Friction Brake Cooling Layout for Low Residual Torque
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Solution Overview
Problem
Existing automotive friction brake systems face challenges in achieving sufficient cooling during braking while minimizing residual torque after braking.
Innovation Solution
The stator features a cooling zone that accommodates the rotor and a reserve zone, with the cooling zone automatically absorbing a greater volume of cooling medium during braking and releasing it to the reserve zone after braking, utilizing natural gravity and inertial fluid reactions for fluid circulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the cooling zone is filled with a large volume of cooling medium to ensure sufficient cooling during braking, then the cooling effect is improved, but the residual torque between rotor and stator increases after braking
Solution Approach 1:
The cooling zone volume is made dynamically adjustable through the movable partition wall that can shift position based on braking conditions. During braking, the partition moves to expand the cooling zone volume for enhanced cooling; after braking, it contracts to reduce cooling medium volume and minimize residual torque. This dynamic adaptation resolves the contradiction between cooling effectiveness and residual torque reduction.
Solution Approach 2:
The system prepares for the transition from braking to normal operation by using the movable partition wall to gradually reduce the cooling zone volume after braking. This preliminary action of reducing cooling medium volume before the vehicle resumes normal operation prevents excessive residual torque while ensuring adequate cooling during the braking period.
2Quantity of substance
If a pump is used to circulate the cooling medium between cooling zone and reserve zone, then the fluid distribution is improved, but the device complexity and energy consumption increase
Solution Approach 1:
The system uses the vehicle's own motion (acceleration and braking) to drive the circulation of cooling medium through inertial forces. During acceleration, the cooling medium is pushed from the cooling zone to the reserve zone; during braking, it returns to the cooling zone. This self-service mechanism eliminates the need for external pumps or power sources, reducing device complexity and energy consumption while maintaining effective cooling medium distribution.
Solution Approach 2:
The patent replaces the mechanical pump system with an inertial-based fluid circulation mechanism. Instead of using a motor-driven pump to move the cooling medium, the system exploits the inertial effects of vehicle acceleration and deceleration to naturally circulate the fluid between zones, thereby substituting a complex mechanical system with a simpler physics-based solution.
3Force
If the cooling zone volume is reduced to minimize residual torque, then the residual torque is reduced, but the cooling capacity during braking is insufficient
Solution Approach 1:
The movable partition wall enables dynamic adjustment of the cooling zone volume to match the thermal demands of different operating conditions. During braking, the partition expands the cooling zone to maximize cooling capacity; during normal operation, it contracts to minimize residual torque. This dynamic volume adjustment resolves the contradiction between cooling capacity and residual torque reduction.
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
This design effectively absorbs heat generated during braking and reduces residual torque by managing the cooling medium distribution efficiently, eliminating the need for pumps and reducing energy consumption.
Implementation Method 1
a cooling device having a liquid cooling medium for dissipating heat under frictional flow of force generated between the rotor and the stator
Implementation Method 2
permanent natural gravity in vertical direction and in the vehicular motion direction the motion directed component of inertial fluid reaction in a driven vehicle are implemented and exploited
Implementation Method 3
the motion directed component of inertial fluid reaction in a driven vehicle are implemented and exploited for free as the currentless natural driver
Implementation Method 4
heat that is generated by the frictional flow of brake force between the rotor and stator
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
An automotive friction brake system (3) for a motor vehicle (1) has a cooling zone (17) with a liquid cooling medium (16) for a fin pack (8) and a reserve zone (18) for storing the cooling medium (16) when the friction brake system is not used (3). The cooling zone (17) and the reserve zone (18) are arranged in the same housing (6) and separated from each other by an indentation (14). When the motor vehicle (1) brakes, the cooling medium (16) sloshes into the cooling zone (17) and cools the fin pack (8). When the motor vehicle (1) accelerates, the cooling medium (16) sloshes into the reserve zone (18) and reduces a residual torque on the fin pack (8).