Wheel Carrier Segmentation for Disc Brake Replacement

Solution Overview

Problem

Existing wheel carriers for heavy vehicles with disc brakes require disassembly of the bearing unit to replace the braking disc, leading to inefficient and labor-intensive processes, with prior solutions suffering from large, cumbersome components and complex assembly procedures.

Innovation Solution

A wheel carrier design featuring a support member and connection flange as separate parts, with independent connecting means allowing for the replacement of the braking disc without disassembling the bearing unit, ensuring easy and reliable disc replacement while maintaining structural integrity and minimizing material usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the wheel carrier uses a single integrated structure for support member and connection flange, then structural integrity is improved, but the braking disc cannot be replaced without disassembling the bearing unit

Engineering Contradiction:

Improvebraking disc replaceabilityVSAvoidconnection structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The wheel carrier is divided into two separate functional parts: a support member that holds the braking disc and a connection flange that connects to the bearing unit. These parts are connected through detachable connecting means, allowing the braking disc to be replaced by removing only the connection flange while leaving the support member and bearing unit in place. This segmentation enables independent replacement of wear components without disassembling the bearing unit.

Inventive Principle:

Principle #1Segmentation

2Productivity

If the wheel carrier uses separate support member and connection flange with independent connecting means, then braking disc replacement is simplified, but the number of parts and assembly complexity increases

Engineering Contradiction:

Improvebraking disc replacement speedVSAvoidnumber of parts

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The wheel carrier is divided into two separate functional parts: a support member that holds the braking disc and a connection flange that connects to the bearing unit. These parts are connected through detachable connecting means, allowing the braking disc to be replaced by removing only the connection flange while leaving the support member and bearing unit in place. This segmentation enables independent replacement of wear components without disassembling the bearing unit.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection flange is designed as a reusable component that can be detached and reattached multiple times during the service life of the wheel carrier. Only the wear-prone braking disc needs to be discarded and replaced, while the connection flange and support member are recovered and reused. This reduces the number of parts that need to be manufactured new with each replacement cycle.

Inventive Principle:

Principle #34Discarding and recovering

3Strength

If the wheel carrier uses a large-sized braking disc bell to prevent deformation during hard braking, then structural strength is improved, but weight increases

Engineering Contradiction:

Improvebraking disc bell strengthVSAvoidwheel carrier weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The wheel carrier is divided into two separate functional parts: a support member that holds the braking disc and a connection flange that connects to the bearing unit. These parts are connected through detachable connecting means, allowing the braking disc to be replaced by removing only the connection flange while leaving the support member and bearing unit in place. This segmentation enables independent replacement of wear components without disassembling the bearing unit.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS8292046B2Wheel carrier for vehicles with a disc brake

Publication Date: 2012.10.23 FRENI BREMBO SPA

AI summary

A wheel carrier for providing a rotary connection between a wheel and the vehicle suspension. The wheel carrier includes a support member for supporting a braking band, a connection flange for supporting the wheel of the vehicle, a first connector for connecting the support member to the vehicle suspension and second connector for rotatably connecting the connection flange to the support member.