Brake Cooling Fluid Diverter for Off-Highway Machines
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Solution Overview
Problem
Existing brake cooling systems for machines, particularly those with electric drive systems, fail to effectively manage brake cooling based on actual or expected use, leading to overheating and excessive wear in heavy-loaded or high-speed conditions.
Innovation Solution
A brake cooling system that includes a controller to divert cooling fluid flow dynamically between friction brake systems based on their activation and usage, ensuring optimal cooling distribution to prevent overheating and extend brake component life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brake cooling fluid is circulated to all brake assemblies equally, then all brakes receive cooling, but cooling efficiency is reduced when only certain brakes are in use
Solution Approach 1:
The brake cooling system employs a diverter valve that dynamically redirects cooling fluid flow based on real-time brake usage conditions. The controller receives signals from brake sensors and adjusts the diverter valve position to allocate cooling fluid preferentially to active brake assemblies, transforming the static equal distribution system into a dynamic adaptive system that optimizes cooling efficiency according to actual operational needs
Solution Approach 2:
The system applies different cooling fluid flow rates to different brake assemblies based on their individual usage conditions. By using sensors to detect which brakes are actively engaged and the diverter valve to route fluid accordingly, the system ensures that only the brake assemblies requiring cooling receive adequate fluid flow, rather than distributing cooling resources uniformly across all brakes
2Force
If service brakes are used for continuous retarding in heavily loaded machines, then braking force is maintained, but brake overheating and excessive wear occur
Solution Approach 1:
The brake cooling system incorporates sensors that continuously monitor brake usage conditions and temperature, feeding this information back to the controller. The controller processes these signals and adjusts the diverter valve to increase cooling fluid flow to brake assemblies that are actively engaged in retarding operations, creating a closed-loop feedback system that prevents overheating by responding to actual brake conditions in real-time
Solution Approach 2:
The system proactively directs cooling fluid to brake assemblies before they reach critical temperatures by detecting early signs of brake engagement and usage patterns. By anticipating heating based on brake activation signals and usage conditions, the system applies cooling fluid in advance to prevent overheating and excessive wear before they occur
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 effectively manages brake cooling by varying fluid flow according to the usage of front and rear friction brake systems, reducing overheating and wear, and improving the overall braking performance in heavy-loaded or high-speed conditions.
Implementation Method 1
Brake cooling fluid is circulated through the brake cooling system to the first friction brake system and to the second friction brake system
Data Source
AI summary
The disclosure relates, in one aspect, to a friction brake cooling system for a machine. The cooling system includes at least one pump connected to at least one reservoir containing cooling fluid. A controller is configured to divert a cooling fluid flow through a valve to a first friction brake system and to a second friction brake system based on the use of the systems. In another aspect, the disclosure relates to a method of cooling a first friction brake system and a second friction brake system including diverting a flow of brake cooling fluid to the systems based on the use of the systems.