Development of the Advanced Disc System
An advanced braking system developed in the Midlands could soon be fitted to cars coming off production lines around the world.
Delphi’s Disc-Brake Innovation Centre at Leamington is a world centre of excellence in disc research and has brought the first breakthrough in base braking technology since the first volume production of disc brakes more than 50 years ago.
The Advanced Disc System has been developed at the heart of the UK’s automotive research and development community and by 2006 the technology could be taken up by the region’s and world’s-car manufacturers.
Leamington is leading the global development of twin-disc technologies and is one of Delphi’s network of 32 technical centres worldwide, which provide support for customers in any automotive manufacturing region.
The Leamington Disc-Brake Innovation Centre works in three areas - the development of ADS, the support of customer ADS evaluation and development programmes, and the support of UK customers using other Delphi chassis control technologies.
In the last three years, it has registered more than 30 patents for advanced braking and associated manufacturing and materials technologies.
ADS engineering director Chris Baylis said: “Our objectives are to simplify every aspect of implementation. This requires us to consider every step, from system integration through to manufacture, vehicle assembly and even servicing.”
To achieve this, the Leamington centre has developed or installed many additional resources to support vehicle manufacturers which include a sophisticated facility taking m the latest systems for both design and analysis.
Advanced analytical laboratories and computer-aided manufacturing of prototype ADS components for any vehicle provide a fast response to test requirements.
The Leamington centre will have its own low-volume assembly line to provide components for prototype vehicles.
“It is often said that the best engineering solutions are the simple solutions, and that is very much the approach we have taken,” said Mr Baylis. “A rigorous approach, combined with the ability to predict and verify in software models, has allowed us to deliver a proven solution that comfortably meets customer cost, risk and reliability targets”.
“It is a tremendous compliment to the team here at Leamington.”
The new technology will help to solve many of the challenges faced by braking engineers. Mr Baylis said the traditional solution to cope with increasing vehicle weight and performance was to increase conventional systems, including larger brakes - often resulting in larger wheels-but this was costly. “ADS helps solve these problems and is the first significant change for 50 years.”
With four pad surfaces, ADS requires approximately half the apply pressure of a conventional disc brake and has superior thermal management.
The new brake helps to reduce noise- related warranty claims, which surveys show are a major consumer issue in the US and the cause of significant warranty costs.
Other benefits include reduced brake fade and, due to the reduced apply pressure, shorter stopping distances in the unlikely event of a loss of vacuum assistance.
The system has completed more than 1.5 million test kilometres in 20 to help ensure that it will continue to perform to specification in any terrain or usage pattern, throughout a vehicle’s life.
Delphi says that ADS could be in production by 2006. Its technology will enable new automatic functions including electric park brake and hill-hold, improved pedal feel, help to simplify assembly and allow an enhanced interior layout and recycling benefits.
“Hybrid brakes help vehicle manufacturers continue to improve their products as well as enhance the vehicle for the driver,” said John Hutson, European director of engineering for Delphi Energy & Chassis Systems. “It is a very exciting solution that offers significant customer value for mid-compact and larger vehicles and is the next step towards full brake-by-wire vehicles.”