SAE R-352-2003 Advanced Brake Technology (To Purchase Call 1-800-854-7179 USA Canada or 303-397-7956 Worldwide).pdf

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1、Advanced Brake Technology Edited by Bert Breuer and Uwe DausendAdvanced Brake Technology Edited by Bert Breuer and Uwe Dausend Warrendale, Pa. Copyright 2003 SAE International eISBN: 978-0-7680-5391-3Other SAE titles of interest: Brake Design and Safety (Second Edition) By Rudolf Limpert (Order No.

2、R-198) Electronic Braking, Traction, and Stability Controls Edited by Ronald K. Jurgen (Order No. PT-76) ABSTCSVDC: Where Will the Technology Lead Us? Edited by Josef Mack (Order No. PT-57) For more information or to order a book, contact SAE at 400 Commonwealth Drive, Warrendale, PA 15096-0001; pho

3、ne 724-776-4970; fax 724-776-0790; e-mail CustomerServicesae.org; website http:/store.sae.org. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise,

4、 without the prior written permission of SAE. For permission and licensing requests, contact SAE Permissions, 400 Commonwealth Drive, Warrendale, PA 15096-0001; phone 724-772-4028; fax 724-772-4891; e-mail permissionssae.org. SAE International 400 Commonwealth Drive Warrendale, PA 15096-0001 USA E-m

5、ail: CustomerServicesae.org Phone: 877-606-7323 (inside USA and Canada) 724-776-4970 (outside USA) Fax: 724-776-1615 Copyright 2003 SAE International ISBN 0-7680-1247-3 Library of Congress Catalog Card Number: 2003110330 SAE Order No. R-352 Printed in the United States of America.III Preface At the

6、invitation of TMD Friction (TEXTAR) some 250 top brake engineers meet at Bad Neuenahr, Germany, annually to hear and discuss expert presentations on the latest developments in road vehicle brakes and brake systems and to exchange technical information and experience in the international bilingual Sy

7、mposium. Many of the attendees are members of the prestigious Club, which was founded 25 years ago and gave rise to the Symposium. The editors are grateful to SAE for disseminating outstanding German and European brake engineering knowledge to the worlds brake experts through this book. It contains

8、the Symposium contributions of the past 4 years covering important areas and aspects of modern brakes, their components and systems and their potentials and interactions with other basic disciplines (e. g. new materials) and automotive systems (e. g. intelligent chassis). We thereby hope to encourag

9、e many automotive engineers and engineering students to turn their attention to the subjects and suggestions of this book and to carry on with their further development. B. Breuer U. DausendIV Dedicated to Georg Naom founder of the Club and creator of the SymposiaV Contents 1 Introduction 1 B. Breue

10、r, U. Dausend, Darmstadt University of Technology 2 TMD Friction Company Profile 3 TMD Friction Group, Corporate Communication Part I Basics, Materials and Methods 3 Braking from the Behavioural Scientists Viewpoint 25 B. Spiegel, Spiegel Institute Mannheim 4 New Material Technologies for Brakes 37

11、T. Haug, K. Rebstock, DaimlerChrysler AG 5 Investigation of the Thermal Behaviour of Vented Disc Brakes by Means of CFD .51 C. Repmann, Volkswagen AG 6 Future Utilization of Stationary Brake Design in Simulation and Analysis of Brake Systems .77 U. Sailer, D. Mahnkopf, S. Knoll, Robert Bosch GmbH 7

12、Controlling the Lateral Dynamics of Vehicles by Braking 105 T. van Zanten, R. Erhardt, K. Landesfeind, G. Pfaff, Robert Bosch GmbH 8 Development Tools to Assist in the Objective Description of Brake Pedal Feel 121 K. Augsburg, R. Trutschel, Ilmenau University of Technology Part II Brakes and Brake S

13、ystems 9 ABS for scooters 151 B. Fisehenich, FTE automotive GmbH 10 BMW Motorrads New Integral ABS in Practical Testing 161 M. Braunsperger, S. Beulich, H.-A. Wagner, G. Heyl, BMW AGVI Contents 11 SBC The Electro-Hydraulic Brake System from Mercedes-Benz 183 U. Stoll, DaimlerChrysler AG 12 New mecha

14、tronic part disc brake 205 M. Semsch, Darmstadt University of Technology 13 Introduction into the Technology of Airvehicle Braking Systems 229 B. Only, formerly MBB, DASA (retired) Part III Test and Experiences 14 The Air Disc Brake in Commercial Vehicles - Field Experiences 243 A. Siebke, M. Gruber

15、, R. Ober, Knorr-Bremse-Systeme fr Nutzfahrzeuge GmbH 15 Effectiveness and Acceptance of Brake Tests in Commercial Vehicles During Periodical Vehicle Monitoring (HU und SP) 259 R. Staebler, H. Erhard, TV Verkehr und Fahrzeug GmbH 16 Brake Noise A Comparison of Subjective and Objective Evaluations 27

16、5 W. Rumold, W. Keiper, Robert Bosch GmbH 17 Porsche Brake Development “From the Race Track to the Road“ 299 D. Neudeck, R. Martin, N. Renzow, Dr.-Ing. h.c. F. Porsche AG Part IV Future Aspects and Outlook 18 Research on Tribological Characteristics between AlMMC Brake Disc and Friction Material 317

17、 K. Shibata, K. Kawasaki, Honda 19 Thoughts on the chassis of the future 341 U. Seiffert, Braunschweig University of Technology 20 Total Chassis Management Heading for the Intelligent Chassis 359 H. A. Beller, P. E. Rieth, ContinentalTeves AG & Co. oHG 21 Automotive Technology Where are we going? 39

18、3 W. Steiger, Volkswagen AG1 1 Introduction Prof. Dr. B. Breuer, Dipl.-Ing. U. Dausend, Darmstadt University of Technology Darmstadt, Germany The technical purpose of brakes is to decelerate moving vehicles through the tire/road contact, to adapt their speed to traffic conditions, and to prevent the

19、ir involuntary movement once stopped. They transform kinetic energy into thermal energy for storage in the brakes, followed by dissipation to the surrounding air, and must be able to exert sizable torques to the wheels even at standstill. Peak power levels in emergency braking far exceed maximum eng

20、ine power. Appropriate brake force distribution to the wheels in keeping with road surface conditions (e.g. icy/dry) and braking stability (left/right and front/rear), adapted to the driving state of the vehicle (e.g. gradual speed change versus emergency braking), are vital for accident prevention.

21、 Customers are particularly interested in short stopping distances, ease of operation, prevention of fading and skidding, high braking comfort (actuation, noise and vibration) and long service intervals. Engineers must meet customer demands as well as strict regulatory and OEM specifications respect

22、ively for brake system safety and reliability, dimensions and packaging, comfort, maintenance, recycling and cost. Nineteenth century automobiles, essentially carriages without a drawbar, had correspondingly very simple brakes. With the advancement of automotive technology and increasing top speeds

23、in the early 20th century, engineers moved from braking the rear axle only to four-wheel systems and replaced mechanical brake actuation by hydraulic systems. The next steps with cars almost always2 ahead of commercial vehicles and motorcycles were disc brakes replacing drum brakes, the addition of

24、a second brake circuit, and antilock brake systems (ABS) first introduced in Mercedes-Benz cars in 1978. ABS allowed simultaneous braking and steering without skidding, making good automatic use of available tire/road friction, and represented a giant step forward in motor vehicle safety. Today, dri

25、ver assistance systems already on the market, such as Adaptive Cruise Control (ACC) and Electronic Stability Program (ESP) cannot function without an advanced brake system which can automatically apply all or individual wheel brakes without a drivers brake pedal actuation, something which was only r

26、ecently unthinkable. Although we still have good reasons to rely on the physical principle of friction for the core brake functions described above and will continue to do so, new materials, new actuation systems, new development and testing methods, new system approaches and stronger cooperation be

27、tween different disciplines are finding their way into automotive braking systems, and will enable formidable improvements in subsystems (e.g. chassis) and the vehicle as a whole within the combined human/vehicle/environment system. The contents of this book demonstrate that brakes are still far fro

28、m technical saturation, and contain promising potential for future enhancements to safety, economy, ecology and comfort in the transport of people and goods on roads.3 2 TMD Friction Company Profile TMD Friction Group, Corporate Communication Leverkusen, Germany 2.1 Changing Markets Globalization co

29、ntinues to be a key characteristic of the automobile industry. Today in Europe and in the US, manufacturers are moving production abroad, including other continents, often overnight. TMD Friction has already adapted itself to this changing market situation and sees it as the major priority for the n

30、ext stage of the companies development. Today the company is amongst the worlds leading manufacturers of brake pads and liners for original equipment and the spare parts market. We supply automobile and brake manufacturers as well as the international spare parts market. A decisive step in the compa

31、nys global approach to world markets was taken with the HSBC Private Equity investment in 2000 renamed as Montagu Private Equity in March 2003. For the first time in its long history, the company has become primarily focussed on its core business of producing brake pads and had a major source of inv

32、estment funding for state of the art technical and production facilities. Looking to the future, as well as maintaining its strong position in Europe the company will be concentrating on international markets in NAFTA - MERCOSUR areas as well as on South East Asia and JAPAN. Local production facilit

33、ies and strategic alliances will provide the crucial foundation for systematic, successful exploitation of potential growth in these markets, enabling us to improve efficiency in key operations and thereby constantly increase both customer satisfaction and the companys earning capacity, Fig. 21.4 Fi

34、g. 21: Locations This is where successful development activities and innovative technologies play a key role. However, efficient cost management is an equally important factor. Worldwide procurement operations, reduced part variety, standardization of technologies and high flexibility must become a

35、part of our everyday activities if we are to be able to maintain our competitive position on international markets. The stringent technical challenges and advances in the automobile industry require us to focus upon innovative concepts involving active and passive safety. This also applies to the su

36、pplying of international spare parts markets and their wide range of brake liner requirements. TMD Friction has already made a significant contribution to improving safety and comfort on the worldwide automobile market. Systems such as ABS or BAS, which are standard features almost everywhere nowada

37、ys, would not have been possible without the use of friction coefficient technology.TMD Friction Company Profile 5 Also, new generations of automotive safety systems, such as Collision Avoidance (CA) or Electromechanical Braking (EMB), which will make a key contribution to mobility safety, represent

38、 a challenge and a duty at the same time, Fig. 22. Fig. 22: Facts and Figures 2002 2.2 World Market Automotive Brake Pads and Liners The world market for brake pads is primarily governed by the locations of the major automobile producers and the number of vehicles in these countries. These are curre

39、ntly Europe, NAFTA and JAPAN. Around 80 % of brake pads are produced and used in these markets, Fig. 23, Fig. 24. Fig. 23: World Market Automotive Brake Liners6 Fig. 24: Friction Materials - Demand over Product Life Cycle However, globalization of the automobile industry and a strong tendency toward

40、s emerging markets will bring about changes from this position. Examples include the German producers who now make more than 4 million vehicles a year at overseas production facilities. Here we should also mention the Chinese market which has grown enormously over the past few years. Against this ba

41、ckground the structure of the market for brake pads and liners will undergo major changes in the future. In the major markets of to-day original equipment volumes will, in the short term, drop or only show marginal growth. At the same time the demand for spare parts will stagnate due to traffic regu

42、lations, such as speed limits and traffic-restricted zones close to cities and residential areas. Furthermore the brake and brake pad product innovations will ultimately lead to a longer service life. However substantial increases in the demand for OE and spare parts are expected in the future growt

43、h areas of MERCOSUR and CHINA, in expanded South East Asian markets and in EASTERN EUROPE.TMD Friction Company Profile 7 2.3 Competition Worldwide TMD Friction commands 29% of the market making it the market leader in Europe and the worlds 3rd largest producer, Fig. 25, Fig. 26. Fig. 25: Competition

44、 Worldwide Fig. 26: Sales by Geographical Regions As our strong position in Europe accounts for almost 90% of our sales (Fig. 27), our strategy will include substantially improving and expanding our position beyond the European continent.8 This will be implemented by using TMD Friction production fa

45、cilities and alliances located in all growth areas of the worlds as well as our European facilities. Turnover includes products supplied via the brake industry. Fig. 27: TMD OEM/OES Sales 2.4 Brands and Products The high market share for original parts and alternative brands in the spare parts marke

46、ts is to a large extent the result of TMD Frictions strong position on the original equipment market. However, when it comes to competing for customers and ensuring customer satisfaction, nowadays it is not simply a question of supplying the markets with high-tech original spare parts. Therefore TMD

47、 Friction has developed a multiple brand strategy towards operating on international markets, Fig. 28, Fig. 29.TMD Friction Company Profile 9 Here, TEXTAR and PAGID OE brands are given top priority in passenger cars. However, segmentation is necessary, on the one hand to take into account aspects li

48、ke loyalty, reliability and customer service, and on the other hand it is created intentionally for the purpose of improved market penetration, market segmentation and hence maximum customer satisfaction. Fig. 28: TMD Brands and Products This strategy is goal-oriented and geared towards potential de

49、mand on the independent global aftermarket. Fig. 29: AM Passenger Car Pads - Turnover by Brands 200210 2.5 TMD Friction - Development Process 2.5.1 Organization of R & D and OE Sales In 2000 TMD Friction centralized research and development at Leverkusen and based it upon the following principles (Fig. 210, Fig. 211). However, local support facilities were also established in Detroit USA and Brazil and these will be points of growth over the next few years. Fig. 210: OE Sales and R & D Objectives Fig. 211: TMD