Axially Retracting Brake Disc Layout for Faster Locking
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Solution Overview
Problem
Existing braking systems suffer from overheating, uneven wear, and residual friction, leading to increased braking time and reduced efficiency, particularly in electric and hybrid vehicles, where energy efficiency and active safety are critical.
Innovation Solution
A brake device with a retraction system that minimizes the distance between brake discs and lining discs, allowing them to rotate without residual friction, using a guiding support, movable pusher elements, and a drive system to adjust the separation distance, reducing wear and overheating through fluid cooling and ventilation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If brake pads are moved axially towards the brake disc to make contact for braking, then braking force is generated, but the separation distance increases and residual friction occurs during rotation
Solution Approach 1:
The brake disc is designed to be movable in the axial direction rather than fixed. During braking, the disc moves axially towards the stationary brake pads to generate contact force. During rotation, the disc retracts axially to minimize separation distance and eliminate residual friction. This dynamic positioning resolves the contradiction by adapting the disc position to the operational state.
Solution Approach 2:
The brake disc is pre-positioned at a minimum separation distance from the brake pads during rotation, before braking is initiated. This preliminary positioning ensures that when braking starts, the disc is already as close as possible to the pads, minimizing the Time to Lock (TTL) while maintaining residual friction-free rotation during non-braking states.
2Force
If brake disc and pads are in constant contact for braking, then braking force is available, but overheating occurs due to friction heat
Solution Approach 1:
The brake disc alternates between two states: during rotation, it maintains a minimal separation from the brake pads to prevent continuous friction and heat generation; during braking, it moves into contact to generate braking force. This periodic switching between contact and separation states allows braking functionality while preventing continuous overheating.
Solution Approach 2:
The brake disc is extracted from the traditional fixed position and made axially movable, separating the functions of rotation (where minimal contact is maintained to reduce heat) and braking (where contact is generated for force). This extraction of the disc from a static to dynamic position allows independent optimization of both rotation smoothness and braking effectiveness.
3Device complexity
If brake pads are fixed in position, then结构简单 (structure is simple), but uneven wear and offsets occur affecting braking performance
Solution Approach 1:
The brake disc is made dynamically movable in the axial direction, allowing it to self-adjust its position relative to the brake pads. During rotation, it maintains optimal minimal separation; during braking, it engages fully. This dynamic adjustment compensates for wear and maintains consistent braking performance without requiring complex active control systems.
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 brake device enhances braking efficiency by reducing the 'Time to Lock' (TTL), improving energy efficiency, and increasing active safety with reduced wear and improved cooling, suitable for electric and hybrid vehicles.
Implementation Method 1
the brake discs can be cooled by means of a fluid that flows through internal cavities
Implementation Method 2
by means of friction between the brake pads and the disc, the braking of the wheels and consequently of the vehicle takes place
Data Source
AI summary
The invention relates to a brake device attachable on a rotating shaft, which includes a guiding support including at least one transmitting guide, a first casing, a first pusher element movable in the axial direction, a lining disc located between a first brake disc and a second brake disc. The first casing includes a drive system configured to, when activated, move the first pusher element, in the axial direction, towards the lining disc, pushing the first brake disc towards the first lining, wherein the drive system is configured to, when deactivated, retract the first pusher element, moving in an opposite direction to the direction of pushing on the first disc brake, in the axial direction.