Integrated Wheel Hub Brake Joint Without Fasteners
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Solution Overview
Problem
The assembly of wheel hub and brake rotor in commercial vehicles is complex, time-consuming, and expensive due to the use of numerous fasteners or clips, which complicates the process and increases costs.
Innovation Solution
A wheel hub apparatus with a unitary, one-piece construction that integrates a circular brake element, using projections and recesses for a direct mechanical connection, eliminating the need for fasteners or clips, and allowing for in situ forming of the wheel hub and brake element during casting to create a high-strength connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional approaches using multiple fasteners or clips are used to connect brake rotor to wheel hub, then the connection is secure, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The brake rotor and wheel hub are merged into a single integrated component where the brake rotor is formed directly on the wheel hub as a unified structure. This eliminates the need for separate fasteners or clips to connect the brake rotor to the wheel hub, thereby reducing assembly complexity while maintaining connection security through the integrated design
2Reliability
If conventional approaches using multiple fasteners or clips are used to connect brake rotor to wheel hub, then the connection is secure, but the manufacturing cost increases
Solution Approach 1:
The brake rotor and wheel hub are manufactured as a single integrated component through a unified casting process. This eliminates the need to manufacture and assemble multiple separate parts including fasteners and clips, thereby reducing manufacturing cost while maintaining connection security through the integrated structure
3Reliability
If multiple fasteners or clips are used to connect brake rotor to wheel hub, then the brake rotor is secured, but the assembly time increases
Solution Approach 1:
The brake rotor and wheel hub are produced as a single integrated component, eliminating the need for assembly operations involving multiple fasteners or clips. This significantly reduces assembly time and increases productivity while maintaining brake rotor securing through the integrated design
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 simplifies the assembly process, reduces costs, and provides a secure, high-strength connection between the wheel hub and brake element, resisting axial and radial movements, and accommodating thermal expansion and contraction without the need for additional fasteners.
Implementation Method 1
The projections and recesses of the wheel hub and the circular brake element transfer loading between each other during a braking operation
Implementation Method 2
One of the wheel hub and the circular brake element is formed in situ on the other of the wheel hub and the circular brake element
Data Source
AI summary
In one aspect, a wheel hub apparatus including a wheel hub that is rotatable about a central axis and has a unitary, one-piece construction. The wheel hub apparatus further includes a circular brake element having a unitary, one-piece construction and extending about the wheel hub. The wheel hub and the circular brake element include engaged portions securing the wheel hub and the circular brake element together. The engaged portions of the wheel hub and the circular brake element fix the circular brake element against axial movement along the wheel hub. In this manner, the engaged portions of the wheel hub and the circular brake element provide a mechanical joint that connects the wheel hub and the circular brake element using the material of the wheel hub and the circular brake element.