Brake Caliper Rattle Noise Reduction via Active Oil Pressure Control
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Solution Overview
Problem
Conventional methods for reducing rattle noise in brake calipers, such as using additional components like boots, bushes, and clips, increase costs and can deteriorate the operation and durability of the caliper device, while also being inefficient in managing clearance gaps.
Innovation Solution
A control system that utilizes a wheel speed sensor to detect road surface unevenness and a controller to intermittently apply minimum oil pressure to the brake cylinder, preventing rattle noise without additional components, by converting wheel speed signals into acceleration signals and analyzing them for power spectral density values to determine the need for noise reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If additional components like boots, bushes, and clips are used to reduce rattle noise, then noise reduction is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent replaces mechanical noise reduction components (boots, bushes, clips) with a control system that uses sensors and actuators to actively manage clearances. The control system detects clearance conditions and applies forces to maintain optimal gaps, substituting passive mechanical elements with an active control mechanism that reduces overall device complexity while effectively reducing rattle noise.
Solution Approach 2:
The patent dynamically adjusts the clearance parameter between caliper components by applying controlled forces through the actuator. By changing the clearance parameter from a fixed mechanical gap to a dynamically adjustable value, the system eliminates rattle noise without adding permanent structural components, thereby reducing device complexity.
2Object-affected harmful factors
If additional components like boots, bushes, and clips are used to reduce rattle noise, then noise reduction is achieved, but manufacturing cost increases
Solution Approach 1:
The patent substitutes multiple discrete mechanical noise reduction components with a single integrated control system comprising a sensor and actuator. This substitution reduces the number of parts that need to be manufactured, assembled, and quality-checked, thereby lowering manufacturing cost while maintaining effective noise reduction.
Solution Approach 2:
The control system performs multiple functions: it detects clearance conditions, determines when noise is likely to occur, and applies corrective forces. This multi-functionality replaces what would otherwise require separate mechanical components for each function, reducing overall manufacturing cost.
3Object-affected harmful factors
If additional components like boots, bushes, and clips are used to reduce rattle noise, then noise reduction is achieved, but operation and durability are deteriorated
Solution Approach 1:
The patent replaces mechanical components (boots, bushes, clips) that can wear, deform, or fail with an electronic control system. The sensor and actuator have no moving parts subject to mechanical wear, significantly improving reliability and durability while maintaining the ability to reduce rattle noise.
Solution Approach 2:
The control system dynamically adjusts clearance based on real-time conditions, allowing the system to adapt to varying operational demands. This dynamic adjustment prevents the fixed-clearance mechanical components from being subjected to excessive or inappropriate forces, thereby improving overall system reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Effectively reduces vibration and noise generated by clearances in the caliper device through software-controlled oil pressure application, maintaining braking power and fuel efficiency without additional hardware costs or operational degradation.
Implementation Method 1
a wheel speed sensor configured to detect a wheel speed of each wheel
Implementation Method 2
processing and analyzing a wheel speed signal received from the wheel speed sensor, and, when the road surface state of the road is determined as a road surface state in which unevenness exists from the determined vibration level value
Implementation Method 3
a braking driver configured to generate and supply the oil pressure for preventing rattle noise according to the control signal output from the controller
Implementation Method 4
the disk brake having the degradation of braking power due to heat dissipation and thermal distortion
Data Source
AI summary
A control system for reducing rattle noise of a brake caliper may include a wheel speed sensor configured to detect a wheel speed of each wheel to which a caliper device is mounted, a controller configured to determine a vibration level value according to a road surface state by processing and analyzing a wheel speed signal received from the wheel speed sensor, and, when the road surface state of the road is determined as one in which unevenness exists, output a control signal for applying oil pressure for preventing rattle noise to a wheel cylinder of a brake device, a braking driver configured to generate and supply the oil pressure for preventing rattle noise according to the control signal output from the controller, and the wheel cylinder of the brake device, to which the oil pressure for preventing rattle noise, which is supplied by the braking driver, is applied.