Brake Control System Managing Pad Position to Reduce Drag
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Solution Overview
Problem
Brake systems experience undesired braking force due to drag between brake pads and rotors, especially with carbon fiber discs, leading to increased CO2 emissions, fuel consumption, and reduced efficiency, as well as issues like 'Pad Knockback' in high-performance vehicles, where brake pads are retracted further than desired, causing delayed brake application.
Innovation Solution
A brake control system that includes a master cylinder, brake line, and fluid reservoir, allowing selective movement of brake fluid during non-braking conditions to adjust the position of the brake pad, reducing drag and addressing knockback by moving fluid into or out of the reservoir to retract or extend the brake pad, thereby minimizing the distance between the pad and rotor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If brake pads are positioned in close proximity to brake rotor to reduce activation time, then brake response time is improved, but brake drag increases due to seal compression preventing piston release
Solution Approach 1:
The patent extracts the brake pad from its fixed position near the rotor by introducing a retractable mechanism. The brake pad is pulled away from the rotor using a spring-loaded or motor-driven retraction system, allowing it to be positioned close to the rotor for quick activation while being pulled back to eliminate drag when not in use.
Solution Approach 2:
The brake pad positioning is transformed from static to dynamic. The system continuously adjusts the brake pad position between two states: close to the rotor for rapid activation and retracted to eliminate drag. This dynamic positioning resolves the contradiction between needing proximity for fast response and needing separation to reduce energy loss.
2Speed
If brake pads are held in light contact with brake rotor to minimize activation distance, then brake response is improved, but heat generation and glazing increase
Solution Approach 1:
Instead of continuous light contact, the system uses periodic or intermittent contact. The brake pad is rapidly deployed to contact the rotor only when braking is required, then quickly retracted. This periodic action maintains fast response capability while minimizing the duration of heat-generating contact, thereby reducing overall temperature and glazing.
Solution Approach 2:
The system performs preliminary retraction of the brake pad away from the rotor during non-braking periods. This preliminary action prevents heat accumulation and glazing by ensuring the pad is not in contact with the rotor when braking is not required, while still enabling rapid deployment when needed.
3Force
If high brake pedal force is applied to overcome drag, then braking effectiveness is improved, but fuel consumption increases
Solution Approach 1:
The invention extracts the source of drag by removing the brake pad from continuous contact with the rotor. By pulling the pad away using a retraction mechanism, the system eliminates the parasitic drag force that would otherwise require additional braking force to overcome, thereby reducing the energy needed for vehicle operation.
Solution Approach 2:
The system converts the potential harm of drag into a benefit by using the same hydraulic system that applies braking force to also drive the retraction mechanism. The drag force, when present during braking, can be used to help retract the pad after braking, turning a harmful force into a useful function that reduces overall energy consumption.
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
The system reduces brake drag, improves brake efficiency, and prevents 'Pad Knockback' by actively managing the position of the brake pad, ensuring quicker brake application and reduced fuel consumption without affecting existing safety features.
Implementation Method 1
a master cylinder, a brake line for communicating brake fluid between the master cylinder and a brake, a fluid reservoir in fluid communication with the brake line during non-braking conditions, and means for selectively moving brake fluid into and/or out of the fluid reservoir during non-braking conditions
Implementation Method 2
When the brake is activated, the brake pad is pressed firmly against the brake disc, and friction between the static brake pad and rotating rotor causes the speed of rotation of the rotor, and therefore the speed of rotation of the wheel, to slow
Data Source
AI summary
A brake control system for a vehicle, the brake control system including a master cylinder, a brake line for communicating brake fluid between the master cylinder and a brake, a fluid reservoir in fluid communication with the brake line during non-braking conditions, and means for selectively moving brake fluid into and/or out of the fluid reservoir. The means for selectively moving brake fluid into and/or out of the fluid reservoir includes means for removing gas from the fluid reservoir, and is configured to move brake fluid into the fluid reservoir, so that brake fluid is moved along the brake line in a direction towards the master cylinder, during non-braking conditions. Upon receiving a signal of an anticipated brake event, brake fluid may also be moved out of the fluid reservoir, so that brake fluid is moved along the brake line in a direction away from the master cylinder.