Development of a 12-NodeThermodynamic Simulation Model of a Disc Brake Assembly

Overheated brakes on a heavy truck can lead to a loss of braking and subsequent crash. This typically occurs after prolonged braking on a downhill grade. The problem is often accompanied by improper brake adjustment, causing one or more of the actuators to reach the end of travel due to thermal expansion. Reconstruction of this type of crash requires the consideration of overheated wheel brake assemblies. A thermodynamic model of a drum-type foundation brake is included in the HVE simulation environment and has been used successfully to study this phenomenon. However, newer on-highway trucks are often fitted with disc brakes. A similar thermodynamic model for a heavy truck disc brake does not exist, making the problem described above difficult to address. This paper describes a new thermodynamic model of a disc foundation brake, such as those often fitted on newer heavy trucks. The model is based on classic thermodynamic heat transfer principles that describe the rate of heat flow through the brake rotor and pads as a function of time and location within the rotor and pad materials. Simulation results are compared with results of brake dynamometer tests to assess the validity of the new model.