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Brake System Design for commercial vehicles

BME Department of Automobiles offers system design services for a vehicle manufacturer.

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Content

Brake System Design for commercial vehicles

� Technical details of modules� Piping, fitting design

� Presenting FEM process

� Presenting packaging design

System Design

Overview of System design activities

� Introduction

� System Design process

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Brake System Design for commercial vehicles

Introduction

History:

A dedicated group was established at summer of 2009 in order to support the Department of Automobiles in his external activity with regard to vehicle development.

Target :

� Extend cooperation between University and Industry� To establish joined activity with the vehicle manufacturers in the development of their future vehicle

products. The Department - extended with the team - can offer this competence mainly in brake systems, together with other electronic vehicle subsystems.

� The Department offers a know-how which could be developed by vehicle manufacturer only troughbigger investment on site.

� Moreover product guide courses, more level training about the designed system can be held at the manufacturer.

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Brake System Design for commercial vehicles

System design process 1

� Requirement Specification� Collect and document customer, market

and legal requirements

� System definition and calculation� Define system layout� Define components, for own design and

also from suppliers � Calculations on system level (using

software developed partly in the project)� Service brake system performance� Compatibility between towing and

towed vehicle� Parking brake calculation like

Reservoir capacity calculation� Air supply system

RAM: RV-1c,ABS,RV-2c, TC(opt.)

ATM: RES,APU(OilSep,AirDryer,Protect.Valve)

∑ Components + Fittings & Piping 0.00 € 0.00 €

Components ∑ 0.00 € time CH ∑ 0.00 € AT PU RA

Product Group Qty Supplier Type Price 60 60 Module Qty Type P rice 0 0 0

Subsystem Air Supply ∑ 0.00 € ∑ 0.00 €

Compressor 1 others 53205-3509015 60 60 1 LKxxxx 0 0 0

Air Dryer 1Wabco, KB,

others432.410.104.0 0 0 0 0 0

Tire inflation Device 1 463.711.100.0 0 0 0 0 0MCPV 1 others, KB 53205-3515400-10 0 0 0 0 0APU 0 0 AT 1 ZB44xx 0 0 0Reservoir Regeneration 1 Kamaz 7l 0 0 --- 0 0 0Reservoir Circuit 21 2 20l 0 AT 2 20l 0 0 0Reservoir Circuit 22 1 20l 0 AT 1 20l 0 0 0Reservoir Circuit 23 1 20l 0 AT 1 20l 0 0 0Reservoir Circuit 24 1 20l 0 AT 1 20l 0 0 0Drain Valve 5 others, Yug 16-3513110 0 AT 5 EE1100 0 0 0"Emergency" valve 1 others RP16-3515510 0 0 0 0 0Double Check Valve 1 others 6025-3562010-20 0 0 0 0 0

0 0 0 0Subsystem Service Brake ∑ 0.00 € ∑ 0.00 €

Foot Brake Valve 1Wabco, RAAZ,

others 461 307 207 0 0 PU 1 MB4630 0 0 0

Load Sensing Valve 1Wabco, RAAZ,

KB, others475.720.008.0 0 0 --- 0 0 0

Relay Valve 0 0 RA 1 AC574 0 0 0Trailer Control Valve 0 0 0 0 0 0

ABS ECU 1Wabco, KB,

others446.004.310.0 0 1 0 0 0

ABS PCV (Rear Axle) 2Wabco, KB,

others472.195.018.0 0 2 BR9156 0 0 0

ABS PCV (Front Axle) 2Wabco, KB,

others 472.195.018.0 0 RA 2 BR9156 0 0 0

Proposal I

6520

Current System

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Brake System Design for commercial vehicles

System design process 2

� Packaging design� 3D design of structure and installation -

Packaging of components� Piping, fitting design� Design of brackets� Optimization of layout� Manufacturing documentation

� Engineering calculation� Fastness calculation� FEM calculation� Fatigue lifetime calculations

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Brake System Design for commercial vehicles

System design process 3

� Testing� Vehicle simulation (Matlab)� Prototype building� Module testing, verification� Bench test, Vibration test, � Vehicle test

� System specification� Create documentation of results

� Support of introduction� Support customer in testing � Homologation, certification � Support customer documentation

� Training

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The following examples will present our completed activity for a truck manufacturer and the benefits of our design concept.

Brake System Design for commercial vehicles

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Brake System Design for commercial vehicles

Design concept : Modular system approach

� System built from modules� Pedal unit (or DCM)� Air treatment module� Rear axle module

� Advantages� Shorten assembly time� Pre-assembled, pre-tested

units delivered to assembly line

� Simplifies logistic� System responsibility at the

supplier

Example 1

Current

Proposal-1

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Brake System Design for commercial vehicles

Technical details of modules

� Driver Control Module (as system element)� Steering wheel� Switches, levers on steering wheel

and upper steering column� Steering wheel position adjustment� Brake pedal with valve� Clutch pedal with master cylinder� Accelerator pedal

� Air Treatment Module (ATM): (SD example)� Battery box used as frame � Air reservoirs� Air dryer with MCPV� Purge tank (option)� Trailer Control Valve

� Rear Axle Module (RAM): (SD example) � Service brake relay valve� Parking brake relay valve� ABS valves� Optional ASR valve

Example 2

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Service BrakeParking Brake

Scope for improvement of piping

Packaging design – piping

Brake System Design for commercial vehicles

Example 3

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Service BrakeParking Brake

New Air Treatment ModuleNew Rear Axle ModuleOptimized piping layout

Brake System Design for commercial vehicles

Packaging design – piping

Our proposal including Air Treatment Module, Rear Ax le Module and an optimized piping layout

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Brake System Design for commercial vehicles

Benefits

Our proposal gives remarkable savings in material an d time for pre- and final assembly

Example 5

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Brake System Design for commercial vehicles

Packaging design - 3D

RAM (Rear Axle Module) concept for low floor buses:Complex module including the following functions:

� Relay function for service brake� ABS and ASR function for service brake� Relay function and select low valve for parking brake� Door opening function with pressure limitation� ELC function (Electronic leveling control)� MCPV (multi circuit protection valve)

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Brake System Design for commercial vehicles

Summary

� Technical University Department of Automobiles offers system design services for commercial vehicle manufacturers.

� Department of Automobiles applies the latest technology and utilizes the know-how provided by the University.

� Engineers with industrial experiences are employed in order to be able to turn the result of latest researches into the practice on an effective way

� The development is process-orientated fulfilling the highest requirement of today automotive industry

� The cooperation with TU offers also the possibility of trainings for the employees of vehicle manufacturer.