Test Specifications for Disc Brake Pads Passenger Cars
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1 PAGE 1 Test Specifications for Disc Brake Pads Passenger Cars Applicable on machines type : RWS60A RWS75A RWS50B RWS75B RWS100B RWDC136B Krauss GmbH Haugweg 24 Tel. (+49) Fax. (+49) p.krauss@kraussgmbh.de Picture Design of Friction Tester Type RWS75B / RWS100B / RWDC136B
2 Theory ECE-R90 - Annex 8 PAGE 2 The friction is counteracted by the relative movement of two objects which are in contact with each other (DIN 50281), and is denoted by the friction coefficient. µ = Friction force F R Normal force F N This friction force is referred to as friction coefficient µ in the following.the calculation of the friction coefficient is done as described below. Picture Calculation of µ Frictional force at the caliper : F R = 2. µ. F N [N] F N = A K. P B. η [N] Frictional torque at caliper : M B = 2. µ. r W. F N [Nm] = R. F Q [Nm] M B Hydraulic pressure : p B = [bar] 2. µ. r W. A B. η M B Coefficient of friction : µ = [ - ] 2. r m. A K. p B. η A. K p. B η F N Pressure upon the lining : P B = = [N/cm²] A B A B Efficiency of brake : η
3 PAGE 3 Extract from VDA Item 7.4. Friction Performance Abreviations A B Pad area [cm 2 ] A K Piston area [cm 2 ] F N Normal Force [N] F R Friction Force [N] F Q Force measured [N] M d Torque [Nm] R Radius (arm length) [m] T A Start temperature [ C] T E Final temperature [ C] V S Pad wear [mm, g] n Speed [1/min] p B Brake pressure [bar] P B Pressure on the friction material [N/mm²] rw Effective friction radius [mm] a Coeff. of heat transmission [J/m 2 gk] η Efficiency [%] Coefficient of friction [-] B Service friction value [-] F Fading friction value [-] K Cold friction value [-] M Mean / average friction value [-] max Maximum friction value [-] min Minimum friction value [-]
4 PAGE 4 FRICTION PERFORMANCE Friction coefficients Test components: Test setup: - Original brake pads, brake caliper and brake disc. Suitable substitutes can be used instead of an original brake caliper and disc for prototype purposes. For the initial sample release and later original components have to be used. If several variants shall be possible per vehicle the thermically most stressed brake disc has to be used. The brake disc may be reworked. Please note minimum thickness according to manufacturer's instructions. - The temperature is measured at the outboard side of the disc in the friction radius r eff at the surface of a thermo-couple pressed in by a Cu pin. The reference sensor is a firmly fixed thermo-couple. Thermo-couple Friction ring Brake disc r eff
5 PAGE 5 Test procedure: Calculation of the friction value: µ = Md η= 0.95 for sliding caliper 2 x p x r w x A k x η η= 0.98 for fixed caliper Test Program - Braking time : 5 sec. = Braking action, after 80 % of demand value is reached Inerval time : 10 sec. = free running after braking action - Disc speed: n = 660 1/min constant (+/- 10/min), No cooling during braking action (ventilator off no air flow around the brake) during the test cycles. Cooling is on for reducing temperature after cycle. Only exhausting (exhausting determined specific to manufacturer or to the project) - Take Md from table (see appendix / drawing) Test Program Groups Cycle Count Brakings Md from table TA = Tmin [ C] TE* of brake [ C] I. Bedding in M Br.<50 C = Tstart Main Program May be up to 250 II. III. IV. µ K1 µ B1 µ F1 7 5 M2 Tstart = 40 Can be up to M2 Tstart = 100 Can be up to M3 Tstart = 100 Can be up to 550 V. µ B M2 Tstart = 100 Can be up to 350 VI. VII. VIII. µ F2 µ B3 µ K M3 Tstart = 100 Can be up to M2 Tstart = 100 Can be up to M2 Tstart = 40 Can be up to 350 *TE: Temperatures are standard values which result from the process. Pad wear is to be determined by weighing and measuring, before and after every test run. Position and number of pad wear measuring points are determined specifically for each project.
6 PAGE 6 Test Procedure: GLOBAL-SPEC. EURO-SPEC 1 Test TESTPROCEDURE Procedure #2 Test Proc. ID: 2 Test ID: Test Date: Dynamometer: untitled Material: Batch No.: Lining Type: Drawing No.: Customer: Comment: Technical Data Brake Disk Eff. Radius : : : 131,0 mm Piston Area : 28,27 cm² Lining Area : cm² C C bar bar µ µ 0,6 0,6 0,5 0,5 0,4 0,4 0,3 0,3 0,2 0,2 0,1 0,1 0,0 revised verified released rejected 0,0 Coefficients of Friction Wear : 0,07 mm 1,3 g : 0,13 mm 2,4 g : mm g Lining I Lining II Disk 0,36 0,38 0,30 0,34 Cold 1: 2: Fade 1: 2: 0,37 0,36 0,38 0,30 0,44 Average 1: 2: 3: Minimum: Maximum: Evaluation
7 PAGE 7 Assessment To calculate frictional results actual figures must be used exclusively, not spec. figures. Constants needed for calculation (e.g. r W ) must be taken from the drawing. The following levels must be determined from test program 2: - Cold friction µ k1 ; µ k2 - Service friction µ B1 ; µ B2, µ B3 - Fading friction µ F1 ; µ F2 - Minimal friction µ min - Maximum friction µ max - Pad wear V B Cold and service friction levels To calculate cold and service friction levels, so-called "instant friction levels" must be calculated by averaging all test results from 1 brake operation measured in a window ± 0.1s centred on the time "80% + 1s". (see figure). (see figure). Drawing:Determination of cold and service friction results
8 PAGE 8 Cold friction levels Cold friction levels µ k1 ; µ k2 are, in each case, the instant friction levels recorded for each first brake operation in the first cycle of test program group II and the last cycle in test program group VIII. All these operations start at a brake temperature of 40 C. Service friction levels The service friction levels are the "instant friction levels" of the first brake operation of each cycle, with 100 C initial temperature, in test program groups III., V. and VII. In each of the program groups III. and VII., three service friction levels are determined; 4 levels are determined in group V. The individual results are then combined into a mean result µ B1, µ B2, µ B3 for each group. Minimum, maximum and fading friction levels The evaluation of the minimum, maximum and fading friction levels is carried out from the time "80% + 0,5s" until the "end of braking" signal is triggered by the test stand computer. (see figure). (see figure).analysis of minimum, maximum and fading friction levels
9 PAGE 9 Minimum friction level The minimum friction value µ min is the smallest friction value which occurred in the test program groups II to VIII. ( apart from block IV and VI ), respectively from the time "80% + 0,5 sec." to the "braking end signal" of the test stand computer. Maximum friction level The maximum friction level µ max is the highest friction level recorded in the test program groups II. to VIII. from the time "80% + 0,5s" until the "end of braking" signal is triggered by the test stand computer. Fading friction levels Fading friction levels µ F1 ; µ F2 are the lowest friction levels recorded in the test program groups IV. (fading 1) or VI. (fading 2) from the time "80% + 0,5s" until the "end of braking" signal is triggered by the test stand computer. Other information All observations made during and after the test (e.g. important smoke development, pad separating from backing plate, cracking on the pad edges or friction surface, break-outs, brake disc condition (hotspots, cracks) etc.) must be noted. Documentation The brake pad data determined as above is to be documented in the pad data sheet, drawing or other data carrier.
10 PAGE 10 Equation for calculating brake torque M = ( TE TA) α A 1 exp cp G α A BS BS t 2 π n α = 59.7 J/m 2 sk c P = 51 J/NK } Material constants for GG c P = Specific heat storage capacity (J/NK) G BS = Weight of brake disc [N] T E = Final temperature [ C] T A = Start temperature [ C] α = Transmission coefficient [J/m 2 sk] A BS = Transmission surface [m 2 ] t = Braking time [s] Assumption s for calculating M 1, M 2, and M 3 or information on the drawing M 1 = T E T A = 125 K, t = 25 s M 2 = T E T A = 225 K, t = 25 s M 3 = T E T A = 450 K, t = 50 s Figures stated on the drawing shall apply!
11 PAGE 11 Lining data sheet The brake lining data determined as above are to be entered into the lining data sheet. These are: 1. Friction level results, individual values being incorporated into scatterbands. 2. Physical-chemical data are to be determined and their min. and max. values entered. The results from the 1st to the 6th batch are used to establish specification limits which will thereafter form a mandatory standard for the pads manufacturer. If a pad is found to the outside the limits, the test must be repeated twice. If the negative result is confirmed, a more accurate check will be made by agreement with the customer. If the final check confirms the friction behaviour to be unsatisfactory, the pads must be taken out of circulation. Deviations in other tests require a repeat test, in agreement with the customer. The release batch is taken as reference for all production batches.
12 PAGE 12 Lining data sheet Friction Coefficient Test Brake torques: M 1: M 2: M 3: Prototypes Initial sample release Production monitoring Lab. results 1st batch Batches 2-6 Spec. figs min / max min / max min / max min / max µ K1 µ K2 µ B1 µ B2 µ B3 µ min µ max µ F1 µ F2 Pad wear [g] Dynamometer test to AK Master Prototypes Initial sample release Production monitoring Characteristics 1st batch Batches 2-6 Characteristic 3 Speed/ Press km/h 4.3 Speed/ Press km/h 4.5 Fading 9. Fading 14. Characteristic 15. min / max min / max min / max Pad wear [g]
13 PAGE 13 Appendix 1 Brake torques Contents: Brake torques for solid discs Brake torques for internally ventilated discs
14 PAGE 14 [mm] Brake torque solid disc [Nm] Outer diameter m[kg]
15 PAGE 15 Brake torque solid disc [Nm] [mm] Outer diameter m[kg]
16 PAGE 16 Brake torque solid disc [Nm] [mm] Outer diameter m[kg]
17 PAGE 17 Brake torque solid disc [Nm] [mm] Outer diameter m[kg]
18 PAGE 18 [mm] Brake torque ventilated disc [Nm] Outer diameter m[kg]
19 PAGE 19 [mm] Brake torque ventilated disc [Nm] Outer diameter m[kg]
20 PAGE 20 [mm] Brake torque ventilated disc [Nm] Outer diameter m[kg]
21 PAGE 21 [mm] Brake torque ventilated disc [Nm] Outer diameter m[kg]
22 PAGE 22 [mm] Brake torque ventilated disc [Nm] Outer diameter m[kg]
} Rev.1/Add.12/Rev.6/Amend.4
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