WO2020073086A1 - Rotor de frein à disque et procédé de fabrication associé - Google Patents

Rotor de frein à disque et procédé de fabrication associé Download PDF

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Publication number
WO2020073086A1
WO2020073086A1 PCT/AU2019/051089 AU2019051089W WO2020073086A1 WO 2020073086 A1 WO2020073086 A1 WO 2020073086A1 AU 2019051089 W AU2019051089 W AU 2019051089W WO 2020073086 A1 WO2020073086 A1 WO 2020073086A1
Authority
WO
WIPO (PCT)
Prior art keywords
pillars
rotor
ring structure
opposing
disc brake
Prior art date
Application number
PCT/AU2019/051089
Other languages
English (en)
Inventor
Stephen Patrick Gavin
Original Assignee
Disc Brakes Australia Pty. Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2018903808A external-priority patent/AU2018903808A0/en
Application filed by Disc Brakes Australia Pty. Limited filed Critical Disc Brakes Australia Pty. Limited
Priority to AU2019356796A priority Critical patent/AU2019356796A1/en
Priority to CN201980063466.7A priority patent/CN112771283A/zh
Publication of WO2020073086A1 publication Critical patent/WO2020073086A1/fr

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D65/12—Discs; Drums for disc brakes
    • F16D65/123—Discs; Drums for disc brakes comprising an annular disc secured to a hub member; Discs characterised by means for mounting
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D65/12—Discs; Drums for disc brakes
    • F16D65/128—Discs; Drums for disc brakes characterised by means for cooling
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D2065/13—Parts or details of discs or drums
    • F16D2065/1304—Structure
    • F16D2065/1328—Structure internal cavities, e.g. cooling channels
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D2065/13—Parts or details of discs or drums
    • F16D2065/134—Connection
    • F16D2065/1344—Connection permanent, e.g. by casting
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D2065/13—Parts or details of discs or drums
    • F16D2065/134—Connection
    • F16D2065/1384—Connection to wheel hub
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D2065/13—Parts or details of discs or drums
    • F16D2065/134—Connection
    • F16D2065/1392—Connection elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2250/00—Manufacturing; Assembly
    • F16D2250/0007—Casting

Definitions

  • the present invention relates to disc brakes for vehicles and, more particularly, to disc brake rotors.
  • Examples of such hybrid systems are disclosed in the patents to Brembo, US5810123, US8733517 and US2014/0158486.
  • Each of these disclose brake bands of cast iron connected by connector elements to a mounting bell of cast alloy.
  • short fins project inwardly from the cast brake bands to engage with forked projections from the mounting bell with pins passing through apertures in both fins and the forked projections.
  • US8733517 discloses an arrangement in which, in one embodiment, projecting“drive elements” engage with niches provided in the inner periphery of the brake band casting.
  • integrally cast fingers project radially inward from the cast brake bands to engage with an annular groove around the periphery of the mounting bell.
  • a disadvantage of each of these systems is that the two opposing brake bands are effectively thermally isolated.
  • US5810123 and US2014/0158486 there is minimal cast material projecting from the brake bands which may allow heat dissipation, while in US8733517 there is none at all.
  • These existing designs incorporate a circular pattern of attachment mechanisms which create a variation in the cross sectional mass and therefore a greater thermal gradient in these regions. These attachment mechanisms also interrupt balanced flow of cooling air passing through the ventilation gallery.
  • the typical one-piece rotor in which the mounting bell is integrally cast with either the outer or inner brake band is disadvantaged by means of the brake band connected with the mounting bell generates a different thermal gradient to the opposing brake band. This causes thermal deformation in the form of coning which reduces the effective contact surface and increasing tensile stresses leading to metal fatigue.
  • a disc brake rotor comprising opposing brake bands separated by arrays of pillars; the pillars integral with, and extending between, opposing internal surfaces of the opposing brake bands; the rotor further comprising a connector ring structure forming an integral casting with the opposing brake bands; the connector ring structure projecting radially outwardly and inwardly from an inner ring of pillars of the arrays of pillars.
  • the arrays of pillars comprise the inner ring of pillars and an outer ring of pillars.
  • a radial line of the rotor passing through the centre of any pillar of the inner ring of pillars is a bisector of radial lines of the rotor passing through centres of adjacent pillars of the outer ring of pillars; the adjacent pillars disposed to opposite sides of the radial line through the centre of the pillar of the inner ring of pillars.
  • connection between the opposing brake bands and the connector ring structure is through the inner ring of pillars; castings of the inner ring of pillars being integral with the casting of the connector ring structure.
  • opposing sides of the connector ring structure are spaced apart from the opposing internal surfaces of the opposing brake bands.
  • annular spacing between the opposing sides of the connector ring structure and opposing internal surfaces of the opposing brake bands define ventilation entries for air flow through the arrays of pillars.
  • an outer periphery of the connector ring structure lies approximately midway between the inner ring of pillars and the outer ring of pillars.
  • the outer periphery of the connector ring structure is shaped so that flows of ventilating air pass through venturi-like constrictions between formations on the opposing internal surfaces of the brake bands and external surfaces of the connecting ring structure thereby increasing volume of cooling air passing between the pillars.
  • the disc brake rotor is a component of a disc brake rotor assembly; the disc brake rotor assembly comprising the disc brake rotor and a mounting bell for mounting the assembly to a wheel hub of a vehicle.
  • an inner periphery of the connector ring structure is provided with a number of equally-spaced inwardly directed projections; the projections provided with apertures adapted to receive therethrough headed securing bolts securing the mounting bell to the connector ring structure.
  • the apertures are elongated slots; elongation of the slots providing for radially sliding movement of the securing bolts in the slots.
  • an outer periphery of the central mounting bell is provided with apertures for receiving the securing bolts for assembly of the central mounting bell to the connector ring structure.
  • the opposing brake bands, the arrays of pillars and the connector ring structure form an integral casting with a mounting bell; the mounting bell projecting outwardly from an inner periphery of the connector ring structure.
  • a method of producing a disc brake rotor of a disc brake comprising opposing brake bands separated by arrays of pillars integral with and extending between internal surfaces of the opposing brake bands; the rotor further comprising a connector ring structure integrally connected with an inner ring of pillars of the arrays of pillars; the method including the steps of:
  • the sand-casting box defining outer surfaces of the disc brake rotor
  • each sand core conforms to a three-dimensional CAD solid model; the solid model defining space between a median plane of the rotor and an internal surface of a brake band of the opposing brake bands and between the arrays of pillars; a portion of an underside of each sand core defining an external surface of the connector ring structure.
  • a first of the two sand cores conforms to a three-dimensional CAD solid model; the solid model defining space between a median plane of the rotor and an internal surface of an outer one of the opposing brake bands and between the arrays of pillars; the solid model farther defining outward facing surfaces of a mounting bell integral with the connector ring structure.
  • a second of the two sand cores conforms to a three-dimensional CAD solid model defining space between a median plane of the rotor and an internal surface of an inner one of the opposing brake bands and between the arrays of pillars; the solid model further defining inward facing surfaces of a mounting bell integral with the connector ring structure.
  • three-dimensional data of the three-dimensional CAD model is used to 3D print the sand core conforming to the three-dimensional solid CAD model.
  • the rotor is part of a disc brake rotor assembly; the assembly including a mounting bell releasably attached to the connector ring structure.
  • a disc brake rotor assembly comprising a casting of a rotor and a casting of a mounting bell; the rotor including opposing brake bands separated by arrays of pillars; the pillars integral with, and extending between, opposing internal surfaces of the opposing brake bands; the rotor further comprising a connector ring structure forming an integral casting with the opposing brake bands; the connector ring structure projecting radially outwardly and inwardly from an inner ring of pillars of the arrays of pillars.
  • casting material of the mounting bell is of lesser density than casting material of the rotor.
  • the mounting bell is secured to inwardly projecting elements at an inner peripheiy of the connector ring structure; the inwardly projecting elements provided with radially elongated slots.
  • the mounting bell is provided at its outer periphery with corresponding apertures; headed mounting bolts through the corresponding apertures securing the mounting bell through the radially elongated slots.
  • the elongated slots provide for differential expansion between the casting of the rotor and the casting of the mounting bell.
  • Figure 1 is a perspective view of a disc brake rotor assembly according to a first preferred embodiment of the invention
  • Figure 2 is a front view of a rotor casting of the disc brake rotor assembly of figure 1 showing hidden detail of a pillar array interconnecting opposing brake bands,
  • Figure 2A is a perspective view of the rotor casting of figure 2
  • Figure 3 is a sectioned end view of the rotor casting of figures 2 and 2A,
  • Figure 4 is an enlargement of a portion of the cross section of figure 3 taken on a radial line through an opposing pair of pillars of the outer ring of pillars,
  • Figure 4A is a similar enlarged portion taken on a radial line through an opposing pair of pillars of the inner ring of pillars,
  • Figure 5 is a sectioned view of the rotor casting and a central mounting bell fastened to a connector ring structure of the rotor casting
  • Figure 6 is an enlargement of a portion of the sectioned view of figure 5
  • Figure 7 is a perspective view of an outer face of one of a pair of identical sand cores for producing the casting of the rotor of figures 2 through 7,
  • Figure 8 is a perspective view of the opposite face of one of the pair of identical sand cores of figure 7,
  • Figure 9 is a cross section view of two of the identical and cores of figure 7 placed back to back for casting the rotor of figures 2 through 6,
  • Figure 10 is a perspective view of a further preferred embodiment of a disc brake rotor according to the invention.
  • Figure 11 is a cross section view of the disc brake rotor of figure 10.
  • a disc brake rotor assembly 10 includes a rotor 12 and mounting bell 13 for mounting to the wheel hub (not shown) of a vehicle.
  • the rotor 12 is comprised of opposing brake bands 14,16 separated by arrays of pillars 18.
  • the pillars 18 are integral with, and extend between, opposing internal surfaces 20,22 of the opposing brake bands as well known in the art.
  • the rotor 12 further comprises a connector ring stracture 24 which forms an integral casting with the opposing brake bands 14,16 and with the pillars 18.
  • the connector ring structure 24 projects radially outwardly and inwardly from an inner ring of pillars 26 of the arrays of pillars 18.
  • connection between the opposing braked bands 14,16 and the connector ring structure 24 is by means of the pillars of the inner ring of pillars 26, so that, in a sense, pillars 26 of the inner ring can be considered as“passing through” the connector ring structure 24, even though the inner pillars and the connector ring form an integral casting.
  • the inner and outer rings of pillars 26,30 are arranged such that a radial line 32 of the rotor 12 passing through the centre of any pillar of the inner ring of pillars 26 is a bisector of radial lines 34,36 of the rotor passing through centres of adjacent pillars of the outer ring of pillars 30; the adjacent pillars being disposed at opposite sides of the radial line 32.
  • the connector ring structure 24 is sized in thickness so that opposing surfaces 36,38 of the connector ring structure 24 are spaced apart from the opposing internal surfaces 20,22 of the opposing brake bands 14,16 thus providing annular spacing defining ventilation entries for air flow through the arrays of pillars.
  • the design enables even flow of cooling air from both inner and outer directions while maintaining a consistent cross-sectional area throughout the entire diameter of the brake bands.
  • the periphery 28 of the connector ring structure is shaped so that the flow of ventilating air passes through venturi-like constrictions between formations 40,42 on the internal surfaces of the brake bands 14,16, thereby increasing the velocity and thus volume of cooling air passing between the pillars 18.
  • the apertures 47 are in the form of elongated slots with the long axes of the slots radially aligned with the centre of the rotor.
  • the width of the apertures 47 is such as to provide sliding fit clearance for the shoulder diameter of the bolts 48 so that the elongation of the slots provides for radially sliding movement of the securing bolts in the apertures to allow for differential thermal expansion of the rotor 12 relative the mounting bell 11.
  • the headed securing bolts 48 are threaded and retained by lock nuts 50.
  • the rotor 12 is produced by casting. Initially, a CAD solid model is prepared which defines the internal space between a median plane 51 of the rotor and the internal surface of a brake band, the pillars of the pillar array, as well as the outer surface of the connector ring structure.
  • the CAD data may be used to produce a mould (not shown) by CNC machining for example or by 3D printing. This mould can then be used to form two identical sand cores, one of which 52 is shown in figure 7. More preferably, two sand cores 52 and 54, two sides of one of which are shown in figures 7 and 8, may be 3D printed directly from the CAD data.
  • FIG. 9 two such sand cores 52 and 54 are placed back to back, outward facing sides 56,58 to define the internal surfaces 40,42 of the opposing brake bands 14,16 with the apertures 55 (see figures 7 and 8) defining the arrays of pillars 18.
  • Cavities 64 formed on the respective rear sides 60,62 of the sand cores 52 and 54 combine to define the connector ring structure 24, when the sand cores are placed back to back as shown in figure 9.
  • the casting of the mounting bell is in material which is of a lesser density than the casting of the rotor, thereby allowing a significant reduction in the weight of the rotor assembly with the concomitant benefits of health and safety as well as a reduction in the unsprung weight of the vehicle to which the assemblies are fitted.
  • a disc brake rotor 112 is in the form of a one-piece casting.
  • the rotor 100 includes opposing brake bands 114,116 interconnected by arrays of pillars 118, arranged, as above, in an inner ring 126 and outer ring 130.
  • the rotor 112 also includes a connector ring structure 124 as described for the first embodiment above, projecting inwardly from between the brake bands 114,116, which is integral with the inner ring of pillars 126.
  • the connector ring structure 124 of this embodiment is configured at its outer periphery 128 in the same manner as described above, as can be seen from the cross section view of figure 11.
  • the connector ring structure 124 forms an integral casting with a mounting bell 113 projecting from the inner periphery 144 of the connector ring structure.
  • each of two sand cores are formed from models of the spaces forming the inside regions between the brake bands 114,116, the arrays of pillars 118 and the connector ring, as well as, in this embodiment, the external surfaces of the mounting bell 113, can be derived from the solid CAD modelling of the rotor and the sand cores generated, preferably by 3D printing.
  • a first of the two sand cores conforms to a three-dimensional CAD solid model defining the space between a median plane of the rotor and an internal surface of an outer one of the opposing brake bands and between the arrays of pillars.
  • the solid model further defines the outward facing surfaces of the mounting bell 113.
  • the second of the two sand cores conforms to a three- dimensional CAD solid model which defines the space between the median plane of the rotor and an internal surface of the inner brake band, between the arrays of pillars as well as defining the inward facing surfaces of a mounting bell.

Landscapes

  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Braking Arrangements (AREA)

Abstract

L'invention concerne un rotor de frein à disque ; le rotor comprenant des bandes de frein opposées, séparées par des réseaux de piliers ; les piliers étant solidaires des surfaces internes opposées des bandes de frein opposées et s'étendant entre celles-ci ; le rotor comprenant en outre une structure annulaire de connecteur formant un moulage d'un seul tenant avec les bandes de frein opposées ; la structure annulaire de connecteur faisant saillie radialement vers l'extérieur et vers l'intérieur à partir d'un anneau interne de piliers des réseaux de piliers.
PCT/AU2019/051089 2018-10-09 2019-10-09 Rotor de frein à disque et procédé de fabrication associé WO2020073086A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
AU2019356796A AU2019356796A1 (en) 2018-10-09 2019-10-09 Disc brakes rotor and method of manufacture
CN201980063466.7A CN112771283A (zh) 2018-10-09 2019-10-09 盘式制动器转子及其制造方法

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2018903808A AU2018903808A0 (en) 2018-10-09 Disc Brakes Rotor and Method of Manufacture
AU2018903808 2018-10-09

Publications (1)

Publication Number Publication Date
WO2020073086A1 true WO2020073086A1 (fr) 2020-04-16

Family

ID=70163609

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/AU2019/051089 WO2020073086A1 (fr) 2018-10-09 2019-10-09 Rotor de frein à disque et procédé de fabrication associé

Country Status (4)

Country Link
CN (1) CN112771283A (fr)
AU (1) AU2019356796A1 (fr)
TW (1) TW202043642A (fr)
WO (1) WO2020073086A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112319132A (zh) * 2020-11-25 2021-02-05 浙江博鑫涵汽车零部件有限公司 一种新型汽车轮毂组件

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5107966A (en) * 1988-07-08 1992-04-28 Schwabische Huttenwerke Gmbh Brake disk for disk brakes
US20040118644A1 (en) * 2001-04-06 2004-06-24 Leone Oberti Braking band, a ventilated disk-brake disk, and a core box for the production of a disk-brake disk core
DE102005033352A1 (de) * 2005-07-16 2007-01-18 Volkswagen Ag Innenbelüftete Bremsscheibe
US20080017460A1 (en) * 2006-07-21 2008-01-24 Dr. Ing. H.C.F. Porsche Aktiengesellschaft Internally ventilated disc brake
US20090272609A1 (en) * 2006-04-05 2009-11-05 Karthik Raju Nmn Venturi Nozzle Aerodynamic Vent Design
US20140158486A1 (en) * 2004-10-26 2014-06-12 Freni Brembo S.P.A. Disc for a Disc Brake
US20170002879A1 (en) * 2013-12-19 2017-01-05 Freni Brembo S.P.A. Ventilated brake disc

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2287623A1 (fr) * 1974-10-11 1976-05-07 Pont A Mousson Disque de frein a disque
WO2006046258A1 (fr) * 2004-10-26 2006-05-04 Freni Brembo S.P.A. Disque pour frein a disque
EP1903248A1 (fr) * 2006-09-19 2008-03-26 BPW Bergische Achsen KG Disque de frein
AU2010324567B2 (en) * 2009-11-30 2014-11-13 Wabtec Holding Corp. Railway vehicle brake disc
US10619689B2 (en) * 2016-12-12 2020-04-14 Westinghouse Air Brake Technologies Corporation Ventilated brake disc

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5107966A (en) * 1988-07-08 1992-04-28 Schwabische Huttenwerke Gmbh Brake disk for disk brakes
US20040118644A1 (en) * 2001-04-06 2004-06-24 Leone Oberti Braking band, a ventilated disk-brake disk, and a core box for the production of a disk-brake disk core
US20140158486A1 (en) * 2004-10-26 2014-06-12 Freni Brembo S.P.A. Disc for a Disc Brake
DE102005033352A1 (de) * 2005-07-16 2007-01-18 Volkswagen Ag Innenbelüftete Bremsscheibe
US20090272609A1 (en) * 2006-04-05 2009-11-05 Karthik Raju Nmn Venturi Nozzle Aerodynamic Vent Design
US20080017460A1 (en) * 2006-07-21 2008-01-24 Dr. Ing. H.C.F. Porsche Aktiengesellschaft Internally ventilated disc brake
US20170002879A1 (en) * 2013-12-19 2017-01-05 Freni Brembo S.P.A. Ventilated brake disc

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112319132A (zh) * 2020-11-25 2021-02-05 浙江博鑫涵汽车零部件有限公司 一种新型汽车轮毂组件
CN112319132B (zh) * 2020-11-25 2022-05-24 浙江博鑫涵汽车零部件有限公司 一种新型汽车轮毂组件

Also Published As

Publication number Publication date
CN112771283A (zh) 2021-05-07
AU2019356796A1 (en) 2021-03-18
TW202043642A (zh) 2020-12-01

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