1、汽車制動(dòng)器 VEHICLE BRAKE,2007-10-26,目錄,制動(dòng)系統(tǒng)的結(jié)構(gòu)原理概述 制動(dòng)器功能和結(jié)構(gòu) 制動(dòng)器的主要失效模式分析 相關(guān)的國(guó)家、行業(yè)和PBR標(biāo)準(zhǔn) 相關(guān)的縮略詞介紹 問(wèn)題解答,制動(dòng)系統(tǒng)的結(jié)構(gòu)原理概述,制動(dòng)系統(tǒng)的作用 在交通運(yùn)輸過(guò)程中,能夠及時(shí)的制動(dòng)使汽車減速、停車和駐車. 制動(dòng)系統(tǒng)的基本組成 供能裝置: 人力和動(dòng)力(氣壓和液壓) 控制裝置: 操縱手柄和制動(dòng)踏板機(jī)構(gòu) 傳動(dòng)裝置: 制動(dòng)總泵和分泵 制動(dòng)器: 鼓式制動(dòng)器和盤(pán)式制動(dòng)器 制動(dòng)力的調(diào)節(jié)機(jī)構(gòu): 比例閥和ABS. 制動(dòng)系統(tǒng)的結(jié)構(gòu) 氣壓制動(dòng)系統(tǒng) 液壓制動(dòng)系統(tǒng): H型和X型,基本制動(dòng)系統(tǒng)(H型)THE BASIC BRAKE SY

2、STEM,卡鉗 CALIPERS,駐車制動(dòng)器 BANKSIA PARK BRAKES,主缸和助力器 M/CYL BOOSTER ASSY,前后分開(kāi)FRONT / REAR SPLIT,前Front,后Rear,卡鉗 CALIPERS,駐車制動(dòng)器 BANKSIA PARK BRAKES,主缸和助力器 M/CYL BOOSTER ASSY,對(duì)角分布DIAGONAL SPLIT,左前 Left Front, 右后 Right Rear,右前 Right Front, 左后 Left Rear,基本制動(dòng)系統(tǒng)(X型)THE BASIC BRAKE SYSTEM,制動(dòng)器的功能,制動(dòng)器的功能 使汽車減速、停

3、車和駐車,把汽車的動(dòng)能和勢(shì)能轉(zhuǎn)換為熱能.,路面制動(dòng)力大小的限制因素 輪胎的正壓力N 路面附著系數(shù)K,前輪或后輪先抱死的影響結(jié)果 后輪先抱死:后軸無(wú)側(cè)向附著力,汽車處于不穩(wěn)定狀態(tài),緊急制動(dòng)時(shí)容易產(chǎn)生甩尾,甚至掉頭. 前輪先抱死:前軸無(wú)側(cè)向附著力,車輛失去轉(zhuǎn)向能力,車輛直行但處于穩(wěn)定狀態(tài). *制動(dòng)力匹配時(shí)應(yīng)避免后輪先于前輪抱死.,制動(dòng)器,制動(dòng)器簡(jiǎn)介,鼓式制動(dòng)器,氣壓鼓式制動(dòng)器(凸輪式) 液壓鼓式制動(dòng)器 2.1 結(jié)構(gòu)型式 根據(jù)制動(dòng)蹄的張開(kāi)力作用點(diǎn)和制動(dòng)蹄支承點(diǎn)的結(jié)構(gòu)布置的不同,液壓鼓式制動(dòng)器主要包括以下幾種型式: 領(lǐng)從蹄式 單向雙領(lǐng)蹄式 雙向雙領(lǐng)蹄式 雙從蹄式 單向自增力式 雙向自增力式 2.2 基

4、本零部件 制動(dòng)底板總成 制動(dòng)分泵總成 制動(dòng)蹄總成 間隙調(diào)整機(jī)構(gòu)總成 回位彈簧.,液壓鼓式制動(dòng)器,Incremental Adjuster 間隙調(diào)節(jié)器,Cable return spring 拉線回位彈簧,Backplate 制動(dòng)底板,Wheel Cylinder 輪缸,Trailing shoe 從蹄,Leading Shoe 領(lǐng)蹄,Upper Spring 上回位彈簧,Lower Spring 下回位彈簧,Abutment 支撐塊,W.C. Mounting screw 輪缸安裝螺栓,Abutment Rivet 支撐塊鉚釘,Shoe retaining pin 蹄定位銷,Backplate

5、 Plug 背板堵蓋,Shoe retaining Clip 蹄定位夾,Shoe retaining pin 蹄定位銷,計(jì)算鼓式制動(dòng)器制動(dòng)力矩的主要參數(shù),Shoe 制動(dòng)蹄,3.駐車制動(dòng)器,4 盤(pán)式制動(dòng)器DISC BRAKES 定鉗盤(pán)式制動(dòng)器 FIXED CALIPER 浮鉗盤(pán)式制動(dòng)器 FLOATING CALIPER,計(jì)算盤(pán)式制動(dòng)器制動(dòng)力矩的主要參數(shù),FUNCTION OF DESC BRAKES,STOP THE VEHICLE,SAVES LIVES,WOULD YOU DRIVE A CAR WITH THE BRAKES YOU MADE ?,盤(pán)式制動(dòng)器功能 DISC BRAKE FU

6、NCTION,Simple 主缸 Master Cylinder,制動(dòng)盤(pán) Rotor,制動(dòng)踏板 Brake Pedal,鉗體運(yùn)動(dòng)方向 Housing caliper movement,活塞 Piston,助力器Booster,盤(pán)式制動(dòng)器總成零部件DISC BRAKE ASSEMBLY COMPONENTS,卡鉗總成ASSEMBLY CALIPER 鉗體HOUSING CALIPER FINISHED 活塞PISTON (X2) 密封圈SEAL-PISTON (X2) 放氣螺釘SCREW- BLEEDER 放氣螺釘防護(hù)罩CAP-BLEEDER 螺紋孔保護(hù)罩PROTECTOR-THREAD 活塞防

7、護(hù)罩PISTON BOOT,支架總成ASSEMBLY ANCHOR BRACKET 支架ANCHOR BRACKET FINISHED 導(dǎo)向銷PIN ,GUIDE 定位銷總成ASSEMBLY PIN LOCATING 定位削PIN, LOCATING 襯套BUSHING, PIN 防塵罩BOOT PIN (X2),彈簧片SPREADER SPRING SLIPPER 螺釘,銷SCREW, PIN (X2) 外側(cè)制動(dòng)塊總成ASSEMBLY PAD OUTER 內(nèi)側(cè)制動(dòng)塊總成ASSEMBLY PAD INNER 磨損報(bào)警片(器)INDICATOR, WEAR,盤(pán)式制動(dòng)器總成 DISC BRAKE

8、ASSEMBLY,盤(pán)式制動(dòng)器總成零部件DISC BRAKE ASSEMBLY COMPONENTS,盤(pán)式制動(dòng)器裝配位置 DISC BRAKE INSTALLATION,鑄件Made from Cast Iron,支架功能 FUNCTION OF THE ANCHOR BRACKET,與汽車懸架連接 BOLTS ONTO THE VEHICLES SUSPENSION 承載 ABSORBS MOST OF THE LOAD DURING BRAKING,裝配孔MOUNTING HOLES,導(dǎo)向銷防護(hù)罩的功能 FUNCTION OF GUIDE PIN BOOT,防止污染物進(jìn)入支架導(dǎo)向孔 PREV

9、ENTS CONTAMINATION FROM ENTERING THE GUIDE PIN HOLES IN THE BRACKET.,導(dǎo)向銷防護(hù)罩 GUIDE PIN BOOT,制動(dòng)和制動(dòng)塊磨損過(guò)程中,導(dǎo)向銷在支架中滑動(dòng). The guide pin slides in the bracket when the brakes are applied and released, and as the pad wears during usage.,導(dǎo)向銷的功能 FUNCTION OF THE GUIDE PINS 導(dǎo)向 滑動(dòng),導(dǎo)向銷Guide pin,支架ANCHOR BRACKET,裝配襯

10、套的定位銷LOCATOR PIN WITH BUSHING,密封圈的功能 FUNCTION OF THE SEAL,活塞回位和密封 TO RETRACT THE PISTON AND PREVENT FLUID LEAKAGE,放氣螺釘?shù)墓δ?Function of Bleeder Screw,對(duì)進(jìn)油口注入氣體AIR APPLIED TO INLET PORT,氣體必須經(jīng)過(guò)缸空從放氣螺釘處排出. AIR MUST MOVE THROUGH THE BORE AND OUT THE BLEEDER SCREW,THIS IS THE FREE FLOW TEST,密封和放氣 To Seal th

11、e system and allow air to be removed during bleeding,制動(dòng)塊的功能 FUNCTION OF THE PADS,制動(dòng)塊由硬的復(fù)合材料組成, 夾住制動(dòng)盤(pán)產(chǎn)生制動(dòng)力.THE PADS ARE MADE FROM VERY TOUGH MATERIALS AND CLAMP AGAINST THE ROTOR TO STOP THE CAR. 內(nèi)側(cè)制動(dòng)塊 THE INNER PAD: 位于活塞端的制動(dòng)塊.THIS IS THE PAD THAT SITS AGAINST THE PISTON FACE 外側(cè)制動(dòng)塊THE OUTER PAD: 位于鉗體

12、鉤頭端的制動(dòng)塊.THIS IS THE PAD THAT SITS AGAINST THE FINGERS OF THE HOUSING.,什么是拖滯? WHAT IS DRAG ?,制動(dòng)盤(pán)Rotor,制動(dòng)釋放后在制動(dòng)塊和制動(dòng)盤(pán)之間殘留的摩擦力. IT IS FRICTION BETWEEN THE PAD AND ROTOR AFTER BRAKES ARE RELEASED. 允許有有限的摩擦扭矩.THERE IS A LIMITED AMOUNT OF FRICTION THAT IS ALLOWED AND IS MEASURED IN NEWTON METRES.,高拖滯的影響EFF

13、ECTS OF HIGH CALIPER DRAG,降低燃油經(jīng)濟(jì)性REDUCED FUEL ECONOMY 加快制動(dòng)塊磨損FASTER PAD WEAR 加快制動(dòng)盤(pán)磨損FASTER ROTOR WEAR. 使制動(dòng)液溫升導(dǎo)致制動(dòng)器失效 CAN BOIL THE FLUID AND CAUSE THE BRAKES TO FAIL,拖滯是如何產(chǎn)生的 ?WHAT CAUSES DRAG?,高的滑動(dòng)阻力HIGH SLIDE LOAD 活塞回位量減少REDUCED PISTON RETRACTION 密封槽加工錯(cuò)誤INCORRECTLY MACHINED SEAL GROOVE 制動(dòng)塊平面度或平行度超差

14、 PADS NOT FLAT OR PARALLEL 活塞相對(duì)于缸孔的間隙太小PISTON TO BORE CLEARANCE TOO TIGHT 使用錯(cuò)誤的潤(rùn)滑脂INCORRECT BORE AND SEAL LUBRICATION,什么是滑動(dòng)阻力?WHAT IS SLIDE LOAD ?,2種類型的滑動(dòng)阻力THERE ARE 2 TYPES OF SLIDE LOAD 1. 鉗體滑動(dòng)阻力HOUSING TO ANCHOR BRACKET SLIDE LOAD 支架和導(dǎo)向銷之間的滑動(dòng)阻力IT IS THE LOAD REQUIRED TO SLIDE THE BRACKET ON THE G

15、UIDE PINS. REMEMBER THE FUNCTION OF THE PINS? 2. 制動(dòng)塊滑動(dòng)阻力PAD SLIDE LOAD 制動(dòng)塊和支架之間的滑動(dòng)摩擦力THE SLIDING FRICTION BETWEEN THE PADS AND THE MACHINED BRACKET. 滑動(dòng)阻力越大,拖滯力越大. THE MORE SLIDE LOAD WE HAVE -HIGHER THE DRAG.,產(chǎn)生高的鉗體滑動(dòng)阻力的原因REASONS FOR HIGH BODY SLIDE LOAD,銷的直徑太大PIN DIAMETER TOO LARGE 銷不合格PINS DAMAGED

16、 錯(cuò)誤的導(dǎo)向銷間距INCORRECT GUIDE PIN SPACING 銷不垂直或不平行PINS NOT SQUARE OR PARALLEL 導(dǎo)向銷孔太小GUIDE PIN HOLES TOO SMALL 無(wú)潤(rùn)滑脂或銷孔生銹NO GREASE OR RUSTY PIN HOLES,制動(dòng)塊太大PADS TOO LARGE 支架的間隙加工的太小ANCHOR BRACKET GAP MACHINED TOO SMALL 彈簧墊片的滑動(dòng)阻力太高SPREADER SPRING SLIDER LOAD TOO HIGH ( DAMAGED PART OR INCORRECT FITMENT),產(chǎn)生高的

17、制動(dòng)塊滑動(dòng)阻力的原因REASONS FOR HIGH PAD SLIDE LOAD,盤(pán)式制動(dòng)器的優(yōu)點(diǎn)和缺點(diǎn),盤(pán)式制動(dòng)器與鼓式制動(dòng)器相比,有以下優(yōu)點(diǎn): 1.散熱性能良好,熱穩(wěn)定性較好,從而制動(dòng)效能較穩(wěn)定; 2.浸水后制動(dòng)效能降低較少,只須經(jīng)一兩次制動(dòng)即可恢復(fù)正常; 3.在輸出制動(dòng)力矩相同的情況下,尺寸和質(zhì)量一般較小; 4.制動(dòng)盤(pán)沿厚度方向的熱膨脹量極小,不會(huì)象制動(dòng)鼓的熱膨脹那樣使制動(dòng)器間隙明顯增加而導(dǎo)致制動(dòng)踏板行程過(guò)大; 5.容易實(shí)現(xiàn)間隙自動(dòng)調(diào)整,保養(yǎng)修理作業(yè)也較簡(jiǎn)便. 盤(pán)式制動(dòng)器與鼓式制動(dòng)器相比,有以下缺點(diǎn): 1.制動(dòng)效能低,用于液壓制動(dòng)系統(tǒng)時(shí)所需制動(dòng)壓力較高,對(duì)系統(tǒng)的密封性要求較高; 2.難

18、以完全防銹; 3.兼用于駐車制動(dòng)器時(shí),需要加裝的駐車傳動(dòng)裝置較鼓式制動(dòng)器復(fù)雜; 4.產(chǎn)品成本較高.,盤(pán)式制動(dòng)器的主要失效模式,噪聲、抖動(dòng) NVH 滲油、漏油 LEAK 制動(dòng)拖滯 BRAKE DRAG 制動(dòng)效能降低 BRAKE FAIL 制動(dòng)跑偏 BRAKE DEFLECTION 其他,制動(dòng)鉗總成的主要試驗(yàn)內(nèi)容介紹,1.泄漏試驗(yàn)(Leak tests) 2.需液量試驗(yàn)(Fluid displacement tests) 3.拖滯扭矩試驗(yàn)(Drag torque tests) 4.活塞回位試驗(yàn)(Piston retraction tests) 5.鉗體滑移力試驗(yàn)(Caliper sliding f

19、orce tests) 6.鉗體變形試驗(yàn)(Caliper deflection tests) 7.力矩耐久疲勞性試驗(yàn)(Torque endurance fatigue tests) 8.液壓疲勞試驗(yàn)(Hydraulic pressure fatigue tests) 9.環(huán)境試驗(yàn)(Environmental tests) 10.耐腐蝕性試驗(yàn)(Corrosion tests) 11.振動(dòng)試驗(yàn)(Vibration resistance tests) 12.缸體爆破試驗(yàn)(Housing burst tests) 13.機(jī)械強(qiáng)度試驗(yàn)(general mechanical strength tests) 14.臺(tái)架性能試驗(yàn)(Dynamometer performance tests) 15.其它(Miscellaneous tests),相關(guān)的國(guó)家、行業(yè)和PBR標(biāo)準(zhǔn),國(guó)家和行業(yè)標(biāo)準(zhǔn) 1.GB126761999 2.GB 7258200