Friction Brake Thermal Modeling for Continuous Braking Power

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Solution Overview

Problem

Existing systems fail to accurately determine the continuous braking power of friction braking devices in vehicles, particularly in commercial vehicles, which is crucial for effective deceleration and energy management, especially when regenerative braking is limited.

Innovation Solution

A method to determine continuous braking power by calculating thermal emission per unit time based on ambient temperature and speed, using a physical model for heat transport, and integrating this with regenerative and friction braking power to manage energy and deceleration effectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of information

If a friction braking device is used without thermal emission calculation, then the braking system is simple and easy to operate, but the continuous braking power cannot be determined or predicted

Engineering Contradiction:

Improvecontinuous braking power informationVSAvoidbraking system complexity

Core Design Contradiction:

Loss of informationVSDevice complexity

Solution Approach 1:

The patent replaces direct mechanical measurement of braking power with a thermal emission calculation model. By substituting the mechanical measurement approach with a thermal physics-based calculation (using ambient temperature, speed, and thermal emission coefficients), the system obtains continuous braking power information without adding complex mechanical sensors to the braking device itself.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces thermal emission as an intermediary parameter to bridge the gap between observable quantities (ambient temperature, speed) and the desired information (continuous braking power). The thermal emission calculation acts as a mediator that translates easily measurable parameters into meaningful braking power data.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If thermal emission calculation is performed continuously, then continuous braking power can be determined, but energy consumption increases

Engineering Contradiction:

Improvecontinuous braking power determinationVSAvoidenergy consumption for calculation

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent uses a simplified thermal emission model that replicates the essential thermal behavior of the braking system without requiring complex real-time simulations. By creating a simplified computational copy of the thermal physics, the system achieves reliable braking power determination with minimal energy expenditure.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent changes the parameters used in thermal emission calculation from continuous high-precision measurements to coarser, less energy-intensive parameters (ambient temperature and speed). By adjusting the precision and frequency of parameter measurement, the system balances reliability with energy consumption.

Inventive Principle:

Principle #35Parameter changes

3Measurement precision

If detailed thermal emission model is used, then measurement precision of braking power improves, but device complexity increases

Engineering Contradiction:

Improvebraking power measurement precisionVSAvoidthermal model complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent extracts only the essential thermal emission parameters from the complete thermal physics model, separating the critical factors (ambient temperature, speed, basic thermal coefficients) from less important details. This extraction maintains measurement precision for braking power while avoiding the complexity of a full thermal model.

Inventive Principle:

Principle #2Taking out (Extraction)

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

Enables reliable determination of continuous braking power, optimizing energy management and deceleration control, preventing overheating and wear, and ensuring safe operation during long-term deceleration.

Implementation Method 1

a friction braking device, a continuous braking device (retarder) and/or an electric traction drive (eDrive) set up for regenerative braking

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

using a physical model for heat transport that considers convection, radiation, and conduction

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

using a physical model for heat transport that considers convection, radiation, and conduction

Methodology Applied

Scientific EffectThermal Radiation: Thermal Radiation

Implementation Method 4

using a physical model for heat transport that considers convection, radiation, and conduction

Methodology Applied

Scientific EffectConduction (thermal): Conduction (thermal)

Data Source

PatentUS12612026B2Method for ascertaining a continuous braking power, computer program and/or computer-readable medium, controller and vehicle, in particular commercial vehicle

Publication Date: 2026.04.28 ZF CV SYST GLOBAL GMBH

AI summary

A method for determining a continuous braking power for a vehicle, in particular a commercial vehicle, the method having the steps: determining an ambient temperature; determining a speed, wherein the speed is representative of the speed of the vehicle, in particular the commercial vehicle; determining a thermal emission per unit time of a friction braking device on the basis of the ambient temperature and the speed; and determining the continuous braking power of the friction braking device on the basis of the thermal emission per unit time.