Thermal Issues in Braking Understanding the Problem Designing brake systems to cope Pad-Disc...
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Thermal Issues in Braking • Understanding the Problem • Designing brake systems to cope • Pad-Disc Interface • Friction Materials • Brake Fluids • Brake cooling • Retarders
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Transcript of Thermal Issues in Braking Understanding the Problem Designing brake systems to cope Pad-Disc...
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Thermal Issues in BrakingUnderstanding the ProblemDesigning brake systems to copePad-Disc InterfaceFriction MaterialsBrake FluidsBrake coolingRetarders
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Braking Duty -Main ConcernsDUTY CONCERNCity running (250-350C) Lining and rotor wearAlpine Descent (600-700C)Fade, wear, vaporisation, pedal travelAutobahn Stops Disc cracking, hot judderFade test (e.g. AMS ) Fade, pedal travel
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City DrivingCritical effect of temperature on brake wearFront Spoiler can severely reduce pad lifeSignificant effect on service intervals and cost of ownership
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Alpine Descent TemperaturesGrossglockner Industry Standard10 miles 10 % gradient600-700C Discs150-200C Fluid
SoakDrivingFrontRearFront Fluid
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LF
RF
RR
LR
LF Fluid
RF Fluid
Time (mins)
Alpine Temperatures (C)
Sheet1
25.20
25.2800
Sheet1
3736.52825.52018.50
4039.529.5262018.50
45.54532282019
53.55336.531.52019
64.562.541362018.5
75.572444019.518.5
87.582.54843.52018.5
99.593.550.5472018.5
1121045450.520.519.5
123.5114.55753.520.519.5
136125.56057.520.519.5
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261.5251109.51102020
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129.516694.594.5133.5166
1291659594.5133.5165.5
LF
RF
RR
LR
LF Fluid
RF Fluid
Time (mins)
Alpine Temperatures (C)
Sheet2
Sheet3
-
Autobahn StopsUp to 300 kw initial heat input600-700C DifferentialDisc crackingHot judder (Blue spotting)
-
Fade e.g. AMS Stopping distances0102030405060708075 Spider 2.0 V6Spider 2.0 TSA4 1.8A4 2.8 (veh 2)A6 2.6A8 4.2318ti COMPACT320i328i (veh 1)523i (E39)535i (E39)728iAlpina B8 4.6M3VOYAGER 2.4SEVOYAGER 3.3SEZX Break 1.9 TDESPERO 1.8NEXIA 1.5 GLCuore GLXDistance (m)COLD HOT 40 m
-
Minimising the thermal input- Designing brake systems to cope
Avoid excessive duty on any brakeOptimising brake distribution
-
Braking DistributionCommercial VehiclesPredominance and load sensing valves Coupling force control to spread duty levels with advent of brake by wireCars and light CommercialsFront brakes have high dutyNeed to maximise rear braking duty
-
High Rear ThresholdsRearFront FluidFrontHigh rear thresholds (e.g. arising from integral PCRV in RWC)- resulting in excessive front duty Large differential between Front and rear axles
Chart1
37.535.52726.535.532.52726.5
3835.52726.535.532.52726.5
38.5362827.535.532.52726.5
43.53929283532.52726.5
53.54830.529.53532.52726.5
595631.529.53532.52726.5
67.565.532.5303532.52726.5
807634.531.53532.52726.5
92893732.53532.52726.5
10410038.53334.53226.526
117.51154134.5353226.526.5
128.5126.542.53534.53226.526
1401394437353226.526.5
151.5150.54638.534.53226.526.5
162160484034.53226.526.5
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&A
Page &P
LHF Disc
RHF Disc
LHR Drum
RHR Drum
LHF Fluid
RHF Fluid
LHR Fluid
RHF Fluid
Time (mins:secs)
Temperature (C)
Chart2
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&A
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Time (mins:secs)
Temperature (C)
Chart3
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563.5
