Pneumatic Brake Disc Bedding Apparatus
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Solution Overview
Problem
The existing methods for bedding carbon composite brake discs are expensive, inconvenient, and energy-intensive, often requiring the use of completed vehicles and test tracks, which can be costly and environmentally harmful.
Innovation Solution
A method and apparatus using pneumatic pressure to frictionally engage brake pads with carbon composite brake discs, allowing for bedding without hydraulic fluid, thus eliminating the need for extensive cleaning and enabling a more controlled, efficient, and cost-effective process in a stable environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If hydraulic fluid is used to operate the calliper during bedding, then the brake pad can be frictionally engaged onto the brake disc, but the calliper requires extensive cleaning to avoid fluid interference with vacuum fill during vehicle assembly
Solution Approach 1:
The patent replaces hydraulic fluid operation with pneumatic (air pressure) operation of the calliper. Air pressure is applied to the calliper piston to frictionally engage the brake pad onto the rotating brake disc, eliminating the use of hydraulic fluid entirely. This resolves the contradiction by maintaining operational capability while eliminating the cleaning requirement associated with hydraulic fluid.
2Reliability
If completed vehicles are used for brake bedding, then the brake disc can be bedded through repeated deceleration, but the procedure becomes expensive and inconvenient requiring test tracks
Solution Approach 1:
The patent separates the brake disc bedding process from the complete vehicle system. The brake disc is bedded independently using a dedicated apparatus with a motor-driven rotation system and pneumatic calliper operation, rather than requiring a complete vehicle on a test track. This segmentation maintains bedding effectiveness while dramatically reducing cost and inconvenience.
Solution Approach 2:
The patent creates a simplified copy of the vehicle braking system specifically for the bedding process. The apparatus includes a motor-driven rotation system that simulates wheel rotation, a pneumatic calliper that replicates brake application, and a support structure that holds the brake disc assembly. This copying approach enables effective bedding without requiring actual vehicles and test tracks.
3Temperature
If traditional brake bedding methods are used, then the brake disc achieves the required temperature for chemical changes, but a considerable amount of energy is consumed
Solution Approach 1:
The patent employs continuous rotation of the brake disc driven by a motor, with continuous application of air pressure to the calliper piston. This creates sustained friction between the brake pad and disc surface, maintaining the required temperature for chemical changes in the carbon composite material without the energy waste associated with repeated heating and cooling cycles of traditional methods.
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 results in a higher quality bedded disc with reduced environmental impact, lower energy consumption, and cost savings by eliminating the need for test tracks and minimizing fluid usage, while ensuring a repeatable and safe bedding process.
Implementation Method 1
applying air under pneumatic pressure into the calliper/brake pad assembly to frictionally engage the brake pad onto the brake disc
Implementation Method 2
the temperature caused in the brakes enabling chemical changes in the carbon structure of the brake discs making them substantially harder
Data Source
Figure 1
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Figure 5
AI summary
A wheel carrier assembly for a vehicle is clamped on a frame (14) and a carbon composite brake disc (41) of the assembly is bedded by pneumatically applying the brake pads (46, 48) to the brake disc so as to heat the disc in cycles, the wheel carrier assembly then being removed from the frame and fitted to the vehicle.