Adaptive Brake Power Derating via Temperature Feedback
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Solution Overview
Problem
Current brake power derating methods during downhill travel are overly conservative, especially for lighter machines, leading to inefficient speed control and potential brake damage due to excessive heat generation.
Innovation Solution
A braking system that determines a power limit for the brakes based on their temperature during engagement, allowing for a speed adjustment to maintain a commanded speed while preventing excessive heat buildup, thereby reducing wear and improving brake longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If brake power is derated based on estimated weight and measured slope, then brake temperature is reduced, but speed control precision deteriorates and brake longevity is compromised due to overly conservative derating
Solution Approach 1:
The system implements feedback by continuously monitoring actual brake temperature and using it to adjust power derating in real-time. The controller receives temperature data from sensors, compares it against threshold values, and dynamically modifies brake power limits accordingly. This closed-loop feedback mechanism replaces static estimated-based derating with adaptive temperature-based control, optimizing both temperature management and speed control precision.
Solution Approach 2:
The system changes the parameter basis for power derating from estimated weight and slope to actual measured brake temperature. By shifting the control parameter from predictive estimates to direct temperature measurements, the system achieves more accurate and adaptive power limiting that responds to actual thermal conditions rather than conservative predictions.
2Reliability
If brake power is limited to reduce heat generation, then brake damage is prevented, but speed control efficiency deteriorates due to overly conservative derating
Solution Approach 1:
The controller continuously monitors brake temperature and adjusts power derating dynamically based on actual thermal conditions. When temperature is within safe ranges, the system allows higher brake power for efficient speed control. When temperature approaches thresholds, the system reduces power to prevent damage. This feedback-driven adaptive control optimizes both reliability and efficiency.
Solution Approach 2:
The system transitions from static power derating based on fixed estimates to dynamic power adjustment based on real-time temperature measurements. The power limit varies continuously with thermal conditions, allowing maximum efficiency when cool and sufficient protection when hot, rather than applying constant conservative limits.
3Temperature
If brake power is derated for lighter machines, then heat generation is reduced, but excessive derating occurs leading to inefficient operation
Solution Approach 1:
The system uses actual temperature feedback from sensors on each brake assembly to determine appropriate power limits. Lighter machines that generate less heat will naturally operate at lower temperatures, allowing the feedback system to permit higher power derating limits compared to heavier machines. This eliminates the need for conservative one-size-fits-all derating and optimizes efficiency for each specific operating condition.
Solution Approach 2:
The system applies differentiated power derating strategies tailored to local conditions of each brake assembly. Each brake's temperature is monitored independently, and power limits are adjusted based on individual thermal states rather than applying uniform conservative limits across all brakes regardless of their actual conditions or the machine's weight class.
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 minimizes brake power derating, reduces wear on the brakes, and extends their useful life by accurately managing brake temperature and power usage during downhill travel.
Implementation Method 1
The braking torque generated by the friction brakes may be dissipated in the form of heat
Data Source
AI summary
A braking system is disclosed. The braking system may include a controller configured to determine a power limit for one or more brakes of a machine based on a temperature of the one or more brakes during engagement of the one or more brakes according to a commanded power. The power limit may be a power at which the temperature of the one or more brakes ceases to increase. The controller may be configured to determine a speed adjustment for the machine based on the power limit and the commanded power, and cause adjustment to a speed of the machine based on the determined speed adjustment.