanism that senses excessive load through deformation and automatically redistributes the load to other clips. This feedback mechanism allows the brake assembly to self-regulate and maintain safety under varying torque conditions, ensuring compliance with regulatory requirements.

Inventive Principle:

Principle #23Feedback

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 deformable feature enables load-redistribution and a ductile failure mode, enhancing the performance and practicality of riveted rotor clips by allowing them to yield under excessive loads, thus supporting brake torque regulatory requirements and protecting torque bars from excessive wear.

Implementation Method 1

a deformable feature configured to permanently deform a first distance in response to a load on the wear face exceeding a load threshold

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS11913510B2Rotor clip apparatus and systems

Publication Date: 2024.02.27 GOODRICH CORP

AI summary

A half cap wear clip may comprise: a wear face configured to interface with a torque bar; a first flange disposed on a first side of the wear face and a second flange disposed on a second side of the wear face, the second side opposite the first side; and a deformable feature disposed on a first end of the first flange and the second flange and the wear face, the deformable feature configured to permanently deform a first distance in response to a load on the wear face exceeding a load threshold.