Browse Topic: Brake calipers

Items (104)
Abstract Brake squeal reduces comfort for the vehicle occupants, damages the reputation of the respective manufacturer, and can lead to financial losses due to cost-intensive repair measures. Mode coupling is mainly held responsible for brake squeal today. Two adjacent eigenfrequencies converge and coalesce due to a changing bifurcation parameter. Several approaches have been developed to suppress brake squeal through structural changes. The main objective is to increase the distance of coupling eigenfrequencies. This work proposes a novel approach to structural modifications and sizing optimization aiming for a start at shifting a single component eigenfrequency. Locations suitable for structural changes are derived such that surrounding modes do not significantly change under the modifications. The positions of modifications are determined through a novel sensitivity calculation of the eigenmode to be shifted in frequency. In the present work, the structural changes are carried out on a beam and a brake caliper. Selected eigenfrequencies are shifted while the frequencies of the other eigenmodes are simultaneously fixed. Experimental investigations for the brake caliper validate the numerical findings and the applicability as well as efficiency of the proposed methods.
Deutzer, MarcelStender, MertenTüpker, NicolasHoffmann, Norbert
This SAE Recommended Practice provides basic recommendations for dispensing and handling of SAE J1703 and SAE J1704 Brake Fluids by Service Maintenance Personnel to assure their safe and effective performance when installed in or added to motor vehicle hydraulic brake actuating systems. This document is concerned only with brake fluid and those system parts in contact with it. It describes general maintenance procedures that constitute good practice and that should be employed to help assure a properly functioning brake system. Recommendations that promote safety are emphasized. Specific step-by-step service instructions for brake maintenance on individual makes or models are neither intended nor implied. For these, one should consult the vehicle manufacturer’s service brake maintenance procedures for the particular vehicle. Vehicle manufacturer’s recommendations should always be followed.
Brake Fluids Standards Committee
This SAE Recommended Practice defines the boundary line for establishing dimensional compatibility between air disc brake calipers and 22.5 x 8.25 inch disc wheels, including bent valve stems on steel wheels and manufacturer recommended valve stems on aluminum wheels. The line establishes the minimum wheel with valve stem envelope to allow interchangeability. The line does not accommodate customer-specific wheels (such as OEM-specific stylized wheels) or customer-specific brakes. This document addresses dimensional characteristics only and makes no reference to the performance, operational dynamic deflections or heat dissipation of the system. It is up to the system integrator to ensure sufficient clearance exists between the caliper, wheel and valve stem to provide safe operating conditions. Mounting systems as noted are referenced in SAE J694.
Truck and Bus Wheel Committee
Influence of Pads and Brake Disc wear on Brake Squeal Noise2019-36-00051/13/2020
The present work aims to investigate the influence of wear of the pads and brake disc on the brake squeal behavior with the help of the Finite Element tool. Brake discs basically work by the pressure of the brake pads against a rotating disc. The friction between the pads and the disc causes the latter to decelerate, but it can also cause dynamic instabilities of the system giving rise to noises. Among the main noise in vehicle brake systems, there is the squeal noise, which is usually associated with the coupling of two neighboring natural modes. One possible way to identify unstable modes is by extracting complex eigenvalues from the system. An unstable mode can be identified when, in the result of the extraction of the complex eigenvalues, the real part of the eigenvalue is positive. In the present work, a brake system (disc and positioned pads and their respective materials and friction coefficients) was duly modeled and validated. The validation was done by means of a correlation between the frequency of the noises found experimentally and the frequency of the unstable modes found in the virtual model. A parametric analysis was performed simulating the wear of the disks and pads to understand the effect of the mass variations and stiffness on the instability of the system. According to the results found in the analyzes that simulate the wear, with the decrease, mainly the thickness of the brake pads, there was an increase of numbers of unstable modes, that is, the brake system is more prone to squeal generation.
dos Anjos, Marco Túlio BatistaGutiérrez, Juan Carlos HortaFerreto, Cláudio JuniorSilva, Felipe DornellasDonadon, Lázaro Valentin
Performance Gains of Load Sensing Brake Force Distribution in Motorcycles2019-28-242611/21/2019
Commercial motorcycles and scooters incorporate independent circuits for front and rear brake actuation, thus precluding load-dependent brake force distribution. In all cases of manual brake force modulation between the front and rear wheels, there is poor compensation for the changes in wheel loads on the account of longitudinal weight transfer, thus making it challenging to provide an adequate braking force to each wheel. The ratio in which the braking force should be distributed between the front and the rear wheels is dependent on the motorcycle’s geometry, weight distribution, mechanical sizing of braking system components, and is a variable based on the instantaneous deceleration. This connotes that a fixed bias of front and rear braking forces can be optimized only for a narrow range of motorcycle’s deceleration. Maximum braking performance occurs just prior to wheel lock-up, as a sliding tire provides less grip than a rolling tire. This is also the scenario when both the tires are doing the maximum work in decelerating the motorcycle. Therefore an optimal brake force distribution is one that locks both the wheels at the same instant. In practice, however, a rider would avoid a front wheel lock-up as it would make the motorcycle challenging to steer. In theory, an apt distribution of the braking forces between the front and rear wheels maximizes the overall braking efficiency of the motorcycle whilst reducing its stopping distance. This paper examines the plausible performance gains of load sensing brake force distribution in a motorcycle.
Chakraborty, Apurva
Squeal Noise Improvement by High Damping & High Stiffness under Layer Material2019-01-21119/15/2019
The purpose of this research is to clarify how damping characteristics of Under Layer (hereafter “UL”) material in the brake pads (hereafter “PAD”) influences brake squeal noise performance. In this study, UL material structure and dynamic viscoelasticity, for two different types of UL formulations are investigated. In addition, PAD damping ratio and squeal noise performance for multiple UL formulations are verified. As a result, the raw material orientation is determined based on manufacturing method, and it causes the UL material’s anisotropic properties. Dynamic viscoelasticity are dependent on the direction in which they are measured. In particular, the loss modulus, which is the damping element of dynamic viscoelasticity, is higher in the direction of the raw material orientation for the high damping and high stiffness UL formulation. In addition, it was confirmed that this loss modulus in the direction of the raw material orientation is effective for bending vibration. In the verification, the study focuses on the PAD damping ratio and squeal noise performance in the 1st bending vibration of the PAD. It is clarified that the PAD damping ratio increased as the loss modulus increases, which leads to improve squeal noise. In conclusion, this research proves that the high damping and high stiffness UL material is effective for squeal noise improvement.
Nishioka, MasatoJohnson, LeanneRosalez, SeanSuzuki, Shusuke
Compressible Brake Fluid Turbulent Flow Simulation and Experimental Verification on Brake Bleeding Performance Improvements of an EPB Caliper2018-01-187610/5/2018
Brake bleeding is the process of removing air bubbles present on hydraulic brake systems from the master cylinder to the calipers of a vehicle, including the brake pipes and hoses. This is very important procedure affecting on brake performance, but still has been a key issue in automobile industry for last decades because reaching best bleeding performance has a limit that there is always remaining air in brake system. In this paper, it is reported on numerical and experimental investigations into the topic of bleeding performance improvements. Compressible brake fluid turbulent flow simulation with two-phase mixture model was performed to investigate the details of the bleeding performance drop during its cycles. The rig test of the hollow cylinder was carried out in order to secure the brake consumption amount curve whose results were used for the criterion of the parametric simulations using Tait equation to estimate the property of the brake fluid with the bulk modulus of 19,535 bar and 0.00016%. It was observed that the experimental curve data from the rig test of the hollow cylinder is divided into two regions with high and low compressibility, and more volume change in the low region below 1 bar is required to gain the same pressure variation due to the compression of the tiny air bubbles. The improved design of the nut-spindle with 6 holes in circumferential direction was drawn for the better removal of the trapped air. The simulation of the improved model showed the manual bleeding performance improvements of 18.9% than the baseline model due to the holes effect on circulation of the trapped air. It was experimentally verified that the air bubbles from their visualization are compressed to form the smaller size bubbles in the process of pressurization and gathered on the topmost side, whereas they are again expanded to form the larger size bubbles in the process of pressure release and spread into the wider space. The bleeding performance for the improved model was also experimentally verified to be effective up to approximately 51% through the caliper performance tester.
Mo, Jang-Oh
Experimental Investigation of Low-Frequency Vibration Patterns in Automotive Disk Brake Systems: Utilization Study for Modal Simulation Methods2018-01-15136/13/2018
Increasing demands on automotive comfort as well as diminishing vehicle noise levels draw new attention towards low-frequency vibration and noise issues of disk brake systems such as creep groan and moan. In view of this problem, the experimental investigation of relevant phenomena is within the scope of this article. The related experiments concerning two different setups have been performed at a drum driven suspension and brake test rig. Both assemblies consisted of a front axle corner including all parts of the integrated brake system. In order to gain understanding of characteristic triggering mechanisms and fundamental subsystem interactions, and moreover, to verify the suitability of modal methods for simulative evaluations of creep groan or moan, specifically elaborated Operating Deflection Shape (ODS) techniques have been applied. Via analyses of four different creep groan emergences, global stick-slip cycles between disk and pads are revealed. For two dissimilar vibrations in the typical frequency range of moan, mechanisms rather associated with dynamic instabilities are identified. Based on measurement results and further theoretical considerations, the suitability of a disk brake Complex Eigenvalue Analysis (CEA), which is a linear modal simulation method designated to efficiently evaluate disk brake squeal noise, is verified with respect to the relevant friction-induced low-frequency phenomena. Even though the disk brake CEA is inappropriate to estimate a highly non-linear behavior such as involved in all four creep groan signatures, its application for accompanying damped natural oscillations as well as for both observed moan appearances is plausible. By investigation of characteristic pad vibration patterns and speeds belonging to the disk rotation, generic parameter spaces for the utilization of modal methods on harmonic low-frequency phenomena are deduced.
Pürscher, ManuelHuemer-Kals, SeverinFischer, Peter
Q&A18AUTP01_161/1/2018
Influences of Initial DTV on Thermomechnical Coupling in Disc Brake System2017-01-24929/17/2017
In this paper, the initial disc thickness variation (DTV) of a ventilated disc in automotive brake system is modeled as sinusoidal function of the second order. The transient thermomechanical coupling properties of the brake system is simulated using finite element (FE) modeling. The system models and results were verified by a thermomechanical coupling test of a disc brake conducted on a brake dynamometer. By using varied evaluation indexes such as the temperature distribution, the normal stress and the elastic deformation of disc surfaces, the influences of the initial DTV and its direction as well as its amplitude on the thermomechanical coupling characteristics were analyzed. The simulation results show that the distribution of temperature and the normal stress in circumferential direction exhibit the same sinusoidal function of the second order as the modeled initial DTV property, which is different from the thermomechanical coupling characteristics caused by disc surface initial run-out (LRO). Whereas the thermomechnical coupling property of the disc in circumferential direction exhibit the same sinusoidal function of the second order as that of the initial DTV, the distribution of the temperature, the normal stress and the elastic deformation in radial direction are found to be uniform. The changes in the magnitude of initial DTV are found to have insignificant effects on the changes in the overall thermomechnical coupling property. However, the circumferential gradients of the temperature, the normal stress, and the maximum disc distortion increase linearly with the increase of the magnitude of the initial DTV. The radial gradients of these quantities are not linear proportional to the magnitude of the initial DTV.
Meng, DejianWang, ZiyiZhang, LijunYu, Zhuoping
Faster, Better, Economic - Newest Acid Zinc-Nickel Technology for Brake Caliper Plating2017-01-25079/17/2017
The demand for zinc-nickel coatings continuously increases in the automotive industry due to their high corrosion protection as well as superior wear and heat resistance compared to pure zinc platings. The state-of-the-art plating systems in the brake caliper industry are acid zinc-nickel electrolytes, as only they allow for direct plating on cast iron. Cast iron is the most common base material for the production of automotive brake components due to excellent mechanical and thermal properties. Well suited coatings will preserve the functional properties and provide additional advantages like improved corrosion protection and homogeneous and long lasting appearance. Consistently increasing quality demands, extended warranty periods and cost pressure lead to further developments and force the industry to look for new solutions. Therefore improvement of throwing power (thickness distribution) of acid zinc-nickel electrolytes would allow for a reduction in plating time and thus an increase in productivity. More homogeneous coatings on the other hand will lead to an improvement of corrosion resistance and quality. With an appropriate post-treatment consisting of passivate and reactive inorganic sealer, a high-end system with superior cathodic corrosion protection, highest wear resistance and perfect appearance is achieved. This study will introduce Atotech´s new ammonium and boric acid-free acid zinc-nickel electrolyte - Zinni® 220 - which, as a result of the significantly improved throwing power, sets new standards in acid zinc-nickel plating. It opens enormous possibilities to improve quality and productivity while keeping the highest corrosion protection and perfect appearance. The superior thickness distribution and nickel incorporation will be presented and compared to conventional acid zinc-nickel electrolytes. Overall this results in higher plating quality at reduced cost and improved productivity.
Hoch, MatthiasKaczmarek, MichalAhr, Markus
Interactive Effects of Thermal Deformation and Wear on Lateral Runout and Thickness Variation of Brake Disc Rotors2016-01-19399/18/2016
Brake judder is one of the most serious problems in automotive-brake systems. It is basically a forced vibration caused by the friction-surface geometry of a brake disc, and therefore, disc rotors play a significant role in judder. There are two types of judder: cold and hot. Hot judder is caused by the thermo-mechanical deformation of a brake disc due to high-speed braking. There are several shapes of deformation, e.g., coning and circumferential waviness. Circumferential waviness is caused by thermo-mechanical buckling and typically found as a butterfly shape in a 2nd rotational-order and hot-spotting. In a previous paper, two groups of disc castings with different material homogeneity were machined intentionally to have two kinds of dimensional variations. From repetitive high-speed braking tests of these discs, both the material and dimensional homogeneity were found to affect the wave-like deformation of discs in the 1st and 2nd rotational-orders with different significance between the two casting groups. There are many mechanisms affecting disc geometry during braking. Plastic deformation and wear cause permanent effects, while thermal expansion and elastic deformation are reversible. A disc’s initial shape before braking affects its geometry both transiently and permanently. Considering these effects, the previous test results were reanalyzed in the present paper. Some discs exhibited large transient runout and DTV but small permanent DTV, while others behaved differently. The thermal deformation and differential wear were confirmed to interactively affect the transient and permanent geometry of operating brake discs.
Okamura, Toshikazu
Vehicle Level Brake Drag Target Setting for EPA Fuel Economy Certification2016-01-19259/18/2016
The strong focus on reducing brake drag, driven by a historic ramp-up in global fuel economy and carbon emissions standards, has led to renewed research on brake caliper drag behaviors and how to measure them. However, with the increased knowledge of the range of drag behaviors that a caliper can exhibit comes a particularly vexing problem - how should this complex range of behaviors be represented in the overall road load of the vehicle? What conditions are encountered during coastdown and fuel economy testing, and how should brake drag be measured and represented in these conditions? With the Environmental Protection Agency (amongst other regulating agencies around the world) conducting audit testing, and the requirement that published road load values be repeatable within a specified range during these audits, the importance of answering these questions accurately is elevated. This paper studies these questions, and even offers methodology for addressing them. It includes a review of how variation in brake drag can affect fuel economy and carbon emissions certification, a review of the many transient and driver-dependent behaviors and operating conditions that can affect drag at a vehicle level (and means of measuring them) and then offers a methodology (based on probabilistic modeling) for predicting the range of drag that can be encountered in fuel economy testing. In the course of developing the methodology, a significant database of vehicle level brake drag measurements is analyzed, and a case study vehicle is used to show correlation in a “walk” from component level to vehicle level caliper drag behavior.
Antanaitis, David B.
Advanced Finishes for Brake Components and Other Castings2016-01-19519/18/2016
Caused by a number of beneficial properties inherently from the zinc-nickel material, this electrodeposited alloy is used more and more for cathodically protecting layers on ferrous components like cast iron brake calipers. Direct plating from acidic solutions is the state-of-the-art solution for zinc-nickel surface finishing of these components. To contribute to the continuous improvement of the final component and reduce the finishing cost, areas for improvement have been scrutinized in a current finishing system. Areas for improvement have been identified in the uniformity of the nickel distribution within different current densities and in the handling and economy of the metallic zinc anodes used for zinc metal replenishment. While today’s acidic zinc-nickel electrolytes suit and usually exceed the requirements for an alloy containing 10-15% nickel, nickel incorporation may drop just below 12% incorporation rate in areas which are plated at high current densities. Formation of white corrosion products is observed in those areas earlier than in areas bearing higher (>12%) nickel. Development on the zinc-nickel plating electrolyte’s additive system has resulted in a significantly more uniform plated deposit with improved resistance against white corrosion. Previous disadvantages in the plating system including rising metal concentrations, anode passivation and insufficient zinc metal utilization will be overcome using the new membrane anode system. This separates the zinc metal anode from the plating bath. The electrolyte can then be operated at constant metal concentrations, constant anode voltages, with no need to remove anodes in idle periods, without any anode reactivation and significantly better anode metal utilization. These developments provide important contributions for improved operating efficiencies through higher productivity and improved material economy. The significant effect of these developments on higher and more consistent quality of the plated layers finally also contributes to the overall reliability of cast iron brake systems.
Dingwerth, Björn
This SAE Recommended Practice provides basic recommendations for dispensing and handling of SAE J1703 and SAE J1704 Brake Fluids by Service Maintenance Personnel to assure their safe and effective performance when installed in or added to motor vehicle hydraulic brake actuating systems. This document is concerned only with brake fluid and those system parts in contact with it. It describes general maintenance procedures that constitute good practice and that should be employed to help assure a properly functioning brake system. Recommendations that promote safety are emphasized. Specific step-by-step service instructions for brake maintenance on individual makes or models are neither intended nor implied. For these, one should consult the vehicle manufacturer’s service brake maintenance procedures for the particular vehicle. Vehicle manufacturer’s recommendations should always be followed.
Brake Fluids Standards Committee
Study of Development Technology of Brake Caliper Which Balances Preventing Squeal with Weight Reduction2015-01-26889/27/2015
It is well known that improving NV performance and weight saving are reciprocity. Brake squeal free is one of the top priority issues during development of brake system. To date, complex eigenvalue analysis has been utilized for prediction of brake squeal. It solves the structural instability problems by modal coupling which is the phenomenon that natural frequencies of normal modes are quite consistent. The positive real parts of complex eigenvalues are identified as instable vibration which causes brake squeal. On the other hand, the needs for light-weight brake system are higher than before due to recent trends of economizing fuel consumption and high driving performance. In order to obtain coexistence of brake squeal free with weight saving, shape optimization technique has been proposed for complex eigenvalue analysis. In this study, the real parts of eigenvalues are shifted to stable side analytically by optimization algorithm using response curved surface with minimizing mass of a brake assembly. For simplified FEM model consisting of a rotor and a pad, thickness of backplate of brake pad is set as design parameter, mass minimization as objective function, and real parts of the eigenvalues are lower than zero as a constraint condition. Shape optimization technology, as mentioned above, achieves the lightweight construction with brake squeal free analytically.
Inoue, HayuruHashimoto, KumiKumemura, Yoichi
Effect of Material and Dimensional Homogeneity on Thermo-mechanical Deformation of Brake Discs during High-speed Braking2015-01-26739/27/2015
Brake judder is one of the most serious problems in automotive-brake systems, and brake discs play a significant role in judder. There are two types of brake judder: cold and hot. Hot judder is caused by the thermo-mechanical deformation of a disc rotor due to high-speed braking. There are several causes and shapes of the deformation, e.g., coning and circumferential waviness. Circumferential waviness of brake discs is typically found as a butterfly shape in a 2nd rotational-order and corrugation (or hot-spotting) around a 10th order, which are caused by thermo-mechanical buckling. The author focused on the effects of material and dimensional homogeneity on the transient and permanent wave-like deformation of ventilated discs in low rotational-orders during repetitive high-speed braking. The tested discs were in two groups that had the same design and gray-cast-iron class but were cast in two foundries by using horizontal- and vertical-molding machines, respectively. Consequently the two groups of disc castings differed in the circumferential homogeneity of material. These discs were machined intentionally to have two kinds of dimensional variations in four rectangular orientations on the basis of the gating locations of each casting group. The temperature and deformation of disc rotors on the same radius were measured simultaneously during braking at a constant speed and torque. Measured deformation shapes were analyzed through fast Fourier analyses. As a result, both material and dimensional homogeneity were found to affect a disc's wave-like deformation in the 1st and 2nd rotational-orders with different significance between the two casting groups.
Okamura, Toshikazu
Configuration of Brake Components2015-01-26689/27/2015
The hydraulic brake products like brake calipers, master cylinders and boosters are the foundation of today complex vehicle brake systems. The state of the art application leads very often to an individual design, due to the fulfillment of customer requirements within the available installation space. Also the enormous pressure on cost and time require optimized design processes. Therefore Continental developed the product configuration software CoBra. Within this software tool, the engineering is able to react very fast on demands. Starting with the brake sizing parameters and the customer interface definition, CoBra supports the design engineer to select the necessary components and positioning them accordingly, considering the actual design standards. The data based configuration software collects all necessary design parameters and provides an export to parametric CAD start up models. Therefore a high level of data quality can be achieved which allows to couple further design and simulation modules. Today all caliper types and the master cylinders are part of the actual software version. In summary we can state that CoBra, as the basis for the start of each caliper application, has a high impact on the standardization approach. The early integration of design rules, manufacturing standards and the attached CAD / CAE process reduces failure modes and gives the engineering more time to concentrate on the project specific optimizations.
Ungethuem, UlrichSimon, Dirk
Brake Noise Prediction Using Altair Multi-Body Simulation2015-36-00025/13/2015
The level of noise transmitted to the passengers of a vehicle can drastically impact a passenger's comfort. Brake noise will give the customer an impression of poor product quality and can thus damage the quality image of the company. Within the automotive industry, the study of mode coupling instability by the use of FEM and modal complex analysis is widespread to reduce this phenomenon. In this paper an alternative method is presented, where potential brake noise issues are predicted by the use of a time transient integration using multi-body system analysis. The simulation model contains a nonlinear contact description, bushing, flexible bodies and the axis kinematics of the vehicle. Transient results are transformed by Fourier for a frequency domain study. The parameters that can be varied for the prediction analysis are brake pressure, vehicle speed, friction laws, system damping and bushing properties. The advantages of the multi-body system analysis approach are in the direct consideration of the non-linearity's which are significant within certain frequency ranges. The multi-body system analysis approach also provides a further method to confirm results from the complex modal analysis and thus increases the informational value of the numerical predictions. Simulations variant results will be presented and discussed and enhancements will be proposed.
Sundaresh, KeshavLeila, Felipe Moretti
Proposed Metrological Method for Identifying Automotive Brake Discs2015-01-06914/14/2015
The main aim of this work is to develop an identification method to demonstrate the crucial surfaces of automotive braking system. Two brand new brake discs manufactured by two different manufacturers are tested. A typical disc to the one of them was put under working condition in actual braking system. Dimensional and geometrical deviations are investigated using advanced engineering metrological technique. Mechanical properties, tribological characteristics and chemical analyses are investigated. A coordinate measuring machine, universal hardness tester, mass comparator and XRF spectrometer are used in these diagnoses. Measurements of dimensional and geometrical deviations such as disc thickness variations, thickness deviations, straightness, parallelism, runout of disc surfaces are conducted. A comparison between form deviations in disc surfaces have been carried out and analyzed. The effect of material properties of the influencing surfaces on the wear rate and hardening of surfaces has been discussed. Wear rate under severe sliding conditions is thus strongly influenced by the geometrical and hardness characteristics. The wear rate of used brake disc rotor induced fatigue phenomena is accurately identified. Correlations between design specifications and real surface characteristics are evaluated. The results showed that implementation of the engineering metrology techniques to understand and predict the dynamic behaviors for auto brake discs are necessary successful. Moreover, repeatability of the measurement results is conducted to confirm their precision.
Ali, Salah H. R.Zahwi, Sarwat Z. A.Dadoura, Hassan H.
Methodology for Sizing and Validating Life of Brake Pads Analytically2014-01-24959/28/2014
An area of brake system design that has remained continually resistant to objective, computer model based predictive design and has instead continued to rely on empirical methods and prior history, is that of sizing the brake pads to insure satisfactory service life of the friction material. Despite advances in CAE tools and methods, the ever-intensifying pressures of shortened vehicle development cycles, and the loss of prototype vehicle properties, there is still considerable effort devoted to vehicle-level testing on public roads using “customer-based” driving cycles to validate brake pad service life. Furthermore, there does not appear to be a firm, objective means of designing the required pad volume into the calipers early on - there is still much reliance on prior experience. This paper builds upon previous work by GM [1], where short duration, objective vehicle and dyno tests were combined with a computer model to allow for accurate pad service life prediction without vehicle tests, and expands it into a methodology combining CAE (CFD), computer modeling, objective friction material characterization data, to enable confident sizing of the brake pads very early in the vehicle development process. In the present work, this method is extended to global vehicles, considering a European-market vehicle (low-metallic lining materials). A case study vehicle will be used to illustrate how these tools and methods can be used to design the initial pad volume, develop the brake system to avoid lining life issues, and then validate the brake pad service life for global vehicles, without using expensive, time consuming, and often inaccurate public road testing.
Antanaitis, David B.Lee, Heewook
Novel Mechanism Using Differential Gears for the Electromechanical Brake2014-01-03844/1/2014
As is well known, the brake systems of vehicles are used in order to decelerate or stop the vehicle while the driving. The operational principle of the brake is the conversion of kinetic energy into thermal energy. In this case, the thermal energy is released to the atmosphere. Recently, electromechanical brakes (EMB) were developed in order to replace hydraulic brake calipers. Such brake-by- wire systems are composed of an electronic pedal, electronic control unit (ECU), wire, and an electromechanical caliper. A typical electromechanical brake is similar to existing floating brakes. In other words, an inner pad pushes out one side of a disc driven by the energy of a motor; by means of a screw-thread gear. Then, the caliper slides in the opposite direction by reaction force and moves the outer pad toward the other side of the disc. Then pads clamp both sides of the rotating disc and stop the wheel. While effective, this design has the problem that there is a difference in the wear of the inner and outer pads. In this paper, we describe a novel electromechanical brake design. Specifically, the proposed mechanism has some new features related to the presence of differential, and rack-pinion, gears. Furthermore, the wear difference of the inner and outer pads can be minimized by using our proposed mechanism. So to speak, both pads are clamped at the same time by the initial braking force. In addition, we focused on how to use the device to improve the braking force during the initial braking.
Park, Tae-SangJin, SunghoMoon, Jeon ILYang, Seung-Han
Characterization of Caliper Piston Material Stiffness and Damping2013-01-20509/30/2013
The brake caliper piston plays a key role in caliper function, taking significant responsibility for qualities such as fluid consumption, insulation of the brake fluid from heat, seal rollback function, and brake torque variation sensitivity to disc thickness variation. It operates in a strenuous environment, being routinely subjected to high stresses and elevated temperatures. Given all of the demands on this safety-critical component (strength, stiffness, wear resistance, stable friction against rubber, thermal stability, machinability, manageable thermal conductivity, and more), there are actually relatively few engineering materials suitable for use as a caliper piston, and designs tend to be limited to steel, aluminum, and engineered plastics (phenolic composites). The lattermost - phenolic composites - has been of especial interest recently due to mass savings and possible reduction in brake corner judder sensitivity to disc thickness variation. This paper focuses on characterizing two important mechanical characteristics, stiffness and damping, of the most common piston materials, steel and phenolic. Data are shown first suggesting the effect of piston material on brake performance, and then stiffness and damping data from different methodologies are presented. From these data, a preferred methodology is recommended and results are reconciled with brake corner subsystem performance and modeling.
Antanaitis, David B.Riefe, MarkCiechoski, ChrisFlaim, ThomasGreening, C
Energy and Timing Advantages of Highly Non-Linear EMB Actuation2013-01-20679/30/2013
With linear actuated brakes the actuation force (or torque) rises linearly from 0 to the full actuation force at full braking. This means that the actuation must be designed for the rare case of full-braking. The parts must be designed for this peak load (e.g. motor, gear) and the transmission ratio is determined by the full-braking actuation torque, which causes the highest transmission ratio and hence determines slow actuation dynamic. Ideally the actuation should make the fastest travel at low normal force and turn to slow movement and high force at the highest pad force. Mathematically the torque transmission ratio should optimally be an exact representation of the actuation characteristics (actuation torque over actuation movement), creating the highest torque-transmission ratio at highest force and the fastest movement at low pad force. This highly non-linear actuation characteristics means that the actuator motor is always running on constant load (although the pad pressing force changes dramatically). The resulting actuation timing is the fastest possible, because the actuation is as fast as possible at low force. The actuator electro motor is running at constant-load and hence can be operated in best efficiency, making the electrical power consumption the lowest possible. How can the optimal, variable transmission ratio (that is mathematically given by the actuation characteristics) be achieved in reality at the Vienna-Engineering EMB (Electro Mechanical Brake)? Firstly the VE-EMB has a non-linear actuation due to the principle of the eccentrics, which are turned to press the pad to the disc. Secondly the VE-EMB uses an approx. 90° angle-range at the eccentrics, making it easy to insert a non-linear gear between eccentrics and the motor gear. It is shown how the behavior can be optimized to the mathematical needs and how the characteristics can cover a wide range of changing transmission ratio. It is also discussed how the optimized non-linearity also assists to turn the brake back to “released” in the power-off case: At high actuation force the VE EMB always automatically rolls back to released by the high internal force and its efficiency of 90% and higher. At low force any EMB must overcome the motor cogging (“snapping” and friction) to roll back to released at power-off. The highly non-linear actuation of the VE-EMB makes it far easier, because at low force the transmission ratio turns to “fast pad movement”, assisting in turning the motor from the side of the pad-force. The VE-EMB Simulator is a detailed (and calibrated) representation of the brake in software, making it easy to accurately study improvements. It also can be used to study linear actuation on the same brake with the same motor. So this work also discusses timing and energy advantages by optimizations in the VE EMB and it also compares it to linear actuated brakes (e.g. screws, electro-over-hydraulic). By these optimizations an extremely simple EMB with the smallest possible electro motor can be shown.
Putz, Michael HerbertWunsch, ChristianMorgan, JohnSchiffer, MarkusBrugger, Johannes
Regenerative Braking Control Enhancement for the Power Split Hybrid Architecture with the Utilization of Hardware-in-the-loop Simulations2013-01-14664/8/2013
This study presents the utilization of the hardware-in-the-loop (HIL) approach for regenerative braking (regen) control enhancement efforts for the power split hybrid vehicle architecture. The HIL stand used in this study includes a production brake control module along with the hydraulic brake system, constituted of an accelerator/brake pedal assembly, electric vacuum booster and pump, brake hydraulic circuit and four brake calipers. This work presents the validation of this HIL simulator with real vehicle data, during mild and heavy braking. Then by using the HIL approach, regen control is enhanced, specifically for two cases. The first case is the jerk in deceleration caused by the brake booster delay, during transitions from regen to friction braking. As an example, the case where the regen is ramped out at a low speed threshold, and the hydraulic braking ramped in, can be considered. During this transition, due to the communication delay and the delay associated with booster dynamics, the regen ramp out and hydraulic braking ramp in are not perfectly synchronized, which can cause a jerk in deceleration. The second case considered is the jerk in deceleration when the regen torque is ramped out to zero during an ABS event. This causes a sudden loss in deceleration, again causing a jerk. By properly controlling regen torque in these two events, it is shown by real time simulation results that smoother deceleration can be delivered without causing vehicle instability.
Bayar, KeremMcGee, RyanYu, HaiCrombez, Dale
Vehicle Integration Factors Affecting Brake Caliper Drag2012-01-18309/17/2012
Disc brakes operate with very close proximity of the brake pads and the brake rotor, with as little as a tenth of a millimeter of movement of the pads required to bring them into full contact with the rotor to generate braking torque. It is usual for a disc brake to operate with some amount of residual drag in the fully released state, signifying constant contact between the pads and the rotor. With this contact, every miniscule movement of the rotor pushes against the brake pads and changes the forces between them. Sustained loads on the brake corner, and maneuvers such as cornering, can both produce rotor movement relative to the caliper, which can push it steadily against one or both of the brake pads. This can greatly increase the residual force in the caliper, and increase drag. This dependence of drag behavior on the movement of the brake rotor creates some vehicle-dependent behavior. Major factors affecting rotor movement include wheel bearing stiffness, wheel radius, vehicle mass and mass distribution, and brake corner geometry. The present work studies two vehicle-integration dependent mechanisms which can affect brake drag. The first involves rotor movement due to sustained tire/wheel loading conditions and brake corner geometry, and is examined through a case study involving two vehicles. The second involves rotor movement due to cornering loads. In both cases, rotor movement is related to brake drag by component dynamometer measurements of brake drag versus small axial movements of the rotor.
Antanaitis, David B.
High Performance Corrosion Protection for Brake Components: Direct Zinc-Nickel Application and Post-Treatment2012-01-18319/17/2012
Cast-iron is a well suited material for manufacturing automotive brake components due to excellent mechanical and thermic properties. The application of a well chosen cathodically protecting coating adds durable appearance and preservation of the functional properties of the components. The selection of the right coating is driven by multiple factors of which economic considerations will always rank within the highest priorities next to protection performance and the appearance of the coating. Aiming for the highest possible performance in cathodic corrosion protection coatings leads directly to zinc-nickel coatings. Zinc-nickel coatings are already state-of-the-art in the finishing of mild steel and carburized steel materials in the automotive industry, mostly being plated from alkaline plating solutions. The application of alkaline solutions to cast iron material is not feasible under industrial conditions at an acceptable reject rate due the electrochemical properties of the cast iron in these electrolytes. Therefore, as a workaround a two layer system with a first zinc layer from acidic electrolytes to cover the cast iron followed by zinc-nickel from an alkaline electrolyte was the often chosen alternative for this application. Those two layer systems are more expensive and bear multiple risks which hamper the reproducibility of the achieved corrosion protection performance. Alternatively, ammonium containing acidic electrolytes are applied directly to the cast iron material. Those electrolytes could not always be applied due to environmental and technical considerations. The newest generation of Atotech's acidic zinc-nickel electrolytes provides consistent deposition of zinc-nickel with homogenous nickel incorporation directly to the cast iron material while being free of ammonium and boric acid. With perfectly matched trivalent chromates and reactive inorganic sealers, a state-of-the-art high end system for cathodic corrosion protection and appearance is applied.
Dingwerth, Bjoern O.
Simulative Investigation of Wheel Brakes in Terms of the Anchor Load and Pad Movement2011-01-23839/18/2011
In the research project between the Institute of Automotive Engineering (FZD) of the Technische Universität Darmstadt (TUD) and Continental Teves AG & Co. oHG a new modeling concept has been developed. With the aim to enhance the current development process, the brake caliper is modeled based on coupled rigid bodies integrated into a nonlinear system model. Using an explicit interface definition, the number of degrees of freedom is minimized and the calculation of caliper performance is possible over a wide range of parameters. Compared to models based on the Finite Element Method (FEM), fully parameterized geometry from CAD is not necessary, thus the caliper can be optimized for a variation of its geometrical and physical parameters. With this modeling approach, typical performance criteria such as caliper fluid displacement, hysteresis, uneven pad wear and residual torque can be calculated in a virtual bench test. Additionally, the pull-push-characteristic and the tendency towards radial pad movement can be assessed. The results are generated before assigning the design parameters in CAD and are suitable to achieve frontloading in the development process. In this paper, the basic approach and the experimental validation regarding the force distribution between inner and outer pad and also the radial pad movement are described. For the validation a high-performance flywheel-dynamometer is used. The tangential load and the pull-push-characteristic are measured with strain gauges on the anchor arms. The inductive linear displacement sensors gauge the radial pad movement. The results show the development process of radial pad movement over time and the sensitivity of different parameter variations.
Haag, MathiasFan, JunliWinner, HermannUngethuem, UlrichSimon, Dirk
Measuring System Approach to Analyze Brake Squeal Triggering Mechanism2011-01-23599/18/2011
There are several different possibilities to analyze a squealing brake system. The present paper introduces a complex measuring system which is mounted on a complete vehicle axle at a test rig. This system was developed because the previously performed state-of-the-art tests did not allow any insights in the squeal triggering mechanisms. First of all, a frequency analysis was performed. Thereby the main vibrating parts and the directions of the oscillation could be determined during a squeal event. The second was a modal analysis of the vehicle axle, which was necessary to get further insights into the system as well as to verify an existing Finite Element Method model. Through these tests, however, it was not possible to get any insight into the contact area, and therefore it was impossible to determine the squeal triggering mechanism. Because of this limitation, special guide pins were developed, which are able to measure the vibrating friction force. Strain gauges allow this measurement through an optimized shape of the pins. The movement of the pads is measured by using eddy current sensors, hence with a non-contact measuring method. Triaxial accelerometers were installed inside the brake disk vents, at the brake caliper, the brake pads and other parts of the wheel suspension. Finally an incremental rotary encoder measures the rotary movement of the axle. In order to get clear and repeatable results, special prototype brake pads were developed, which are very noisy. The measurement system described above allows the detection of the main vibrating parts and to test different countermeasures as well as the effect of environmental influences, such as humidity and temperature. Thus, the measured variables are as closely as possible to the contact area of brake pad and brake disk. The aim is to develop a brake disk/pad contact model for the virtual design of less noisy brake systems.
Wallner, DanielBernsteiner, Stefan
Evaluation of AL 2 O 3 , Graphite and Sulphide Effects on MU Behavior in Different Humidity Environments Through Combined Mixture-Environmental DOE2011-01-23499/18/2011
The friction performance of a Disc Brake Pad is even more required to present stable mu behavior in various environmental conditions such as different temperature and humidity. Interaction between compositional variables (raw materials) and environmental conditions cannot be revealed by a simplistic approach without taking into account their mutual interactions. Thereby is necessary a "crossed" design able to combine mixture components with environmental factors. This paper reports the mu behavior of a commercial Brake Pad Formulation in two different environmental conditions (winter condition, e.g., low humidity, and summer condition, e.g., high humidity) through a Combined Design of Experiment. The design was defined by the variation of three mixture components (Al₂O₃, Graphite and Sulfides) of the Brake Pad Formula according to a Response Surface Method (RSM). The μ behavior has been evaluated on a full-scale dynamometric bench test (AK-Master) with climatic control. The DoE output reports the effect of 7 different compositions at 2 levels of humidity and temperature on the friction performance at different speed, pressure and temperature conditions. Moreover a Physical and Chemical characterization of the 7 different composition brake pads has also been reported.
Merlo, FabrizioPassarelli, UmbertoBuonfico, Pietro
On Tangential Friction Induced Vibrations in Brake Systems2008-01-258010/12/2008
The basis for the analysis of friction in brake systems is the brake pad's tribological interface. An investigation of this interface reveals friction intensive surface structures, so-called ‘patches’. Their development is determined by an equilibrium of flow, which depends on the loading of the brake pad and which allows extensive insights into friction dynamics, wear behavior and heat generation. All of these aspects are mostly influenced by the varying size of the patches over time. This paper deals with a detailed analysis of the lateral vibrational dynamics of these patches on a very fast timescale. This timescale is so small that processes of patch growth and destruction are negligible. Beyond that, the vibration frequencies of the patches, as well as the actual local friction power on each of these surface structures, vary over a wide range of values, which is the result of a great variety of patch sizes and heights in the interface. Generally, one would expect a smoothing of these local and stochastically distributed vibration effects. It can however be shown, that the oscillations of the patches are subject to synchronization processes, with the result being in-phase patch vibrations on macroscopic areas of the brake pad of significant size. Thereby, self-excited vibrations of the patches can lead to lateral oscillations of the pad's friction force on a macroscopic scale. These are able to excite the whole system of brake pad and disk.
Ostermeyer, G.-P.
Brake System and Subsystem Design Considerations for Race Track and High Energy Usage Based on Fade Limits2008-01-08174/14/2008
The friction material is arguably at the heart of any brake system, with its properties taking one of the most important roles in defining its performance characteristics. High performance applications, such as race track capable brake systems in high powered vehicles, exert considerable stress on the friction materials, in the form of very high heat flux loads, high clamp and brake torque loads, and high operating temperatures. It is important, for high performance applications, to select capable friction materials, and furthermore, it is important to understand fully what operating conditions the friction material will face in the considered application. Vehicle dynamic effects during testing on the race track and the resultant effect on braking traction available at each wheel can significantly influence the distribution of braking energy within the brake system, often driving individual rotor temperatures significantly higher than most simplified (non vehicle dynamic-dependent) models would predict. Brake force distribution, front vs. rear brake fade behavior, tire traction, and chassis controls behavior can significantly affect the front to rear braking energy distribution. Similarly, differing rotor cooling behavior in effects such as vehicle slip angle and front wheel steer angle will affect the distribution of cooling ability in the vehicle. Within a given brake corner, deflection of the brake caliper, rotor, and pads under braking clamp and torque loads and the resultant changes in pad to rotor pressure distributions can drive a substantial temperature gradient over the surface of the brake rotor. A temperature or heat-flux related issue on any single brake corner can significantly reduce overall brake system performance, in the form of pedal travel increase, fade, thermal roughness, and/or rotor cracking. A successful race-track oriented brake system design accounts for all of these effects and avoids these issues on even the most heavily loaded (from an energy standpoint) brake corner. This paper first covers a theory of brake fade behavior, which serves to set operating condition limits (a ‘fade envelope’) on the brake corners and therefore define the design space for the brake system. It will cover a proposed modeling approach involving brake system and brake corner models utilizing 1-D thermal models. In this approach, a 2-dimensional vehicle dynamics/brake system model is used to predict brake rotor bulk temperatures during race track usage. Next, selected braking events are focused on at the brake corner subsystem level to predict the temperature distribution in the friction interfaces, subject to the operating conditions and design parameters of the brake corner. The results of these analyses are then compared to the fade envelope of the friction material to insure that it is operating below its limits in the intended design. In future work, a full 3-dimensional, lumped parameter vehicle dynamics model will be used to give a more accurate prediction of brake rotor temperatures and temperatures distributions during race track operation.
Antanaitis, DavidMonsere, PatrickRiefe, Mark
Items per page:
1 – 50 of 104