Brake Running Clearance Adjustment for Faster Response
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Solution Overview
Problem
Existing brake designs face challenges in maintaining an optimal running clearance that balances minimizing brake drag, ensuring quick brake application, and avoiding delays due to thermal expansion of brake components during braking events, particularly at high speeds or steep descents.
Innovation Solution
A method and system that adjusts the running clearance based on temperature, wear, and likelihood of a braking event using a sensor system and an electrically operated adjuster, allowing for dynamic adjustment of the clearance to optimize brake performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the running clearance is made large to prevent brake drag and accommodate thermal expansion, then brake drag is reduced and fuel consumption decreases, but the time delay between brake application and force application increases
Solution Approach 1:
The patent implements dynamic adjustment of running clearance based on real-time temperature sensing and braking event prediction. The adjuster mechanism continuously modifies the clearance between friction material and rotor according to thermal conditions, transforming the static clearance into a dynamic parameter that adapts to operating conditions, thereby resolving the contradiction between minimizing brake drag and reducing time delay.
Solution Approach 2:
The system changes the physical parameter of running clearance based on temperature and braking likelihood. By sensing temperature and predicting braking events, the system adjusts clearance parameters dynamically - reducing clearance when braking is anticipated and increasing it during normal operation, thus optimizing both energy efficiency and response time.
2Loss of time
If the running clearance is made small to reduce time delay, then brake responsiveness improves, but brake drag increases and fuel consumption rises
Solution Approach 1:
The patent implements dynamic adjustment of running clearance based on real-time temperature sensing and braking event prediction. The adjuster mechanism continuously modifies the clearance between friction material and rotor according to thermal conditions, transforming the static clearance into a dynamic parameter that adapts to operating conditions, thereby resolving the contradiction between minimizing brake drag and reducing time delay.
Solution Approach 2:
The system changes the physical parameter of running clearance based on temperature and braking likelihood. By sensing temperature and predicting braking events, the system adjusts clearance parameters dynamically - reducing clearance when braking is anticipated and increasing it during normal operation, thus optimizing both energy efficiency and response time.
3Reliability
If the running clearance is made large to accommodate thermal expansion, then the brake can continue operating after hot braking, but brake drag increases during normal operation
Solution Approach 1:
The patent implements dynamic adjustment of running clearance based on real-time temperature sensing and braking event prediction. The adjuster mechanism continuously modifies the clearance between friction material and rotor according to thermal conditions, transforming the static clearance into a dynamic parameter that adapts to operating conditions, thereby resolving the contradiction between minimizing brake drag and reducing time delay.
Solution Approach 2:
The system performs preliminary action by predicting braking events using sensor data (camera, radar, LIDAR, GPS) and proactively adjusting the running clearance before actual braking occurs. This anticipatory adjustment ensures optimal clearance is established in advance, preventing brake drag during normal operation while preparing for imminent braking events that require quick response.
4Device complexity
If a fixed running clearance is used, then the brake structure is simple, but the brake cannot adapt to varying thermal conditions and braking requirements
Solution Approach 1:
The patent implements dynamic adjustment of running clearance based on real-time temperature sensing and braking event prediction. The adjuster mechanism continuously modifies the clearance between friction material and rotor according to thermal conditions, transforming the static clearance into a dynamic parameter that adapts to operating conditions, thereby resolving the contradiction between minimizing brake drag and reducing time delay.
Solution Approach 2:
The system employs feedback mechanisms through temperature sensors and prediction systems that continuously monitor brake conditions and adjust running clearance accordingly. The sensor system provides feedback on temperature and predicted braking events, creating a closed-loop control system that automatically optimizes clearance without requiring complex manual intervention or overly complicated mechanical structures.
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
Enhances brake responsiveness by reducing delays and brake drag, improving fuel efficiency, and ensuring safe and efficient vehicle operation under varying conditions.
Implementation Method 1
This heat energy causes various brake components to heat up and therefore expand. In particular, where the brake is a disc brake, the brake disc and the friction material of the brake pads will expand.
Data Source
Figure 1
AI summary
A method of adjusting a brake, the method including the steps of: providing a mechanically operated brake including friction material, providing a rotor, providing an adjuster for adjusting a running clearance between the friction material and the rotor, providing a sensor system for determining a likelihood of a braking event, and upon a determination of a change in the likelihood of a braking event operating the adjuster to adjust the running clearance of the brake.