Railway Disc Brake Pad Spacer Stack for Braking Noise Reduction
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Solution Overview
Problem
Disc brakes for medium/low-speed railway vehicles face challenges in reducing braking noise while maintaining braking efficiency and minimizing fine dust production, as solutions that reduce noise often compromise on these factors.
Innovation Solution
The pad for disc brakes features multiple spacers made of stacked metal plaques, such as brass or bronze, which are 0.1 to 1 mm thick, between the base plate and friction elements, providing effective noise reduction without compromising braking efficacy or increasing fine dust production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If multiple friction elements of smaller size are used instead of a single large friction element, then braking noise is reduced and braking efficiency is improved, but the structural complexity increases due to the need for multiple spacers and rivets
Solution Approach 1:
The spacer is divided into multiple metal plaques (2-7 plaques per spacer) stacked on top of each other, with each plaque having a fixing hole. This segmentation reduces the noise generated by the spacer during braking while maintaining the structural function of spacing and cooling the friction elements.
Solution Approach 2:
The spacer is constructed as a composite structure made of multiple metal plaques (such as brass or bronze) stacked together. This composite approach combines the advantages of multiple thin layers for noise reduction with the structural integrity needed for spacer function, resolving the contradiction between noise reduction and structural complexity.
2Temperature
If spacers with holes engaged by rivets are used to cool friction elements, then cooling efficiency is improved, but the number of parts and assembly complexity increases
Solution Approach 1:
The spacer is segmented into multiple metal plaques stacked together, where each plaque contributes to the cooling function through the holes that allow air flow. This segmentation provides effective cooling while the stacked structure reduces the overall number of separate spacer components needed.
Solution Approach 2:
The stacked metal plaques serve multiple functions simultaneously: they provide cooling through their holes, maintain the spacing between base plate and friction element, and their stacked configuration inherently dampens noise. This multi-functionality reduces the need for separate dedicated cooling components.
3Adaptability or versatility
If medium/low-speed trains make frequent stops to serve high population density areas, then accessibility is improved, but braking noise in the sensitive frequency range (1000-4000 Hz) increases
Solution Approach 1:
The spacer is divided into multiple thin metal plaques (0.1-1 mm each) stacked together. This segmentation creates a structure that effectively dampens noise in the sensitive frequency range (1000-4000 Hz) generated during frequent braking operations, while still allowing the train to make the necessary frequent stops for accessibility.
Solution Approach 2:
The use of composite spacer structure made of multiple metal plaques (such as brass or bronze) provides effective noise reduction in the frequency range most sensitive to human ear, enabling frequent stops in urban areas without excessive noise disturbance to residents.
Data Source
AI summary
A pad for disc brakes for railway vehicles includes a base plate, a plurality of friction elements fixed to the base plate, and a plurality of spacers, each of which is mounted between the base plate and a respective friction element. At least one fixing hole is obtained in each one of the spacers, which is engaged by a respective rivet to lock the friction element to the base plate. Each one of the spacers includes a plurality of metal plaques, each having a fixing hole obtained in the plaque. The metal plaques are stacked on top of one another so that the respective fixing holes coincide.