Wheel Brake Force Release Control to Reduce Brake Drag
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Solution Overview
Problem
Brake drag occurs due to insufficient withdrawal of the brake pad from the brake disc, leading to energy inefficiency and increased pedal effort, and existing solutions either require continuous force or compromise pedal feel.
Innovation Solution
A brake apparatus with a control unit that determines if a brake action request is present and the vehicle is stationary, instructing the brake actuator to reduce the brake force when the vehicle is still, minimizing brake drag by optimizing brake pad engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a brake pad with a single-layer friction material is used, then the structure is simple and easy to manufacture, but the service life is insufficient and braking performance deteriorates over time
Solution Approach 1:
The brake pad friction material is divided into two distinct layers: a wear-resistant base layer and a high-friction surface layer. This segmentation allows each layer to perform its specific function optimally, extending service life while maintaining braking performance.
Solution Approach 2:
Different regions of the brake pad have different material properties tailored to specific functional requirements. The base layer provides structural stability and wear resistance, while the surface layer provides high friction coefficient for effective braking, creating local quality optimization throughout the component.
2Reliability
If a brake pad with complex multi-layer structure is used, then the service life is extended, but the manufacturing complexity and cost increase
Solution Approach 1:
The base layer is manufactured first as a pre-formed substrate with optimal wear-resistant properties. Subsequently, the friction surface layer is applied to this pre-prepared base, streamlining the manufacturing process by separating the fabrication of structural and functional properties into sequential steps.
Solution Approach 2:
The manufacturing process merges the formation of two functional layers into an integrated brake pad assembly. The adhesive bonding process combines the base layer and friction layer into a unified structure that performs both wear resistance and high-friction braking functions simultaneously.
3Force
If the friction material is made softer to increase friction coefficient, then braking performance improves, but wear resistance decreases
Solution Approach 1:
The friction material system is segmented into two layers with different properties: the base layer is formulated for wear resistance with harder material composition, while the friction layer is formulated for high friction coefficient with softer, more compliant material that maximizes contact with the brake disc.
Solution Approach 2:
The brake pad exhibits local quality differentiation where the friction layer in contact with the brake disc has high friction properties, while the underlying base layer provides wear-resistant structural support. This allows optimal friction performance at the contact surface without compromising overall durability.
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
Reduces the risk of brake drag by easing the removal of the brake pad from the disc when the vehicle is stationary, enhancing energy efficiency and reducing pedal effort.
Implementation Method 1
a brake pad comprising a pressure-resistant plate, a friction layer, and an adhesive layer, in which the friction layer is formed on the pressure-resistant plate through the adhesive layer
Data Source
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AI summary
A brake apparatus for a wheel of a vehicle, comprising a brake pad to generate a brake force when the brake pad engages a brake disc, the brake disc being associated with the wheel of the vehicle a brake actuator, which is adapted to move the brake pad towards the brake disc, and bring the brake pad into contact with the brake disc, therewith generating a requested brake force in response to a brake action request, a control unit configured to determine whether a brake action request is present, determine whether the vehicle is standing still, instruct the brake actuator to reduce the brake force with which the brake pad engages the brake disc when the control unit has determined that the brake action request is present and the control unit has determined that the vehicle is standing still.