Brake Component Molding Control for Vibration and Squeal Conformity
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Solution Overview
Problem
Current methods for monitoring the acoustic conformity of brake components during manufacturing are inefficient, requiring numerous sensors and extensive time to identify and correct geometric anomalies causing vibrations and squealing noises, which can lead to non-conforming brake production.
Innovation Solution
A method involving simulations and sensitivity analysis to identify relevant geometric dimensions affecting natural frequencies, using a limited number of vibration sensors and a three-dimensional scanner to measure and correct mold wear, allowing for rapid detection and rectification of anomalies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a large number of sensors are used to precisely locate geometric anomalies, then measurement precision is improved, but loss of time increases due to significant time spent acquiring and interpreting data
Solution Approach 1:
The patent extracts only the critical geometric dimensions that have the greatest impact on natural frequencies, rather than measuring all geometric parameters. By identifying and focusing on these key dimensions through sensitivity analysis, the method achieves adequate detection precision with significantly fewer measurements, thereby reducing the time required for data acquisition and interpretation.
Solution Approach 2:
The patent performs preliminary sensitivity analysis to identify which geometric dimensions most strongly influence natural frequencies before actual measurement. This preliminary action allows the quality control process to focus only on these critical dimensions during production, avoiding the time-consuming measurement of less influential parameters while maintaining detection effectiveness.
2Measurement precision
If numerous sensors and extensive testing are used to identify geometric anomalies, then detection accuracy is improved, but device complexity increases
Solution Approach 1:
The patent extracts and focuses only on the critical geometric dimensions that most significantly affect natural frequencies. By identifying these key dimensions through sensitivity analysis and measuring only them, the system achieves adequate anomaly detection accuracy without requiring a complex array of sensors and measurement devices.
Solution Approach 2:
The patent applies partial action by measuring only the critical geometric dimensions that have the greatest impact on frequency, rather than performing exhaustive measurements of all geometric parameters. This selective approach maintains detection accuracy for the most important anomalies while significantly simplifying the measurement system.
3Reliability
If continuous production monitoring with multiple sensors is implemented, then reliability of quality control is improved, but productivity decreases due to slow anomaly identification and correction
Solution Approach 1:
The patent performs preliminary sensitivity analysis to identify critical geometric dimensions before production monitoring begins. During continuous production, only these pre-identified critical dimensions are measured, enabling rapid anomaly detection and correction without interrupting the production flow, thus maintaining both reliability and productivity.
Solution Approach 2:
The patent extracts and monitors only the critical geometric dimensions that most affect natural frequencies during continuous production. This focused monitoring approach maintains quality control reliability by detecting the most significant anomalies while minimizing measurement time, allowing continuous production to proceed at high speed.
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 approach significantly reduces component conformity control time, enables quick identification and correction of mold defects, and prevents non-conforming brake production, ensuring improved safety and user comfort by minimizing unwanted vibrations and squealing noises.
Implementation Method 1
the measurement of said at least one relevant dimension is carried out with a three-dimensional scanner
Implementation Method 2
the vibration sensors are accelerometers
Data Source
Figure 1
AI summary
Method for monitoring and correcting the manufacturing process by molding of a brake component for a motor vehicle, comprising a component conformity control step that can be performed by a production line operator having at his disposal either geometric measuring instruments, or a limited number of vibration sensors and a computer for data acquisition and visualization.