Hirschvogel Automotive Group, together with its cooperation partners from industry, is rethinking the conventional design of a brake system consisting of friction ring, brake shell, wheel hub and wheel bearing. The current approach is to connect the friction ring directly to the wheel hub by a pot shape. Compared to conventional braking systems, our innovative system is able to transfer higher external loads and save mass at the same time. In addition, it is ensured that the friction ring mounted on the wheel hub can be removed at any time without impairing the dynamic driving characteristics. In order to be able to connect the friction ring directly to the hub, radial arms evenly distributed over the circumference are forged onto the wheel hub. The focus of the development is not only the concept of the radius arms, but also a detachable connection between friction ring and wheel hub. In the design phase, initial brake load scenarios are simulated with simulation tools such as FEM software. The results of these simulations show both in the area of the connection and in the radius arms that the mechanical and temperature-related loads occurring during operation can be endured by the system. The newly developed system features a lower weight compared to conventional brake disc with pot connection to the wheel hub. It will generate lower cost compared to more modern multi-piece brake disc / wheel hub connections. There will be less joining surfaces between wheel rim and wheel hub. The new system will need less assembly space in axial direction. Finally, the filigree structure will provide a sporty, transparent, dynamic look.
Raphael Leibl, Hirschvogel Automotive Group, Germany; Marcelino de la Cruz, Hans-Willi Raedt, Wilfried Strauß, Fritz Winter Eisengießerei GmbH & Co. KG, Germany