Integrated Retarder and Service Brake Control
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Solution Overview
Problem
Large machines face challenges in braking efficiency, particularly with retarder systems that struggle to bring the machine to a complete stop and friction brake systems that can overheat with overuse, necessitating a more integrated and efficient braking solution.
Innovation Solution
A control system that integrates the retarder system with the service brake system, using a controller to operate both based on inputs from a brake pedal sensor and speed sensor, calculating and adjusting retarding power to prevent overheating, and providing operator indications to manage brake usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the friction brake system is used to stop the machine, then the machine can be brought to a complete stop, but the friction brake system can overheat and wear with overuse
Solution Approach 1:
The patent combines the retarder system and friction brake system into an integrated braking system that operates together. The controller coordinates both systems to share the braking workload, allowing the retarder to handle a portion of the braking demand and reduce thermal stress on the friction brakes while maintaining the ability to bring the machine to a complete stop.
Solution Approach 2:
The system activates the retarder in advance during braking operations to preemptively reduce the braking demand on the friction brake system. By having the retarder engage first and handle initial deceleration, the friction brakes experience reduced thermal loading before they are applied, preventing overheating and excessive wear.
2Productivity
If the retarder system is used to slow down the machine, then braking efficiency is improved, but the retarder system becomes ineffective at low machine speeds
Solution Approach 1:
The integrated braking system merges the operational strengths of both the retarder and friction brake systems. The retarder handles high-speed braking where it is most effective, while the friction brake system supplements at lower speeds to ensure the machine can be brought to a complete stop, maintaining reliable braking across the entire speed range.
Solution Approach 2:
The system dynamically adjusts the contribution of each braking system based on operating conditions. As machine speed decreases, the controller progressively reduces retarder engagement and increases friction brake application, ensuring optimal performance at all speeds while preventing any single system from being overloaded.
3Speed
If the friction brake system is overused to maintain ground speed with descending grades, then the machine can maintain speed control, but the friction brake system and associated oil overheat
Solution Approach 1:
During descents, the integrated system combines retarder and friction brake operations to share the continuous braking demand. The retarder handles the majority of the speed control burden on descending grades, significantly reducing the thermal load on the friction brake oil while maintaining precise ground speed control throughout the descent.
Solution Approach 2:
The controller activates the retarder in advance during descent scenarios to preemptively assume the speed control function. By having the retarder engage first and handle the primary braking demand during grade control, the friction brake system experiences minimal thermal stress, preventing oil overheating even during extended descent operations.
Data Source
AI summary
A machine includes: an axle having wheels mounted to it; a brake system configured to provide service braking to the wheels; a brake pedal operatively connected to the brake system to provide a braking power to the wheels in proportion to the position of the brake pedal; a pedal sensor operatively connected to the brake pedal to sense the position of the brake pedal; a retarder system configured to selectively slow the wheels down; a speed sensor operatively connected to the machine to detect a speed associated with the machine; a controller operatively connected to the speed sensor, brake pedal position sensor, and retarder system wherein the controller is configured to operate the retarder system based on signals received from the speed sensor and brake pedal position sensor. A method for providing an indication to an operator may also be included.