The Optimization Of Air Disc Brake Assembly

With the growing popularity of vehicle active safety control systems(such as ABS, EBS, ESP, etc.) on the commercial vehicles, the higher requirements of braking performance, stability and durability of brake assembly are proposed. As the development trend of pneumatic braking technology for commercial vehicles, the pneumatic floating caliper disc brake is becoming the focus of the research and development in the main engine factory.In this paper, a domestic 22.5 inch pneumatic floating caliper disc brake for commercial vehicle was chosen as an example. With reference of existing products, the design of the structure was optimized. A complete model of the brake assembly was built in ABAQUS finite element analysis software. According to the project performance objectives, and combined with the actual use of customers, the bench test standard of high load fatigue condition and medium load torsion fatigue condition based on national standards is presented. Boundary conditions are analyzed and calculated, including thermal boundary, displacement boundary and load boundary condition. The composite stress, displacement and safety factor of the brake caliper shell, the brake caliper and the brake caliper bracket under the two conditions were calculated in the finite element analysis software. The force of the brake in braking process was analyzed, combined with cloud of each brake assembly.On the basis of the results of the finite element analysis, the structure optimization design is carried out for the brake caliper shell, the brake caliper and the brake caliper bracket. While strengthening the structural strength, the lightweight design of the brake assembly is carried out. Through the simulation results of optimized brake model, the structural strength and reliability of the optimized brake under the two conditions can meet the design requirements.In order to make the analysis result accurate enough, the test verification of the optimized disc brake under two conditions was taken on the existing platform. It provides basic theory and method for the optimization of brake structure and lightweight design.