Abstract
In this research project between the Institute of Automotive Engineering (FZD) of the Technische Universität Darmstadt (TUD) and the Continental AG, a new modeling concept in addition to the current state of brake technology has been developed. The aim is to enhance the efficiency of the development process. The wheel brake is modeled on the basis of coupled rigid bodies integrated into a nonlinear system model. The model makes use of explicit interface identification between the components of wheel brake, which is based upon experimental investigation of system performance. With this approach, the number of degrees of freedom is minimized and the calculation of component performance is possible over a wide range of parameters. Therefore, a simulation of caliper deformation, pad deformation, volume consumption, clearance generation and residual torque, pad movement under load, efficiency of an integral caliper under a variation of its dimensions, component stiffness and frictional coefficients between components is achievable. In contrast to models based on the Finite Element Method (FEM), the fully-parameterized geometry from CAD is not necessary, however, can be used for parameterization in the first step. This allows for the caliper to be optimized for a variation of its geometrical and physical parameters. In this paper the modeling approach and the experimental validation regarding the simulation of the volume consumption of a wheel brake is described.
Keywords: Brake modeling concept, caliper simulation, volume consumption, caliper deflection, brake pad modeling