Sensitivity analysis and Taguchi optimization procedure for a single-shoe drum brake

Abstract

Drum brakes have dominated the braking industry for many years and will most likely continue to do so for the foreseeable future due to their low cost and adequate operating performance. Basic equations for conventional brake are presented, while complicated analysis has been published using finite element methods to predict brake squeal and instability. This paper seeks to step away from the complexity of numerical models to consider the fundamental braking phenomenon of a single-shoe drum brake, using nondimensional, closed-form analysis and a Taylor series expansion to examine the effects of perturbing dimensionless design parameters. In addition, an optimal design for the conventional brake is achieved using Taguchi method. In conclusion, this paper shows that the braking torque is dependent upon only four dimensionless groups, and that two of these groups dominate the physics of braking. Furthermore, it is shown that adjustments to these two dominating groups have a direct impact on the contact pressure between that shoe material and the brake drum, and that this pressure must be kept below the yield strength of the braking material in order to prevent a mechanical failure of the brake. Since the results are nondimensional, they are generally applicable to all single-shoe drum brakes having a design with mechanical features that are similar to the one analyzed in this paper. There is very good agreement between the results of both Taguchi and sensitivity regarding the significance and insignificance of the design parameters.

Optimization of Power Consumption Associated with Surface Roughness in Ultrasonic Assisted Turning of Nimonic-90 Using Hybrid Particle Swarm-Simplex Method

“…In the conventional methods Taguchi, signal to noise (S/N) ratio, analysis of variance, regression, desirability analysis etc. have been introduced to solve the optimization issues [20,21,22]. However, the conventional methods are subjected to some issues, such as the lack of targeting the global optimal solution with these methods, which may result in low accuracy and non-robustness of the results.…”

Braking performance oriented multi–objective optimal design of electro–mechanical brake parameters

“…From the analyses, the optimal objectives in the [5][6][7][8][9][10][11][12][13] are the structural parameters, and the objectives in the [14][15][16][17][18] are the control parameters. Except for the [14] and the [17], the objectives in other studies are limited to improving the brake responses and reducing its size and weight.…”

“…Fig 1A shows the structure of a pneumatic-disc-brake, and Fig 1B shows the improved EMB. The power transmission path of the pneumatic-disc-brake is shown with red arrows in Fig 1A . During the working of the brake, the pressured air is injected into the chamber through the inlet (10), and the diaphragm (9) and the push rod (6) are pushed by the air. At the same time, the spring (8) is compressed, and the push rod and diaphragm jointly change the air pressure into axial thrust and act on the arm (5) in the caliper.…”

“…Wang, Zhao et al optimized an electro-hydraulic brake parameters based on the objectives of the brake feeling and the energy recovery rate [9]. Khafaji and Manning tested the influence of the drum brake parameters and optimized the parameters based on the Taguchi method [10]. Zhang, Lu et al introduced a differential evolution cellular multi-objective algorithm, and optimized the structural parameters of a drum brake aimed to improve the efficiency and reduce the volume and the temperature of the brake [11].…”

“…optimized an electro–hydraulic brake parameters based on the objectives of the brake feeling and the energy recovery rate [ 9 ]. Khafaji and Manning tested the influence of the drum brake parameters and optimized the parameters based on the Taguchi method [ 10 ]. Zhang, Lu et al .…”