Drum Brakes Research Articles

Influence of contact parameters on the radiated noise from an automotive drum brake

Drum brakes are the major source of noise and vibrations in the automobile as the drum acts as a significant source of the noise. High-frequency noises are generated at the interfacial contact between the brake shoe and brake drum. Hence, the variation in the contact parameters (friction, contact stiffness, and contact damping) will significantly affect the vibro-acoustic noise emanating from the drum brake. The current work quantifies the variation in vibro-acoustic noise due to an asymmetry in the contact of leading and trailing shoes with the drum. The overall sound pressure level is estimated numerically using a finite element model of the drum brake. Multiple spring-like components in parallel between the brake shoe and the drum imitate the contact in real drum brakes. The numerical model predicts the noise generated by a symmetric system (without any asymmetry defects) and a system with controlled asymmetric defects introduced into the model. The results show that the overall sound pressure level is a strong function of the contact parameters. The current research is envisioned to better the selection of contact parameters and hence the drum and shoe properties.

Measurement of vibro-acoustic noise of drum brake under various contact conditions

Drum brakes are vital safety components, widely used in automobiles due to their greater availability and quick replaceability compared to disc brakes. Since automobiles are used in all weather conditions, the braking performance also changes accordingly. Penetration of water, oil, and dust between the brake lining and the drum directly affects the contact parameters. These critical contact parameters (such as friction coefficient, contact damping, and stiffness) in turn affect the dynamic and acoustic responses of the nonlinear system. In this paper, the variation in the vibro-acoustic characteristics of a drum brake due to the presence of water, oil, and dust on the brake lining is studied experimentally by measuring the radiated acoustic signals and the system response. The braking performance under different conditions is quantified based on the system response while the acoustic behaviour of the system is studied using the acoustic measurements. This study would help in determining the safety of the automobile even under such abnormal braking conditions. Further, the acoustic measurements can be used to assess the contact condition of the braking system. It is envisaged to develop an improved health monitoring system for drum brakes.

Application of Conical Surface Brakes in Cranes

Both drum brakes and disc brakes have their own structural limitations and advantages. As a new type of industrial brake, cone brake combines the advantages of electric hydraulic drum brake and electric hydraulic disc brake, makes up for the shortcomings of drum brake and disc brake, and greatly improves the service performance and safety performance of the brake. This paper introduces the structure composition and working principle of the conical surface brake, analyzes the advantages of the conical surface brake through the comparison with the drum brake, carries out experimental research, analyzes the test results, gives optimization suggestions for the existing shortcomings, and explores the application prospect of the new brake combined with the introduction of application examples. This paper provides a reference for the technical innovation of brake and a new choice for brake users.

ОБҐРУНТУВАННЯ КОНСТРУКТИВНИХ ТА ЕКСПЛУАТАЦІЙНИХ ВИМОГ ДО ПІДЙОМНИКА ДЛЯ ОБСЛУГОВУВАННЯ ОПОР ВУЛИЧНОГО ОСВІТЛЕННЯ

The article is an overview, and the presented information is of an overview nature and is dedicated to the justification of the choice of component parts of the selected structure of mechanized lifts for servicing street lighting poles. The purpose is to consider the shortcomings of the chosen analogue and to justify the components of the chosen design of the wheel lift, namely each individual part of it, which should ensure operation on street lighting poles with poles of different cross-sections. The main structural and operational requirements for the component parts of the selected lift structure were determined, namely: the lift components must be reliable, quickly reconfigurable in the field and without the use of special tools; the fastening of the wheels to the frame must be reliable and durable enough to withstand a heavy load; wheels must withstand large tangential loads, have good grip on the surface supports; brakes must meet certain requirements; the manipulator must be so reliable that it is possible to lift not only tools and equipment, but also a person, be compact and have enough controlled degrees of movement to easily fold down to the smallest possible dimensions; weight and size characteristics should allow its transportation in cargo or cargo-passenger vehicles of category "B" and above, as well as on trailers (semi-trailers) to them. Deficiencies of the existing design are identified and changes to the design details are proposed. Special attention is paid to brakes. Among the existing brakes are: disc brakes, drum brakes, foot brakes, regenerative brakes and electronic brakes. Disk ones were chosen. Types of brakes are arranged in order of efficiency types of electric scooter brakes. Therefore, taking into account the advantages and disadvantages of each type of b rake, disc brakes were chosen. The wheels themselves must be selected according to the following parameters: they must withstand a large tangential load, tires and the pressure in them must be selected so that there is good engagement with the support, a diameter of 11 inches.

Nonlinear dynamics of system with combined rolling–sliding contact and clearance

Rolling–sliding contacts are found in a variety of systems, such as gears, drum brakes, and tire pavements. Such systems inherently have multiple nonlinearities such as kinematic, contact, and friction nonlinearities. Further, most of these systems have clearance between components which causes excessive vibration and noise. The combination of clearance with other nonlinearities makes the system dynamically interesting. It is important to understand the dynamic behavior of such systems under various operating conditions. Hence, this article focuses on theoretically investigating the transient and steady-state responses of a cam–follower system with rolling–sliding contact and clearance as an exemplary case. A contact mechanics-based model for the same has been developed for this purpose. The transient behavior of the system is examined based on energy and time-varying frequency contents. The domain of attractors, frequency response plots, and phase portraits are deployed to analyze the effect of initial conditions and excitation speed on the steady-state behavior, quantitatively and qualitatively. The steady-state solutions were classified into various branches based on periodicity and phase portraits. In addition, parametric analyses of the effects of loading, damping, and friction on the response have been conducted. Finally, the system is examined for start-up and shut-down characteristics with a constant rate of change in excitation frequency.

Design of a Drum Brake Turnover Machine

In order to meet the demand of turning over brakes in an automatic assembly line of drum brakes, a drum brake turnover machine is designed. SolidWorks software is used to complete the three-dimensional modeling of the mechanical structure of the whole device; The control system of the drum brake turnover machine based on Schneider M241 PLC is designed, and the AC servo system control based on CANopen BUS is realized. The precise control of the position of reclaiming, overturning, discharging and turning angle of the drum brake is achieved. The engineering application results show that the equipment has a high degree of automation, stable operation, and good economy.

Regenerative braking on electric vehicles: working principles and benefits of application

The application of electric vehicles leads to a change in the principle of operation and functioning of some systems in the vehicle, which also lead to a change in the concept of the vehicle itself. One of those systems that has a new concept, which differs from vehicles powered by IC engines, is the braking system. The previous function of the braking system was to stop the vehicle, i.e. to reduce the speed of the vehicle in a safe way. In the case of electric vehicles, the friction brakes were retained, with the addition of a regenerative braking system that has the role of replenishing the vehicle's batteries. The regenerative braking system has the role of converting the vehicle's kinetic energy into electrical energy that recharges the batteries. This system is already used today on full electric and hybrid vehicles, i.e. on vehicles powered by an electric motor. The benefits of regenerative braking are reflected on the fact that the vehicle batteries are recharged during braking, vehicle maintenance costs are reduced, the service life of discs and drum brakes on the vehicle is extended, brake non-exhaust emission is reduced, and heat energy emission is reduced, too.

Impact of Adjusting Brake Lining Gap and Brake Drum Temperature on Brake Efficiency of Motor Vehicles

In motor vehicle systems, brakes are one of the important components that have a major role in reducing the risk of accidents on the highway. In the brake system, especially drum brakes, improper component adjustment can cause the brakes not to work optimally. This research was conducted to determine the impact of large variations in the brake lining gap and brake drum temperature on brake efficiency in motorized vehicles. This study uses an experimental method with variations in the adjustment of the size of the brake lining gap and the temperature of the drum brake. The main brake efficiency was tested using a brake tester from these several variations. The variations of the brake lining gap used are 0.3 mm, 1 mm, and 1.7 mm. Meanwhile, the brake drum temperature is set at 30, 90, and 150 degrees Celsius. The result of this research is that the wider the brake lining gap, the smaller the brake efficiency. The greater the temperature on the drum brake also affects the smaller the efficiency of the brake. Meanwhile, the variable brake lining gap and temperature simultaneously (together) affect the level of brake efficiency. The larger gap between the lining and the temperature of the drum brake, the lower the efficiency of the brake obtained.

A reliability‐based robust optimization design for the drum brake using adaptive Kriging surrogate model

AbstractTo decrease random parameters’ influence on the drum brake reliability, the reliability‐based robust optimization design (RBROD) of the electric vehicle brake is proposed. Based on the assumption that the maximum temperature of the brake cannot exceed the allowable temperature, a performance function model of thermal–mechanical coupling reliability of drum brakes is established by the adaptive Kriging method, and the analysis of reliability sensitivity and RBROD are conducted. The accuracy of the proposed model is verified by temperature measurement experiment under emergency braking condition. The robust optimization design improves the drum brake reliability to 0.99998 and reduce the influence of the design parameters on the reliability, with the absolute values of the reliability sensitivity and the weight of the drum brake are significantly smaller. Therefore, the objectives of reliability design, robustness design, and optimization design are simultaneously achieved by the proposed methods. Besides, the relative error of the proposed method is 0.373%, the number of function evaluations is 39, and the comparison with four meta‐model methods show that the proposed method holds high‐accuracy and high‐efficiency. This study provides a high‐precision theoretical explanation for the robust optimization design of drum brake.

A Method to Predict the Durability of Friction Materials Applied on Drum Brakes Based on the Dissipation of Braking Energy

It is becoming more and more common to apply simulation tools with the purpose of reducing the development time of new products and processes in the industry. Researchers have been engaged in developing simulation models based on the energy dissipation to predict the behavior of materials submitted to wear processes. From the characterization of a friction material applied to drum brakes, a method was developed to predict its durability from the energy dissipated in events of braking. For this, it was necessary to develop and apply the Wear Damage Accumulation Rule. The concept behind this rule was based on the Palmgren–Miner damage linear accumulation rule, applied to predict the fatigue response of structural components. For the characterization of the friction material, scale wear bench tests, where specimens were cycled at different intensities of normal load and temperatures, were performed. The energy dissipated in the brakes of a commercial vehicle equipped with the same friction material was obtained along a typical route using adequate equipment. The Wear Damage Accumulation Rule was applied to predict its life. The result was compared to the prediction of its durability obtained by a traditional method applied by the industry. The results obtained by both methods were similar, indicating that the proposed method has the potential for practical application. From the validation of the method presented in this work, new simulation tools could be created and developed to make the process of development of friction materials faster and less expensive for the automotive industry.

Tribological Aspects Concerning the Study of Overhead Crane Brakes.

The aim of the study is the tribological analysis of the crane drum brakes. A theoretical analysis of the wear processes for brake lining was performed and the coefficient of friction under tribological conditions was determined experimentally simulating the operating conditions for three types of brakes. The theoretical study of the wear was oriented towards of determining the lifetime of the brake lining. In the experimental determination of the coefficient of friction, the following parameters were taken into account: the contact pressure between the shoe and the drum; the initial speed of the brake drum; the humidity of the working environment; and the temperature of the drum-brake lining friction surfaces. After performing the experiments, a statistical analysis was conducted, that shows the amount the coefficient of friction is influenced by the previously mentioned parameters: the highest weight was humidity with a value of 35.58%, followed by temperature with a percentage of 23.95%, velocity with 4.54%, and lastly pressure with 4.19%. Furthermore, the equation that expresses the dependence between the coefficient of friction and the parameters is determined. We consider that the results obtained are important for brake manufacturers in order to improve braking efficiency and the safety of overhead cranes.

Comparing Grade Severity Rating System Models for Trucks Fitted with Drum Brakes versus Disc Brakes

Comparing Grade Severity Rating System Models for Trucks Fitted with Drum Brakes versus Disc Brakes

Friction-induced noise in drum brakes: finite-element modeling and experiments with special focus on damping

Brake squeal in friction brakes is a typical audible noise phenomenon in vehicles leading to high development and sometimes warranty costs for the suppliers. The friction forces generated during braking are responsible for self-excited vibrations in the audible frequency range starting from 1hbox { kHz}. In the past countermeasures against friction-induced vibrations are mostly investigated for disk brakes while the present study focuses on drum brakes. Damping is in the context of self-excited vibrations often one of the key measures. Nowadays recuperative braking in electric vehicles relieves the conventional friction brake. Due to safety reasons, electric vehicles need to possess at least a second independent brake system. Therefore, simpler drum brakes are on the rise again when developing brake systems. Compared to brake disks, where damping elements can hardly be implemented, the freely accessible drum surface and the brake shoes offer so far unused potential for applying passive damping measures. The present paper focuses on how damping measures influence the noise behavior of drum brakes. Industrial and non-industrial brake components are investigated in detail. Experimental as well as numerical procedures are used to assess damping and noise characteristics.

Experimental study of the effect of brake drum cooling grooves on motorcycle braking performance

Some important indicators in the braking system performance on a motorcycle are the braking temperature and stopping distance. High temperatures due to frictional heat in the drum brake can decrease the braking force and cause a slip. To improve braking performance, an effective strategy is needed to reduce the drum temperature and shorten the stopping distance. This study aims to analyze the effect of cooling grooves on the standard brake drum to decrease the drum brake temperature and the length of stopping distance. The measurements were compared to the standard drum brake as a reference, and two types of the modified ones to increase the braking performance by adding the slant-grooved and a straight grooved on brake drum. Braking is performed by providing a compressive load of two kg on the brake pedal for three cases of motorbike speed: 20, 40, and 60 km/hour. The results show that the brake drum with straight cooling grooves provides better braking performance compared to other drum brakes. For a speed of 60 km/h, the temperature of the straight grooved brake is 3.5 ºC. The stopping distance is 29.1 % shorter compared to the standard one. It shows that adding cooling grooves on drum brake can increase the effectiveness of motorcycle braking performance at various speeds. The results show that the brake drum with straight cooling grooves provides better braking performance compared to other drum brakes

Regenerative Braking System: A Review

Abstract: Electric cars square measure associate interest within the market. Today, existing braking technologies are used. This braking technology consumes tons of energy throughout braking within the style of heat. Therefore, regenerative braking is that the most significant methodology of focusing as a result of it's associate energy saving methodology. Increase the potency of electrical vehicles by reducing waste of energy. In electrical vehicle regenerative braking mode, the K.E. of the wheels is bornagain into electricity and keep within the battery or electrical condenser. This methodology has been improved mistreatment flywheels, DC-DC converters. Once a quick moving vehicle is applied a brake the momentum energy is wasted. The brake energy converter could be a compact system mounted in cylinder that absorbs this power and converts it to electricity that may be keep in battery for more use. Compact, efficient, low value and recycles energy nicely, prevents wastage. This method fits within the vacant house of the drum brakes of auto as a result of currently day's disk brakes square measure used. Low weight, compact size and power is made altogether four wheels of the vehicle. Straightforward construction, low value and straightforward to use. Absorbs brake power that the load on the hydraulic brakes is reduced thus less wear of brakes. Motor is within the earlier models with a centralized battery unit, system power to weight magnitude relation is extremely low, i.e., low power is made as compared to the burden of the system. Braking potency is low and tends to explosive brake in emergency conditions. Keywords: Energy, Brake, Electricity, Flywheel, Vehicle.

Robust design for reducing drum brake noise

A limited number of studies have explored drum brake noise with uncertainty. Therefore, a new method for the robust design of drum brakes is presented herein on the basis of complex modal analysis and Taguchi's robust design. Based on the finite element method, complex modal analysis is used to predict drum brake noise. Taguchi's robust design is adopted to reduce drum brake noise and improve system robustness. In this method, the Young's moduli of the brake drum, brake shoes, and friction lining are considered as control factors, the friction coefficient and brake pressure are taken as noise factors, and the weighted instability tendency coefficient is regarded as the objective function. When the proposed method is applied to drum brake design, drum brake noise is significantly reduced and system robustness is increased. Specifically, the signal‐to‐noise ratio increases by 62.94%, and the average value of the weighted instability tendency coefficient decreases by 91.7%. © 2022 Institute of Electrical Engineers of Japan. Published by Wiley Periodicals LLC.

Automotive simplex and duplex drum brake squeal analysis using the finite element method

Despite the fact that disk brakes are used on almost entire mass produced vehicle, drum brakes are still applied on light-, medium-, and heavy-duty vehicles. However, both exhibit a high level of brake noises in which squeal is the most uncomfortable and one of the reasons behind high warranty costs that concern the automotive industry. Hence, the development of prediction methods and models of brake noise have prompted significant efforts. This study intends to analyze two types of drum brakes of a commercial automotive application. Their parametric finite element model comprises drum, shoes, and frictional linings and are submitted to a computational process that includes static calculations of the system under the brake forces to get a pre-stress state around which is computed the complex eigenvalues of the system which characterize their stability. These calculations indicate the unstable frequencies of the entire system. After the design of experiments (DOE) process, the influence of drum brake parameters on system stability can be seen. The friction coefficient and Young’s modulus presented a strong correlation with squeal incidence. At the end is presented a comparison and the optimal material parameters to decrease squeal noise occurrence of these brakes.

Reliability Analysis and Optimization for the Brake Drum

In order to research the static and dynamic characteristics of drum brake in the braking process and avoid resonance, it is necessary to carry out static analysis and modal analysis of drum brake. By establishing the three-dimensional model of the brake drum and imported to ANSYS for static analysis, the maximum equivalent stress and maximum deformation of the brake drum are obtained. The first, second and third natural frequencies and modal vibration shapes of the brake drum are obtained by modal analysis. Four dimensional parameters are selected as design variables, and the sensitivity is carried out by using experimental design. Taking the maximum deformation, first natural frequency, second natural frequency and mass of the brake drum as the objective function, the multi-objective optimization algorithm is used to optimize the design variables. Based on the optimization design, the six sigma reliability analysis of the brake drum is carried out, and the six sigma reliability analysis method is given in detail. The cumulative distribution graph of the maximum deformation, first natural frequency, second natural frequency and mass of the brake drum are obtained. The analysis results show that the reliability of the brake drum is close to 100%, and then it is judged that the brake drum has high reliability. The research results provide a reference basis for structural reliability analysis.

Thermomechanical Behavior of Brake Drums Under Extreme Braking Conditions

Braking efficiency is characterized by reduced braking time and distance, and therefore passenger safety depends on the design of the braking system. During the braking of a vehicle, the braking system must dissipate the kinetic energy by transforming it into heat energy. A too high temperature can lead to an almost total loss of braking efficiency. An excessive rise in brake temperature can also cause surface cracks extending to the outside edge of the drum friction surface. Heat transfer and temperature gradient, not to forget the vehicle's travel environment (high speed, heavy load, and steeply sloping road conditions), must thus be the essential criteria for any brake system design. The aim of the present investigation is to analyze the thermal behavior of different brake drum designs during the single emergency braking of a heavy-duty vehicle on a steeply sloping road. The calculation of the temperature field is performed in transient mode using a three-dimensional finite element model assuming a constant coefficient of friction. In this study, the influence of geometrical brake drum configurations on the thermal behavior of brake drums with two different materials in grey cast iron FG200 and aluminum alloy 356.0 reinforced with silicon carbide (SiC) particles is analyzed under extreme vehicle braking conditions. The numerical simulation results obtained using FE software ANSYS are qualitatively compared with the results already published in the literature.

Variation in vibro-acoustic noise due to the defects in an automotive drum brake

Drum brakes are significant contributors to noise and vibration in automobiles causing discomfort to the passengers. The vibration and hence the resulting noise increase due to various inherent defects in the drum brake, such as asymmetry. This work aims to quantify the variation in the vibro-acoustic noise due to several common defects in the drum brake using an integrated non-linear vibration analytical model and a numerical acoustic model. The sources of vibro-acoustic noise sources such as contact and reaction forces are predicted using a four-degree-of-freedom non-linear contact mechanics based analytical model. A finite element based acoustic model of the drum brake is utilized to predict the force to the sound pressure transfer function in the drum brake. Product of the transfer functions and the forces gives the corresponding sound pressure level from which the overall sound pressure levels are estimated. The variation in the overall sound pressure levels due to different drum brake defects is evaluated by introducing defects to the analytical model. The results show that the overall sound pressure level is a strong function of the defects. It is envisioned that the current work will help in the development of effective health monitoring systems.