A central element in the operation strategy of an electric vehicle is the vehicle deceleration by recuperation in order to maximise efficiency and range. As a consequence, the operation of wheel brakes becomes less and less frequent. Audi asks whether it is relevant to consider to what extent a brake downsizing is possible, and what new requirements evolve, especially in the premium segment. Developing innovative wheel brakes requires the analysis of altered load spectra, questioning of classical development premises, and promotion of innovative technologies.
PROPERTIES OF TODAY’S WHEEL BRAKES
Wheel brakes, which dissipate kinetic energy via friction, are crucial safety components of any motor vehicle and have undergone continuous improvements from the start. They are faced with numerous challenging and often conflicting demands that, during the development process, require a multidisciplinary handling of various technical questions.
Under all operating conditions, the brake system must offer sufficient deceleration power. High temperatures, as a consequence of consecutive stops or a hill descend, must be limited through proper dimensioning of the components and a suitable inflow of air. The friction physics between brake pad and brake disc must ensure high and stable friction coefficients over a broad temperature range, even under the influence of ambient media. This must be achieved while maintaining low wear rates and high resistance to corrosion. Aspects such as zero tolerance of noise, the desire to have a “sportive” pedal feel, and the requirement of minimising residual drag, add to the complexity.
In principle, suitable brake concepts and their dimensions are the result of designing on complete vehicle level. With drive power, vehicle mass, centre of gravity position, tyre size and wheel base as central input parameters, this design mainly considers the following scenarios [1]:
Minimum deceleration during failure of the power brake unit;
Thermal situation during (consecutive) high speed stops;
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