I. Industry Background and Overall Overview
(1) The Importance of the Truck Braking System
The braking system is at the core of commercial vehicle safety. Approximately 12% of commercial vehicle accidents globally are caused by braking system failures. Policies are also driving its upgrade. China's National VI Emission Standard and the EU's ECE R90 regulation both impose strict requirements on braking components.
(2) The Functional Synergy of the Three Major Components
Brake Air Chamber: Converts air pressure into mechanical thrust to drive the brake shoes.
Brake Drum: Bears and dissipates the heat generated during braking to maintain the stable operation of the system.
Brake Pads: Directly contact the brake drum to generate friction force. The material and structure affect the braking effect.
Synergy Mechanism: The brake air chamber provides power, the brake pads generate friction, and the brake drum dissipates heat. The three components work together to decelerate the vehicle.
II. Brake Chamber: The Hub of Air Pressure Power Conversion
(1) Working Principle and Structural Design
Working Principle: Compressed air enters the air chamber, deforming the diaphragm to push the push rod and output mechanical thrust. After braking, the diaphragm returns to its original position, and the push rod retracts.
Structural Design Types: The diaphragm type has a simple structure and low cost, but the diaphragm is prone to aging. The piston type has high reliability, but it has a complex structure, high cost, and strict sealing requirements.
(2) Technological Innovation and Market Competition
Technological Innovation Directions: Research and development of new materials for manufacturing diaphragms and pistons, optimization of the air chamber structure to improve air pressure conversion efficiency, and shortening of the braking response time.
Market Competition Pattern: International brands such as WABCO and Knorr-Bremse have an advantage in the high-end market. Domestic companies like Ruili Group and Wan'an Technology, relying on their price and localized services, are making efforts in the mid-to-low-end market and gradually moving towards the high-end.
III. Brake Drum: The Key to Heat Energy Bearing and Heat Dissipation
(1) Material Characteristics and Manufacturing Process
Material Characteristics Requirements: Commonly used materials include gray cast iron, ductile iron, and aluminum alloy. Gray cast iron has a low cost but poor heat resistance. Ductile iron has good comprehensive performance. Aluminum alloy is lightweight and has good heat dissipation, but it has a high cost and low hardness.
Detailed Explanation of the Manufacturing Process: It goes through processes such as casting, machining, and heat treatment. There are various casting methods. Machining ensures dimensional accuracy, and heat treatment improves comprehensive performance.
(2) Heat Dissipation Technology and Performance Optimization
Research and Development of Heat Dissipation Technology: Technologies such as ventilated design, surface grooving, and installation of heat dissipation fins are adopted to reduce the operating temperature of the brake drum.
Performance Optimization Strategies: Optimize the structure, adopt coating technology, and strengthen component matching to improve the comprehensive performance of the brake drum.
(1) Material Composition and Friction Characteristics
Analysis of Material Composition: It is composed of binders, reinforcing fibers, friction performance regulators, and filler materials, each with different functions.
Analysis of Friction Characteristics: An appropriate and stable friction coefficient is crucial, and at the same time, wear resistance should be taken into account to prevent braking fade.
(2) Quality Standards and Brand Competition
Interpretation of Quality Standards: Strict standards have been formulated at home and abroad, such as China's GB 5763-2018 and the EU's ECE R90 regulation, to ensure the quality of brake pads.
Brand Competition Situation: International brands such as Bosch and Akebono dominate the high-end market. Domestic enterprises such as Xinyi and Jin Qilin are rising and expanding their market share with their advantages.
V. The Synergy Effect and Mutual Influence of the Three Major Components
(1) Collaborative Work to Improve Braking Performance
The Synergy Mechanism during Braking: The thrust of the brake air chamber affects the clamping force between the brake pads and the Brake Drum, and the heat dissipation of the brake drum affects the friction performance of the brake pads. The synergy ensures efficient braking.
The Impact of Synergy Optimization on Braking Stability: Optimize the parameters of the air chamber, brake drum, and brake pads to improve braking stability and deal with different working conditions.
(2) Challenges and Countermeasures Brought by Mutual Influence
Analysis of the Mutual Influence among Components: The failure of the brake air chamber affects the pressure distribution, the wear of the brake drum affects the fit of the brake pads, and the fade of the brake pads increases the load on the brake drum.
Discussion of Countermeasures: Conduct collaborative design in the design stage, strictly control the quality during production, and conduct regular inspection and maintenance during use and maintenance to reduce risks.
VI. Outlook on Future Development Trends
Component Upgrades Driven by New Technologies
The Impact of Electronic Braking Technology on Components: With the rise of electronic braking technology, the brake air chamber needs to respond more accurately and quickly, and the design and use methods of the brake drum and brake pads will also change.
