Air cooling of disc brake unit by longitudinal vortex generator

Abstract

A vehicle disc brake unit comprises a rotatable brake rotor and non-rotatable brake pad of caliper. During the vehicle braking, the non-rotatable brake pad presses against the rotating brake rotor, producing friction heat on frictional contact bands where the brake rotor and the brake pad engages with each other. A plurality of longitudinal vortex generators configured in fins is mounted either to a rotatable vehicle component such as hat of a brake rotor, or a non-rotatable vehicle component such as a protective plate, generating longitudinal vortices in the cooling air flows around the brake rotor, especially across the hottest frictional contact bands. The induced longitudinal vortices in the cooling air flows optimize the heat dissipation from brake rotor into atmosphere.

Claims

1. A disc brake unit for a vehicle, the disc brake unit comprising: (a) a vehicle axle; (b) a wheel, a hub and a brake rotor that are rotatable members of the vehicle coupled to the vehicle axle, the brake rotor further comprising an annular friction ring and a hat, the hat outwardly connecting to the annular friction ring and inwardly being coupled to the vehicle axle; (c) a friction member that is a non-rotatable member of the vehicle, being in frictional contact with the annular friction ring during the vehicle braking, thereby defining an annular frictional contact band on the surface of the friction ring; (d) a vortex generating device that is disposed on the rotatable member of the vehicle, generating longitudinal vortex in the cooling air flow that passes across at least part of the frictional contact band, the longitudinal vortex having a central axis in the primary downstream air flow direction.

2. The disc brake unit according to claim 1, wherein said vortex generating device is a plurality of fins evenly distributed on the surface of the rotatable member of the vehicle, each fin expands in a plane that takes an acute angle of less than 45 degrees relative to the radial plane that is perpendicular to the axis of the rotatable member.

3. The disc brake unit according to claim 2, wherein said fins are made by casting out of the same material as said rotatable member.

4. The disc brake unit according to claim 1, wherein said vortex generating device is a plurality of fins with thickness to height ratio generally less than 0.4.

5. The disc brake unit according to claim 2, wherein said fins are formed on a ring that is coupled to said rotatable member.

6. The disc brake unit according to claim 2, wherein said vehicle is a railway vehicle equipped with axle mounted brake rotor, the friction member is a brake pad, the rotatable member on which said fins are disposed is the hub coupled to the vehicle axle.

7. The disc brake unit according to claim 2, wherein said vehicle is a railway vehicle equipped with wheel mounted brake rotor, the friction member is a brake pad, the rotatable member on which said fins are disposed is the hub section of the wheel, said wheel carries the brake rotor and is coupled to the vehicle axle.

8. The disc brake unit according to claim 2, wherein said vehicle is a road vehicle, the friction member is a brake pad, said hat is coupled to the vehicle axle through the hub and the rotatable member on which said fins are disposed is the hat of the brake rotor.

9. The disc brake unit according to claim 2, wherein said vehicle is a road vehicle, the friction member is a brake pad, and the rotatable member on which said fins are disposed is the wheel.

10. A disc brake unit for a vehicle, the disc brake unit comprising: (a) a vehicle axle; (b) a wheel, a hub and a brake rotor that are rotatable members of the vehicle coupled to the vehicle axle, the brake rotor further comprising an annular friction ring and a hat, the hat outwardly connecting to the annular friction ring and inwardly being coupled to the vehicle axle; (c) a friction member, a friction member support means and a protective plate that are non-rotatable members of the vehicle, the friction member being in frictional contact with the annular brake rotor during the vehicle braking, thereby defining an annular frictional contact band on the surface of the friction ring, the friction member support means being coupled to the vehicle and supporting the friction member, the protective plate laterally covering at least part of the frictional contact band; (d) a vortex generating device that is disposed on one of the non-rotatable members of the vehicle, generating longitudinal vortex in the cooling air flow that passes across at least part of the frictional contact band, the longitudinal vortex having a central axis in the primary downstream air flow direction.

11. The disc brake unit according to claim 10, wherein said vortex generating device is a plurality of fins disposed on the surface of one of the non-rotatable members, each fin takes an acute angle of less than 85 degree relative to primary flow direction of the cooling air.

12. The disc brake unit according to claim 11, wherein said fins are made of the same material as the non-rotatable member of the vehicle.

13. The disc brake unit according to claim 10, wherein the vortex generating device is a plurality of fins with thickness to height ratio generally less than 0.4.

14. The disc brake unit according to claim 10, wherein said vortex generating device is a plurality of triangular ribs that have an elevation angle with respect to the primary downstream air flow direction.

15. The disc brake unit according to claim 11, wherein the non-rotatable member to which the fins are disposed is the protective plate and the fins are formed by stamping.

16. The disc brake unit according to claim 10, wherein the non-rotatable member to which the longitudinal vortex generator is disposed is the protective plate that is movable by a driving mechanism between a deployed position at which the longitudinal vortex generator is in contact with the cooling air flow before said cooling air flow passes across at least part of the frictional contact band, and a hidden position at which longitudinal vortex generator separates from said cooling air flow.

17. A disc brake unit for a vehicle, the disc brake unit comprising: (a) a vehicle axle; (b) a wheel, a hub and a brake rotor that are rotatable members of the vehicle coupled to the vehicle axle, the brake rotor further comprising at least an annular friction ring having mutually faced outer surfaces, and a hat outwardly connecting to the annular friction ring and inwardly being coupled to the vehicle axle; (c) a plurality of friction members, a plurality of friction member support means and at least one protective plate that are non-rotatable members of the vehicle, the friction members being in frictional contact with the outer annular surfaces of the friction ring during the vehicle braking, thereby defining annular frictional contact bands on the surfaces of the friction ring; the friction member support means being coupled to the vehicle and supporting the friction members; the protective plate laterally covering at least part of the frictional contact band; (d) a plurality of vortex generating devices that is disposed on at least one of the non-rotatable members of the vehicle, and at least one of the rotatable members of the vehicle, generating longitudinal vortices in the cooling air flow that pass across at least part of the frictional contact bands, the longitudinal vortex having a central axis in the primary downstream air flow direction.

18. The disc brake unit according to claim 17, wherein said vehicle is a road vehicle, the friction member is a brake pad, the rotatable member on which the longitudinal vortex generator is disposed is the hat of the brake rotor, the non-rotatable member on which the longitudinal vortex generator is disposed is the protective plate being coupled to the vehicle.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Other uses and advantages of the present invention will become apparent to those skilled in the art upon reference to the specification and the drawings, in which:

[0010] FIG. 1 is a partial inboard side view of a conventional road vehicle disc brake unit with a solid brake rotor, and a protective plate coupled to a brake yoke of the vehicle;

[0011] FIG. 1B is a partial outboard side view of the conventional road vehicle disc brake unit shown in FIG. 1, also included are schematic views of primary cooling air flows surrounding the moving vehicle represented by arrows icons;

[0012] FIG. 1C is a partial cross-sectional view of the conventional road vehicle disc brake unit shown in FIG. 1, also included is a wheel rim profile in dotted lines;

[0013] FIG. 2 is a partial inboard side view of a road vehicle disc brake unit to which longitudinal vortex generators are mounted to both hat of the brake rotor, a rotatable component of the disc brake unit, and protective plate, a non-rotatable component of the disc brake unit, according to an embodiment of the present invention;

[0014] FIG. 2A is an enlarged partial top view of the road vehicle disc brake unit shown in FIG. 2, providing details of the arrangement of the longitudinal vortex generator mounted to the protective plate, also included are schematic views of swirling secondary cooling air flows induced by the longitudinal vortex generator, represented by arrows icons;

[0015] FIG. 2B is a partial outboard side view of the road vehicle disc brake unit shown in FIG. 2, also included are schematic views of swirling secondary cooling air flows induced by the longitudinal vortex generator, represented by arrows icons;

[0016] FIG. 2C is a partial perspective view of the road vehicle disc brake unit shown in FIG. 2, without showing the brake caliper and the brake pad, also included are schematic views of swirling secondary cooling air flows induced by the longitudinal vortex generator, represented by arrows icons;

[0017] FIG. 2D is an enlarged view of the longitudinal vortex generator mounted to the hat of the brake rotor shown in FIG. 2.

[0018] FIG. 3 is a partial inboard side view of a road vehicle disc brake unit to which a longitudinal vortex generator is mounted to the protective plate according to an alternative embodiment of the present invention;

[0019] FIG. 3A is an enlarged partial angled top view of the alternative embodiment of the present invention shown in FIG. 3, giving details of arrangement of longitudinal vortex generators mounted to the protective plate, also included are schematic views of swirling secondary cooling air flows, represented by arrows icons, induced by the longitudinal vortex generator;

[0020] FIG. 3C is a partial perspective view of the road vehicle disc brake unit shown in FIG. 3, once its brake caliper and brake pad are removed, also included are schematic views of swirling secondary cooling air flows, represented by arrows icons, induced by the longitudinal vortex generators;

[0021] FIG. 4C is a partial perspective view of a road vehicle disc brake unit to which longitudinal vortex generators are mounted to not only hat of the brake rotor and protective plate, but also neighbouring wheel rim, according to alternative embodiment of the present invention;

[0022] FIG. 5 is a partial side view of a conventional railway vehicle ventilated brake disc mounted to a hub, also included are schematic views of primary cooling air flows, represented by arrows icons;

[0023] FIG. 5A is a partial top view of the conventional railway vehicle ventilated brake disc shown in FIG. 5;

[0024] FIG. 6 is a partial side view of a railway vehicle ventilated brake rotor mounted to a hub to which a pair of longitudinal vortex generator rings is disposed on the cylindrical surfaces of the hub according to an embodiment of the present invention, also included are schematic views of swirling secondary cooling air flows, represented by arrows icons, induced by the longitudinal vortex generators;

[0025] FIG. 6A is a partial top view of the embodiment of the present invention shown in FIG. 6, also included are schematic views of swirling secondary cooling air flows, represented by arrows icons, induced by the longitudinal vortex generators;

[0026] FIG. 6B is a side view of the longitudinal vortex generator ring in which a longitudinal vortex generator is mounted to a standalone circular band;

[0027] FIG. 6C is a top view of the longitudinal vortex generator ring shown in FIG. 6B;

[0028] FIG. 6D is a schematic illustration showing a pair of longitudinal vortex generator rings is mounted to two sides of the hub shown in FIG. 6;

[0029] FIG. 7 is a top view of an alternative embodiment of the longitudinal vortex generator ring presented in FIG. 6B;

[0030] FIG. 8 is a partial side view of a railway vehicle ventilated brake rotor with integrated hub to which a pair of longitudinal vortex generator is built directly to the brake rotor hub section according to an alternative embodiment of the present invention, also included are schematic views of swirling secondary cooling air flows, represented by arrows icons, induced by the longitudinal vortex generators;

[0031] FIG. 8A is a partial top view of the embodiment of the present invention shown in FIG. 8, also included are schematic views of swirling secondary cooling air flows, represented by arrows icons, induced by the longitudinal vortex generator.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0032] FIG. 1, FIG. 1B and FIG. 1C show relevant components of a conventional road vehicle disc brake unit for a front left wheel.

[0033] A brake knuckle 11, as a friction element supporting means, is secured to a vehicle. The brake knuckle 11 supports the stationary protective plate 14 and the brake caliper 15 that comes with brake pad 16. Meanwhile, the knuckle supports an axle 10 through sets of roller bearing (not shown). An integrated brake rotor 13 is coupled to the axle 10 through a wheel hub 12. The section 133 is referred by the industry as hat of the brake rotor and can be made either together with the brake rotor in the same material or as a separate component in different material.

[0034] During road vehicle braking, a pair of non-rotatable brake pad 16 presses against rotatable brake rotor to exert a friction force to decelerate and stop the vehicle, leaving a pair of annular frictional contact bands 17 on both sides of the friction ring of the brake rotor 13.

[0035] Arrow icons in FIG. 1B gives schematic view of primary air flows passing across the frictional contact bands 17 for a moving vehicle. Those air flows travel generally in parallel to the frictional contact bands 17, especially in the areas in close proximity to the friction ring of the brake rotor.

[0036] The dotted line in FIG. 1C provides a schematic view of a wheel rim 131 surrounding the brake rotor 13. It helps appreciate the tight space available around the vehicle disc brake rotor 13.

[0037] FIG. 2, FIG. 2A, FIG. 2B, FIG. 2C and FIG. 2D depict one embodiment of the present invention. In addition to the road vehicle disc brake unit, identical to the unit shown in FIG. 1, two longitudinal vortex generators 28 and 29 are provided.

[0038] As shown in FIGS. 2 and 2A, a longitudinal vortex generator 29 configured in form of a plurality of fins, for example, the fin 291, 292, 293 and 294, is mounted to the protective plate 24 made in metal sheet. The fins of the longitudinal vortex generator 29 are formed from the protective plate 24 by stamping process, with aid of die and tool.

[0039] As shown in FIG. 2A, the fin 291, 292, 293 and 294 of the longitudinal vortex generator 29 are all punched out from the left side and bent around a vertical line at right side, so that each fin extends from the protective plate 24 and takes an acute angle 29A of less than 85 degree relative to the primary air flow direction represented by the first arrow icon at the extreme right.

[0040] As shown in FIG. 2B, FIG. 2C and FIG. 2D, a longitudinal vortex generator 28 is mounted to the rotatable brake rotor 23. The integrated brake rotor 23 comprises a friction ring and a hat 233. The longitudinal vortex generator 28 configured in a plurality of fins, for example the fin 281, 282, 283, 284, 285 and 286, being evenly distributed on a cylindrical surface of the hat 233 of the brake rotor 23.

[0041] As shown in FIG. 2D, each fin of the longitudinal vortex generator 28 extends within a reference plane 288 represented in dash line that takes an acute angle 28A against radial plane 289 represented by another dash line which is parallel to the frictional contact bands 27.

[0042] The fins of the longitudinal vortex generator 28 are manufactured by casting, forging or other suitable manufacturing method, and produced out of the same material, for example, vermicular graphite cast iron or spheroidal graphite cast iron. In the case where the friction ring and the hat of the brake rotor are produced separately as individual component, the fins of the longitudinal vortex generator 28 are made out of the same material as the hat. Other suitable material such as alloy steel, aluminum alloy, or carbon-ceramic etc., may be used to produce brake rotor 23, the hat 233 and the fins of the longitudinal vortex generator 28 as well.

[0043] During vehicle braking, the heat generated by friction at the frictional contact band 27 is absorbed by the mass of the brake rotor 23 and the brake pad 26. Temperature differences are developed from frictional contact band 27 toward the inside body of the brake rotor, with temperatures at frictional contact bands remain the highest among all surfaces of the brake rotor.

[0044] On the inboard side of the brake rotor 23, the cooling air flows in the gap between the brake rotor 23 and the protective plate 24. The cooling air flows pass the tips of the fins of the longitudinal vortex generator 29, generating longitudinal vortices in the air flows that travel along the frictional contact bands 27 on the inboard side of the brake rotor 23.

[0045] On the outboard side of the brake rotor 23, cooling air passes the tips of certain fins of the longitudinal vortex generator 28, for example, as shown in the FIG. 2B, the fin 281, 282 and 283 which rotates to the highest position at the hat 233 and the fin 284, 285 and 286 which rotates to the lowest position at the hat 233, creating longitudinal vortices in the downstream air flows that travel across the frictional contact bands 27 on the outboard side of the brake rotor 23.

[0046] Longitudinal vortex enhances convective heat transfer in the following way: reducing boundary layer thickness, flow destabilization, and growing the temperature gradient near the heat transfer surface.

[0047] From microscale, as air passes fins of the longitudinal vortex generator, strong secondary swirling flow is generated, and the tangential velocity of the vortices can be higher than the main flow velocity. The high-velocity swirling secondary flow can not only promote mixing of the cooling air in the proximity of the frictional contact band 27, but also inject the high-energy flow into the boundary layer established between the cooling air and the frictional contact bands 27, to suppress and delay the boundary layer separation, which decrease profile drag.

[0048] As a result, the longitudinal vortex generator 28 and 29 promote substantially convective heat transfer between the brake rotor 23 and surrounding cooling air flows, accelerating the heat dissipation from the brake rotor 23 and the brake pad 26, reducing the operating temperatures on the frictional contact band 27, while introducing only mild drag to the vehicle and adding limited mass to the disc brake unit.

[0049] The introduction of those longitudinal vortex generators improves the air cooling along the frictional contact bands 27 and improve the performance of said disc brake unit.

[0050] FIG. 3, FIG. 3A and FIG. 3C depict an alternative embodiment of the present invention to the one presented in FIG. 2. Taking the fin 391, 392, 393, and 394 as examples, they are pressed out of the protective plate 34, with the aid of die and tool. The partially punched out triangular sections are bent 90 degrees towards the backside of the protective plate 34. The resulting fins in the form of triangular ribs 391, 392, 393, and 394 are perpendicular to the protective plate 34 and takes an acute angle of 39A against the primary cooling air flow direction represented by the arrow icon at the extreme right.

[0051] FIG. 4C depicts another alternative embodiment of the present invention to the one presented in FIG. 2 or FIG. 3. The longitudinal vortex generator 48 has two rows of fins mounted to the hat 433 of the brake rotor 43 which is coupled to the axle 40. Additional longitudinal vortex generator 432 is mounted to inner face of the wheel rim 431 and it can be die casted at the same time when the wheel rim in aluminum alloys is manufactured.

[0052] FIG. 5 and FIG. 5A show two components of a conventional railway vehicle disc brake unit, a ventilated brake rotor 53 and a hub 52. They are coupled to an axle of the railway vehicle (not shown). The hat 531 in the form of a plurality of teeth extends inwardly and is coupled to the annular wing 521 of the hub 52 with the help of a plurality of fastening members 51. Both hub 52 and brake rotor 53 are rotatable components of the vehicle.

[0053] The cylindrical hub 52 defines a central axis and an outer diameter which in turns defines an outer hub periphery 522. The ventilated brake rotor 53 has two opposed annular friction rings 535 and 536, each having an outer surface and inner surface. Two annular friction rings are connected to each other by a plurality of vanes 530 extending from the inner surface of one friction ring to the inner surface of the other friction ring.

[0054] During railway vehicle braking, the non-rotatable brake pad of a caliper (not shown) presses against rotatable brake rotor 53 to exert a friction force to decelerate and stop the vehicle, thereby defining a pair of frictional contact bands 537 on the outer surfaces of the brake rotor 53 that are engaged with the non-rotatable brake pad of a caliper (not shown). The friction heat produced at the frictional contact band 537 is partly dissipated to the atmosphere by convective air cooling and partially transferred to the body and inner surface of the two friction rings 535 and 536 by thermal conduction. Among all the surfaces of the brake rotor 53, the temperature at the frictional contact bands 537 remain the highest during the vehicle braking.

[0055] Arrow icons in FIG. 5 and FIG. 5A give schematic views of primary air flows passing across the frictional contact bands 537. Those air flows travel generally in parallel to the frictional contact bands 537, and at lower speed in proximity to the frictional contact bands 537 than the zone at a distance from the brake rotor 53.

[0056] FIG. 6, FIG. 6A, FIG. 6B, FIG. 6C and FIG. 6D depict one embodiment of the present invention. In addition to a hub 62, a ventilated brake rotor 63 as well as outer hub periphery 622 and frictional contact band 637, identical to the hub 52, the brake rotor 53, the corresponding outer hub periphery 522 and the frictional contact band 537 shown in FIG. 5, a pair of longitudinal vortex generator rings 68 and 69 are provided.

[0057] The longitudinal vortex generator ring, taking the ring 68 as an example, is composed of a circular band 684 and a plurality of fins, for example 681, 682 and 683, evenly distributed to the outer surface of the circular band 684. Each fin extends within a reference plane 688 represented in dash line that takes an acute angle 68A of less than 45 degrees relative to radial plane 689 represented by another dash line which is perpendicular to the axis of the circular band 684. The ring 68 is made by casting, forging, injection molding or fabricated by stamping and welding or any other suitable manufacturing method. The ring 68 and 69 can be made of any suitable heat resistant material including but not limited to cast iron, steel alloys, aluminum alloys, or heat resistant non metallic material or composite material. The band 684 and the fin 681, for example, can be made out of the same material or be made out of different material as separate components that are joined or connected to each other later on.

[0058] As shown by the FIG. 6D, the ring 68 and 69 are mounted to the outer periphery 622 of the hub 62 by interference fit or shrink fit.

[0059] During railway vehicle braking, the rotatable brake rotor 63 is engaged with a pair of non-rotatable brake pads of a caliper (not shown) to decelerate and stop the vehicle. The friction heat produced at frictional contact band 637 is partially dissipated with the help of the passing air flows surrounding the vehicle. The cooling air passes the tips of certain fins of the longitudinal vortex generator ring 68 and 69, for example as shown in the FIG. 6 and FIG. 6A, the fin 681, 682 and 683 which rotates to the highest position at the hub 62, as well as other fins (not shown) which rotates to the lowest position at the hub 62, creating longitudinal vortices in the air flows that travel across part of frictional contact bands 637.

[0060] Longitudinal vortex enhances convective heat transfer in the following way: reducing boundary layer thickness, flow destabilization, and growing the temperature gradient near the heat transfer surface.

[0061] From microscale, as air passes fins of the longitudinal vortex generator ring 68 and 69, strong secondary swirling flow is generated, and the tangential velocity of the vortices can be higher than the main flow velocity. The high-velocity swirling secondary flow can not only promote mixing of the cooling air in the proximity of the frictional contact band 637, but also inject the high-energy flow into the boundary layer established between the cooling air and the frictional contact bands 637, to suppress and delay the boundary layer separation, which decrease profile drag.

[0062] As a result, the longitudinal vortex generator 68 and 69 promote substantially convective heat transfer between the brake rotor 63 and passing cooling air, accelerating the heat dissipation from the brake rotor 63, reducing the operating temperatures on the frictional contact band 637, while introducing only mild drag and adding limited mass to the railway vehicle.

[0063] The introduction of those longitudinal vortex generator rings improves the convective air cooling along the frictional contact bands 637 and improve the performance of said disc brake unit.

[0064] In FIG. 7, an alternative arrangement of the longitudinal vortex generator ring 78 is provided. The ring 78 comprises a band 784 of a split clamp ring type, a set of fastening device 781 and a plurality of fins 782 being mounted to the band 784. The two ends of the split band 784 can be joined together with the help of the fastening device 781. The band 784 is made of any suitable material, including but not limited to spring steel SAE5160. Instead of press fit or shrink fit to a hub, the ring 78 can be mounted by wrapping around the hub and securing to it by the set of fastening device 781.

[0065] FIG. 8 and FIG. 8A provides another alternative arrangement to the embodiment of present invention presented by FIG. 6. The brake rotor 83 is a type of integrated brake rotor and hub for directly mounting to an axle of a railway vehicle. The longitudinal vortex generator 88 and 89 which are composed of a plurality of fins, taking the fin 881, 882 and 883 of the longitudinal vortex generator 88 for example, are mounted to the outer periphery 832 of the hub section of the brake rotor 83 by casting or forging or other suitable manufacturing method and is made of the same material as the brake rotor 83, for example, vermicular graphite cast iron or spheroidal graphite cast iron, cast steel alloys or carbon-ceramic etc.

[0066] It should be noted that other embodiments of the present invention different from the ones shown in attached figures are possible, for example,

[0067] The longitudinal vortex generators can be integrated into a disc brake unit using either solid or ventilated brake rotor, mounted to a railway axle or a railway wheel of a railway vehicle including freight rail cars, passenger coaches, locomotives, electric multiple units train (EMU), diesel multiple units train (DMU) etc.

[0068] Embodiment of the longitudinal vortex generator mounted to a protective plate of a road vehicle can be applied to a railway vehicle by disposing protective plate and longitudinal vortex generator to each side of the brake rotor. Furthermore, the protective plate can be actuated by a moving mechanism and have two positions, a deployed position at which the protective plate and mounted longitudinal vortex generator are placed upstream of the cooling air flows that later on travel across the frictional contact band, a hidden position at which the protective plate is withdrawn to inside of the railway vehicle body without introducing any drag.

[0069] The longitudinal vortex generators can be mounted to two different sections of an integrated wheel hub and brake rotor of a road vehicle, for example, one longitudinal vortex generator is mounted to the hat section on the outboard side and another longitudinal vortex generator is mounted to the hub section on the inboard side.

[0070] The present invention has been described in connection with the preferred embodiments of the various figures. It is to be understood that other similar embodiments may be used, or modifications and additions may be made to the described embodiment for performing the same function of the present invention without deviating therefrom. Therefore, the present invention should not be limited to any single embodiment, but rather construed in breadth and scope in accordance with the recitation of the appended claims.