Design Development of Lightweight Disc Brake for Regenerative Braking – Finite Element Analysis

Abstract

Abstract-The automotive industry has for many years identified weight reduction as a way of improving product competitiveness and thus the ability to make profits. One area that has been examined for weight reduction is vehicle with regenerative braking system (RBS). The greatest advantages of electric vehicles (EVs), and hybrid electric vehicles (HEVs) is their ability to recover significant amounts of braking energy using a RBS. Regenerative braking is an effective method to extend brake disc life, minimise disc rotor weight, minimise brake pad wear and to extend the working range of an EV or HEV. Regenerative braking would extend the working range of an EV or HEV provided that any extra energy consumption e.g. from increased vehicle mass and system losses did not outweigh the saving from energy recuperation, also reduce duty levels on the brakes themselves, giving advantages including extended brake rotor and friction material life, but more importantly reduced brake mass, minimise brake pad wear. The objective of this research is to define thermal performance on lightweight disc brake models. Thermal performance was a key factor which was studied using the 3D model in Finite Element Analysis simulations. Ultimately a design method for lightweight brakes suitable for use on any car-sized hybrid vehicle was used from previous analysis. The design requirement, including reducing the thickness, would affect the temperature distribution and increase stress at the critical area. Based on the relationship obtained between rotor weight, thickness, undercut effect and offset between hat and friction ring, criteria have been established for designing lightweight brake discs in a vehicle with regenerative braking.

Experimental analysis in the test rig to detect temperature at the surface disc brake rotor using rubbing thermocouple

“…This research begins with a literature study on brake temperature measurements [11], dynamics of vehicle motion in braking conditions, understanding the conversion of motion energy into heat energy during braking [12], analytical maximum brake force, simulated rotor brake temperature [14], and brake temperature sensor. Then the vehicle data collection is done to calculate the brake load data.…”

“…This work only displays measurements on one drum brake unit. The development of brake failure detection devices has also been performed by several researchers using microcontroller devices and infrared sensors [11,12]. This study only shows the form of a series of tools without proving work in actual conditions.…”

“…Experiments carried out to obtain the brake temperature, which is then analyzed data on the increase in brake temperature. The temperature data collection procedure was developed from various literature [2,3,12] for more details can be displayed as follows:…”

Determination of parameters of abnormal wear of brake pads of freight cars

“…Foreign researchers are focused on the study of disc brakes, strength calculations of their elements, real-time observations of their operation, and also on the calculations of the temperature conditions of some elements of the brake systems of rolling stock [5,6]. When a train is braked with friction brakes, thermal energy is generated in the contact area of tribotechnical bodies, which is dissipated by forced convection, conduction, and radiation from the open surfaces of the brake.…”

A Review Paper on Contactless Braking System

“…An arrangement for manual operation-of-the-caliper-is-addedto-framework. S. Sarip [11]describe that This design of the connection between the friction ring and the hub is important in a lightweight brake disc. Significance of this association has been perceived and comprehended for a long time and auto brake circle creators give careful consideration to the plan of the alleged "top cap" area of the plate.…”