Abstract: The invention relates to a brake rotor having improved damping characteristics and a method for producing the same. A surface of the brake rotor is EDG machined, also known as EDM machined, for improving the damping characteristics of the rotor. The decay rate of the brake rotor is increased and the Q factor of the brake rotor is reduced. The portion of the brake rotor which is EDG machined is formed of an electrically conductive material, preferably a ferrous material, more preferably a cast iron material, a gray iron material or a damped iron material. The brake rotor may include a solid friction section or a ventilated friction section. The brake rotor is preferably cast from a single material, although alternatively, it may be a composite rotor formed of more than one material.

Abstract: A method of increasing the length, thickness, and density of graphite flakes in a brake rotor includes forming a brake rotor of gray iron, cast iron, or damped iron. The method further includes EDG machining a surface of the brake rotor.

Abstract: A vented disc brake rotor having an airflow director for funneling air into the braking plate vents thereby improving the cooling effectiveness of the rotor. The vented disc brake rotor includes first and second braking plates connected together in a mutually parallel, spaced apart relationship. Braking plate fins are disposed between the inwardly facing surfaces of the braking plates forming a plurality of braking plate vents between the braking plates. The rotor includes an airflow director having an annular flange extending generally radially inwards from the radially inner end of one of the braking plates. The flange includes an inner surface forming an angle with respect to the inner surface of the other braking plate such that the distance between these inner surfaces increases as the flange extends radially inwards. A plurality of director fins are disposed between the flange and the inner surface of one of the braking plates.

Abstract: A modular brake rotor includes a core having a central wall and a plurality of support ribs extending radially outwards therefrom. A pair of friction rings are secured to the support ribs. A viscoelastic vibration reducing element is disposed between the support ribs and the friction rings for creating a vibration reducing interface therebetween. The viscoelastic vibration reducing element is preferably a viscoelastic adhesive. In an alternate embodiment, the viscoelastic vibration reducing element is viscoelastic laminate including one or more layers of viscoelastic adhesive bonded to one or more intermediate materials.

Abstract: The present invention is a drum brake shoe assembly having an improved support structure which limits the lateral travel of the leading brake shoe, to thereby reduce or eliminate audible impacts between the brake shoe and the backing plate of the drum brake assembly. In accordance with the invention, two or more spaced apart hold down devices are provided on the leading brake shoe while a single hold down device is used on the trailing brake shoe. Each of the hold down device includes a hold down pin connected at a first end to the backing plate of the drum brake assembly. The second end of each hold down pin extends through an opening in the web of the brake shoe. Springs such as coil springs or the like are disposed between the second ends of the hold down pins and the brake shoe web for urging the brake shoe against the backing plate.

Abstract: The present invention discloses a vented brake rotor having tubular ducts. The rotor includes universal rotor blank having a hat section and a peripheral section radially extending therefrom. The hat section includes a mounting face and hat wall extending from the periphery of the mounting face. The peripheral section includes a first and a second braking plate joined together in a parallel, spaced apart relationship by a plurality of spacers. A plurality of duct tubes are fastened to the inner surfaces of the braking plates. Each one of the duct tubes has an inlet and an outlet allowing air to flow through the duct tube to provide an airflow path between the braking plates for cooling the rotor. In an alternate embodiment, the present invention may include a plurality of fins fastened to the inner surfaces of the braking plates. The fins extend between the braking plates forming a passages between them. A plurality of duct tubes are fastened in the passages between the fins.

Abstract: The invention is directed to a vehicle braking system having a plurality of two-state actuators disposed at each vehicle wheel and method braking same. The vehicle braking system further includes a brake rotor or brake drum secured to each vehicle wheel for rotation therewith. The brake rotors or drums each include a plurality of friction surfaces. A plurality of brake pads are disposed adjacent the friction surfaces such that a different brake pad corresponds to each friction surface. A different two-state actuator corresponding to each brake pad is disposed adjacent the corresponding brake pad. Each two-state actuator is either unactuated or actuated to provide a maximum translational force against the corresponding brake pad to achieve the desired braking force requirements at each vehicle wheel.

Abstract: The invention relates to an air flow test apparatus for determining the amount of air moving through vents in a turning ventilated rotor. The air flow test apparatus includes an elongated cylindrical shaft journalled for rotation in spaced apart bearing blocks mounted in a frame. A conventional belt drive couples the shaft to a variable speed motor for rotation. An adapter is mounted to the shaft and a work piece is mounted to the adapter end for rotation with the shaft. The work piece includes a hub secured to the adapter for receiving a plurality of different sized rotors, and a ventilated rotor mounted to the hub. The work piece may also include other vehicle components such as the caliper, a wheel, even an entire corner portion of a vehicle for simulation purposes. A pressure gauge is disposed adjacent the rotor, near the vents, to measure the air pressure near the turning rotor.

Abstract: The present invention relates to a modular brake rotor having friction rings secured to a core. The core includes a hat section having a hat wall, and a plurality of circumferentially spaced apart support ribs. A pair of friction rings having inner surfaces are secured to the support rib inboard and outboard mounting surfaces. The support ribs extend into recesses formed in the inner surfaces of the friction rings to secure the friction rings to the support ribs. The ribs may include protrusions formed using dowels which extend through the support ribs and project out of the inboard and outboard mounting surfaces and into the recesses. Alternatively, the protrusions may be formed integrally with the support ribs.

Abstract: An improved wheel disc and disc and and rim wheel assembly, and method and press apparatus for manufacturing the same. The wheel disc is adapted for telescopic press fit precision mounting into a mating wheel rim to form the wheel assembly. A flat disc blank is progressively die formed into a disc preform having a cross-sectional contour proximating that of the finished disc. The disc preform is then placed in a segmental expand punch and die tooling of the press apparatus which operates to apply radial expansion pressure to substantially the entire inner circumference of the peripheral flange portion of the disc preform to thereby permanently deform the same into a finished flange portion on the disc having precision finished predetermined dimensions.

Abstract: An improved wheel disc and disc and and rim wheel assembly, and method and press apparatus for manufacturing the same. The wheel disc is adapted for telescopic press fit precision mounting into a mating wheel rim to form the wheel assembly. A flat disc blank is progressively die formed into a disc preform having a cross-sectional contour proximating that of the finished disc. The disc preform is then placed in a segmental expand punch and die tooling of the press apparatus which operates to apply radial expansion pressure to substantially the entire inner circumference of the peripheral flange portion of the disc preform to thereby permanently deform the same into a finished flange portion on the disc having precision finished predetermined dimensions.

Abstract: Expanding apparatus and method for sizing a one-piece drop-center wheel rim having first and second ganged arrays of rim sizing die segments insertable into the rim from one side thereof, and a third array of rim sizing die segments insertable into the opposite side of the rim, all three arrays cooperating to form a complete array of die segments for expansion sizing of the rim. A single wedge mechanism moves the arrays radially outwardly to individually size the inboard bead seat, outboard bead seat and drop-center well zones of the rim in response to relative coaxial movement of the wedge and arrays in a rim expansion working stroke along a longitudinal axis of the wedge. The wedge includes an expansion cone mechanism comprising first, second and third cone cams respectively individually operably associated with the first, second and third die arrays for radially expanding the same in such working stroke.

Abstract: An improved wheel disc and disc and rim wheel assembly, and method and press apparatus for manufacturing the same. The wheel disc is adapted for telescopic press fit precision mounting into a mating wheel rim to form the wheel assembly. A flat disc blank is progressively die formed into a disc preform having a cross-sectional contour proximating that of the finished disc. The disc preform is then placed in a segmental expand punch and die tooling of the press apparatus which operates to apply radial expansion pressure to substantially the entire inner circumference of the peripheral flange portion of the disc preform to thereby permanently deform the same into a finished flange portion on the disc having precision finished predetermined dimensions.

Abstract: A method and apparatus for manufacture of a vehicle wheel rim and disc assembly with controlled lateral runout characteristics in which a preformed rim is fixtured and rotated while gauges measure lateral runout of the inboard and outboard rim bead seats. Phase angle and amplitude of the first harmonic of average lateral runout of the bead seats are determined, which effectively identify a rim plane of substantially zero first harmonic of bead seat lateral runout. The wheel disc is fixtured with its mounting surface, defined by the inboard face of the disc, at predetermined orientation with respect to the rim plane of substantially zero first harmonic of bead seat lateral runout, either parallel thereto for a true running wheel or at predetermined angular orientation with respect thereto for placing the high point or low point of the first harmonic of lateral runout of the rim and disc assembly adjacent to a predetermined location circumferentially of the rim.

Abstract: A method and apparatus (50 or 110) for forming bolt and center-pilot mounting openings (36, 30) in vehicle wheels (16 or 112), particularly styled-disc vehicle wheels. A preformed rim and disc assembly is engaged and fixtured around the rim bead seat (20, 22) with the inboard disc face resting on a lower die assembly (82) and without plastic deformation to the rim or disc. An upper die assembly (52) having an array of bolt hole punches (56) is moved into piercing-and-coining engagement with the disc to form the bolt openings. Continued motion of the upper die assembly pushes the disc and lower die assembly into shearing engagement with a center punch (76 or 76a or 76b) which forms the center-pilot opening. The axes BH, CH, BS) of the bolt openings and/or center-pilot opening and/or bead seats may be aligned or offset from each other.

Abstract: A method and apparatus (50 or 110) for forming bolt and center-pilot mounting openings (36, 30) in vehicle wheels (16 or 112), particularly styled-disc vehicle wheels. A preformed rim and disc assembly is engaged and fixtured around the rim bead seat (20, 22) with the inboard disc face resting on a lower die assembly (82) and without plastic deformation to the rim or disc. An upper die assembly (52) having an array of bolt hole punches (56) is moved into piercing-and-coining engagement with the disc to form the bolt openings. Continued motion of the upper die assembly pushes the disc and lower die assembly into shearing engagement with a center punch (76or 76a or 76b) which forms the center-pilot opening. The axes (BH, CH, BS) of the bolt openings and/or center-pilot opening and/or bead seats may be aligned or offset from each other.

Abstract: Apparatus and method for manufacturing a vehicle wheel rim and disc assembly with controlled lateral runout characteristics, as well as the resulting wheel and a pneumatic tire and wheel assembly having overall improved ride characteristics. The method and apparatus of the invention contemplate fixturing of a preformed rim so that the average plane of the rim bead seats is at preselected orientation with respect to axis of interference press-fit of a preformed disc therein, and thus at preselected orientation with respect to the wheel mounting plane defined by the inboard disc surface. In one implementation of the invention, the average bead seat plane is made nominally parallel to the wheel mounting plane by selective adjustment of the fixturing bead seat locators, so as to minimize lateral runout of the resulting wheel.

Abstract: A method and apparatus for forming bolt and center-pilot mounting openings in vehicle wheels, particularly styled-disc vehicle wheels. A preformed rim and disc assembly is engaged and fixtured around the rim bead seat with the inboard disc face resting on a lower die assembly and without plastic deformation to the rim or disc. An upper die assembly having an array of bolt hole punches is moved into piercing-and-coining engagement with the disc to form the bolt openings continued motion of the upper die assembly against the wheel disc pushes the disc and lower die assembly into shearing engagement with a center punch which forms the center-pilot opening. The axes of the bolt openings and/or center pilot opening and/or bead seats may be aligned or offset from each other.

Abstract: Apparatus and method for manufacturing a vehicle wheel rim and disc assembly with controlled lateral runout characteristics, as well as the resulting wheel and a pneumatic tire and wheel assembly having overall improved ride characteristics. The method and apparatus of the invention contemplate fixturing of a preformed rim so that the average plane of the rim bead seats is at preselected orientation with respect to the axis of interference pressfit of a preformed disc therein, and thus at preselected orientation with respect to the wheel mounting plane defined by the inboard disc surface. In one implementation of the invention, the average bead seat plane is made nominally parallel to the wheel mounting plane by selective adjustment of the fixturing bead seat locators, so as to minimize lateral runout of the resulting wheel.

Abstract: Apparatus for manufacturing a vehicle wheel rim and disc assembly with controlled lateral runout characteristics. The apparatus of the invention contemplate fixturing of a preformed rim so that the average plane of the rim bead seats is at preselected orientation with respect to the axis of interference press-fit of a preformed disc therein, and thus at preselected orientation with respect to the wheel mounting plane defined by the inboard disc surface. In one implementation of the invention, the average bead seat plane is made nominally parallel to the wheel mounting plane by selective adjustment of the fixturing bead seat locators, so as to minimize lateral runout of the resulting wheel. In another implementation of the invention, the average bead seat plane is intentionally angulated with respect to the disc mounting plane so as to locate a peak of the first harmonic of lateral runout circumferentially adjacent to a selected location on the wheel rim, such as the rim valve hole.