A brake apparatus (1) and method of operating the apparatus are disclosed. The apparatus (1) has a plurality of brake elements (2, 3, 4, 5, 6) with a combined thickness of Y. At least one of the brake elements (2, 3, 4, 5, 6) has a wear portion (22a, 22b) for tribological interaction with a wear portion (52b, 62a) of an adjacent element (5, 6) and is formed in two separable parts (21a, 21b) having thicknesses A.sub.1 and A.sub.2. The method includes operating an actuator (8) at an actuation extension length less than a maximum actuation extension length to cause the wear portions (22a, 22b, 52b, 62a) of the brake elements (2, 5, 6) to tribologically engage and thereby wear. This tribological engagement is such that as the elements (2, 5, 6) wear to a combined thickness of less than Y the extension length of the actuator is increased. A spacer (23) is inserted between the two parts (21a, 21b) of the brake element (2) to cause the wear portions (22a, 22b, 52b, 62a) to be tribologically engagable at a actuation extension length less than the increased actuation extension length.

A brake system includes a series of rotors for operatively coupling to a shaft and stators for operatively coupling to a frame. A service brake system includes a singular annular service piston extending continuously around the series of rotors and stators and a parking brake system includes a singular annular parking piston positioned to extend continuously around the series of rotors and stators. The service piston nests with the parking piston, under a spring bias, such that the parking piston and service piston continuously engage together around the series of rotors and stators to thereby create the parking brake forces. Springs act on the parking piston to drive the parking piston and nested service piston to engage for parking brake forces. Pressurization of the parking piston deactuates the nested pistons. Then separate pressurization of fluid acts on the service piston to overcome the spring bias and separate the service piston from the parking piston to create service brake forces.

An article includes a structural core, one or more friction pads, and a plurality of elongated fasteners. The structural core includes two core surfaces and a plurality of pockets extending between the core surfaces. Each friction pad includes a pad surface and a friction surface opposite the pad surface. Each pad surface includes a planar pad surface configured to contact the core surface and a plurality of bosses extending from the first planar pad surface and including a bore. Each planar pad surface is at least about 50% of a surface area of the respective first and second pad surfaces. The plurality of bosses engages with the plurality of pockets to position the respective first and second friction pads relative to the structural core. The plurality of elongated fasteners passes through bores of corresponding bosses of friction pads to fasten the friction pads to the structural core.

An article includes a structural core, one or more friction pads, and a plurality of elongated fasteners. The structural core includes two core surfaces and a plurality of pockets extending between the core surfaces. Each friction pad includes a pad surface and a friction surface opposite the pad surface. Each pad surface includes a planar pad surface configured to contact the core surface and a plurality of bosses extending from the first planar pad surface and including a bore. Each planar pad surface is at least about 50% of a surface area of the respective first and second pad surfaces. The plurality of bosses engages with the plurality of pockets to position the respective first and second friction pads relative to the structural core. The plurality of elongated fasteners passes through bores of corresponding bosses of friction pads to fasten the friction pads to the structural core.

A method of making a brake assembly using recycled friction disks may comprise removing a first friction disk from a worn brake assembly, removing a portion of the first friction disk to reduce a thickness of the first friction disk, and incorporating a previously unused friction disk and the first friction disk into a brake assembly comprising unworn rotor disks made of a first material. The previously unused friction disk and the first friction disk may comprise a second material different from the first material. The thickness of the first friction disk may be different from a thickness of the previously unused friction disk.

An article includes a structural core, one or more friction pads, and a plurality of elongated fasteners. The structural core includes two core surfaces and a plurality of pockets extending between the core surfaces. Each friction pad includes a pad surface and a friction surface opposite the pad surface. Each pad surface includes a planar pad surface configured to contact the core surface and a plurality of bosses extending from the first planar pad surface and including a bore. Each planar pad surface is at least about 50% of a surface area of the respective first and second pad surfaces. The plurality of bosses engages with the plurality of pockets to position the respective first and second friction pads relative to the structural core. The plurality of elongated fasteners passes through bores of corresponding bosses of friction pads to fasten the friction pads to the structural core.

A brake caliper device is adapted to be used with a brake disk, and includes a main body unit, first and second pads, and a caliper actuator unit. The caliper actuator unit includes an actuating member, a bolt member that abuts against the actuating member, and a threaded sleeve that is threadedly engaged to the bolt member. When the actuating member is driven by an external force, the actuating member is capable of vibrating axially to cause an axial vibration of the bolt member, which prompts the threaded sleeve to rotate relative to the bolt member for pushing the first pad toward the brake disk, thereby automatically providing a travel stroke that compensates for pad wear.

A brake system for a piece of equipment includes a series of rotors and stators, and a first brake actuator including at least one first piston positioned within a first chamber such that pressurization of the first chamber causes the at least one first piston to operatively engage at least one of rotors or stators such that the rotors and stators are compressed together and thereby create braking torque, and may also include a second brake actuator including at least one spring operatively coupled to at least one second piston positioned within a second chamber such that depressurization of the second chamber causes the at least one second piston to operatively engage at least one of the rotors or stators such that the pluralities of rotors and stators are compressed together and thereby create braking torque.

A brake caliper device is adapted to be used with a brake disk, and includes a main body unit, first and second pads, and a caliper actuator unit. The caliper actuator unit includes an actuating member, a bolt member that abuts against the actuating member, and a threaded sleeve that is threadedly engaged to the bolt member. When the actuating member is driven by an external force, the actuating member is capable of vibrating axially to cause an axial vibration of the bolt member, which prompts the threaded sleeve to rotate relative to the bolt member for pushing the first pad toward the brake disk, thereby automatically providing a travel stroke that compensates for pad wear.

An article includes a structural core, one or more friction pads, and a plurality of elongated fasteners. The structural core includes two core surfaces and a plurality of pockets extending between the core surfaces. Each friction pad includes a pad surface and a friction surface opposite the pad surface. Each pad surface includes a planar pad surface configured to contact the core surface and a plurality of bosses extending from the first planar pad surface and including a bore. Each planar pad surface is at least about 50% of a surface area of the respective first and second pad surfaces. The plurality of bosses engages with the plurality of pockets to position the respective first and second friction pads relative to the structural core. The plurality of elongated fasteners passes through bores of corresponding bosses of friction pads to fasten the friction pads to the structural core.