Wheel Brake Assembly Mechanical Stop for Torque Tube Deformation
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Solution Overview
Problem
Existing brake systems in vehicles experience excessive linear deformation of the torque tube during high heat conditions, leading to increased displacement between the actuator housing and the brake disc stack, requiring additional piston travel to maintain compression force, which can result in premature maintenance or replacement.
Innovation Solution
Incorporation of a mechanical stop that transfers load from the torque tube to limit displacement between the actuator housing and the brake disc stack, reducing the need for additional piston travel and minimizing torque tube deformation by unloading the torque tube when it experiences linear deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the actuator compresses the brake disc stack during high heat conditions, then the braking force is maintained, but the torque tube experiences excessive linear deformation requiring additional piston travel
Solution Approach 1:
A mechanical stop is introduced as an intermediary component between the actuator and the torque tube. The mechanical stop absorbs and limits the linear deformation of the torque tube during high heat conditions, preventing excessive displacement while allowing the actuator to maintain compression force on the brake disc stack.
Solution Approach 2:
The system changes the thermal and mechanical parameters by introducing a mechanical stop that alters the load path. During high heat conditions, the mechanical stop changes the displacement parameter of the torque tube, limiting its linear deformation while maintaining the compression force parameter on the brake disc stack.
2Reliability
If additional piston travel is provided to compensate for torque tube deformation, then compression force is maintained, but the actuator stroke length increases requiring more space
Solution Approach 1:
The mechanical stop serves as a mediator that decouples the relationship between torque tube deformation and actuator piston travel. It allows the actuator to maintain compression force without requiring additional stroke length, thereby reducing the volume and displacement requirements of the actuator housing.
3Adaptability or versatility
If the torque tube is allowed to deform under compression load, then the brake system can accommodate thermal expansion, but the displacement increases leading to premature maintenance
Solution Approach 1:
The mechanical stop changes the displacement parameter of the torque tube during thermal expansion. It allows controlled accommodation of thermal effects while limiting excessive deformation that would lead to premature maintenance, thereby extending brake disc life.
Solution Approach 2:
The mechanical stop provides preliminary anti-action by pre-limiting the maximum displacement of the torque tube before excessive deformation can occur. This prevents the conditions that would lead to premature maintenance while still allowing necessary thermal expansion accommodation.
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 mechanical stop reduces the required stroke length of the actuator, conserves space, extends brake disc life, and minimizes the need for frequent maintenance by limiting excessive deformation and displacement during high heat conditions.
Implementation Method 1
Incorporation of a mechanical stop that transfers load from the torque tube to limit displacement between the actuator housing and the brake disc stack
Implementation Method 2
the brake system may displace pistons against a pressure plate to compress the rotating rotor discs engaged with the wheel against the stationary stator discs, therefore producing torque that decelerates the rotational motion of the wheel
Data Source
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AI summary
In some examples, an assembly includes a wheel configured to rotate around an axis and a brake system configured to reduce a rotation of the wheel. The brake system includes a disc stack having a rotor disc rotationally coupled to the wheel and a stator disc, wherein the wheel is configured to rotate relative to the stator disc. The brake system includes an actuator configured to compress the disc stack. The brake system is configured to exert a reaction force on the disc stack when the actuator compresses the disc stack. The assembly includes a mechanical stop configured to encounter the brake system, wherein the mechanical stop is configured to limit a linear displacement between the actuator and the disc stack.