Heated Brake Disc Circuit Layout for Ice-Free Braking
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Solution Overview
Problem
Brake systems in vehicles face performance issues in low-temperature and high-humidity environments due to condensation or icing on brake discs, leading to slip and potential rust, and excessive noise from friction.
Innovation Solution
A brake system with embedded electric circuits in the brake disc, wheel hub, and bearing assembly that generates heat to evaporate water and prevent icing, using resistance wires and conductive paths to maintain functionality and ease of assembly, while an electronic control unit manages heating based on temperature sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a brake disc is made of metal material, then the brake system can provide sufficient braking force, but condensed water or ice forms on the brake disc in low-temperature and high-humidity environments, causing slip and reduced brake performance
Solution Approach 1:
The heating element embedded in the brake disc performs preliminary heating action before braking occurs in cold conditions. The control unit activates the heating element when temperature sensors detect low temperatures, preemptively preventing ice formation on the brake disc surface, thereby ensuring reliable brake performance from the start of vehicle operation
Solution Approach 2:
The patent converts the harmful effect of electrical resistance (which generates heat and could cause noise) into a beneficial function by using the heating element to prevent ice formation. The electrical resistance that would otherwise be a source of noise is utilized to generate heat that melts condensation and prevents icing, turning a potential harm into a benefit for brake performance
2Reliability
If heating elements are embedded in the brake disc to prevent icing, then brake performance is improved in cold conditions, but the device complexity increases
Solution Approach 1:
The heating element is merged with the brake disc structure itself, embedding it within the disc rather than adding separate external heating components. The control unit and temperature sensors are integrated into the existing brake system architecture, combining multiple functions (heating, sensing, control) into a unified system that minimizes additional complexity while ensuring reliable brake performance
3Reliability
If electrical circuits are embedded in the brake disc and wheel hub, then the heating function is achieved, but the assembly process becomes more difficult
Solution Approach 1:
The electrical circuit is segmented into modular components: temperature sensors positioned on the brake disc, heating elements embedded in the disc, and a control unit separate from the mechanical assembly. This segmentation allows each component to be installed independently, with the heating element and sensors integrated during brake disc manufacturing, and the control unit added separately, thereby maintaining ease of assembly while achieving full heating functionality
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
The system effectively keeps the brake disc dry and functional in adverse conditions, ensuring reliable braking performance without hindering assembly or causing noise, and adapts to movement within the bearing assembly.
Implementation Method 1
when an electric current flows to the first electric circuit through the second and third electric circuits, the first electric circuit generates heat for applying to the brake disc
Implementation Method 2
the heat generated by the first electric circuit can melt the condensed water or the thin layer of ice on the brake disc
Data Source
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AI summary
The present application relates to a brake system comprising a brake disc, a wheel hub connected to the brake disc, and a bearing assembly mounted around the wheel hub, the brake system further comprising: a first electric circuit embedded inside the brake disc; a second electric circuit embedded inside the wheel hub and electrically connected with the first electric circuit; and a third electric circuit embedded inside the bearing assembly and electrically connected with the second electric circuit, wherein when an electric current flows to the first electric circuit through the second and third electric circuits, the first electric circuit generates heat for applying to the brake disc.