• Journal of the Korean Society for Railway
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• v.20 no.1
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• pp.1-10
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• 2017

Brake squeal noise has been a challenging problems for a long time. It is very annoying to passengers and residents near tracks. Two methods have been applied to reduce or eliminate brake squeal noise. One is to improve frictional materials; the other is to optimize the topology and structures of brake pads. In this study, we developed two kinds of brake pads; one is a pad whose frictional material is different from the KTX brake pad friction material; the other is a flexible pad that has the same frictional material as that of the KTX brake pad, but a different structure. Squeal noise and friction coefficients were measured and analyzed using a full-scale brake dynamometer. It was found that the dynamometer test can simulate the squeal noise of KTX trains at stations. The squeal frequency of the KTX at 4500Hz was exactly reproduced; this value of 4500Hz was one of the natural frequencies of the KTX brake disc. It was also found that the squeal noise depended on the caliper pressure, initial disc temperature and braking speed. The average friction coefficient was 0.35~0.45. The new pad lowered the squeal noise by 17.3~21.6dB(A).

• Proceedings of the KSR Conference
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• 2007.05a
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• pp.786-791
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• 2007

Korean high speed train(HSR-350x) has adopted a combined electrical and mechanical(friction) braking system. Brake blending control unit(BBCU) controls each brake system to fulfill the required brake performances such as braking distance, deceleration and jerk. Also the braking system should be designed considering the economical management, such as effective use of generated braking energy and the minimum wear of friction materials(a pad and a brake shoe). In this paper, we establish the disc braking force pattern that reduces the wear of pad in the disc braking system by minimizing the variance of the instantaneous disk baking energy during braking time, and compare the wear mass of pad between the conventional disc braking force pattern and the established results.

• Journal of the Korean Society for Railway
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• v.16 no.4
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• pp.253-261
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• 2013

According to the measured results of KTX brake squeal noise in this study, high level brake noise occurred in a wide frequency range, 100~18,000Hz. To identify the sources of the brake squeal noise, unstable vibration modes due to brake disc/pad interaction were analyzed under various conditions by the finite element method. Complex eigenvalues for a brake unit with a disc and four pads were obtained. It was found that the real parts of the complex eigenvalues, that is, unstable vibration modes, were closely related to friction coefficients, pressure on the brake cylinders, elastic moduli of the components, and other conditions.

• Journal of the Korean Society for Railway
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• v.17 no.4
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• pp.223-227
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• 2014

The brake pad is one of the basic brake elements of a railway vehicle. It accomplishes braking action by friction between a pad and a brake disc. Because the brake pad must endure specified high pressure, the compressive strength is managed as the main performance factor. The standards for measuring the compressive strength of brake pads are KRS, KRCS, and KRT. These standards specify the size of the test piece for measuring compressive strength as $20mm{\times}10mm{\times}15mm$ ($W{\times}D{\times}H$). To reduce the uncertainty of the compressive strength, factors of uncertainty were analyzed. The results show that changing the dimensions of the cross section was useful to reduce the uncertainty. The uncertainty due to the new cross-sectional dimension shows the effectiveness of reducing uncertainty.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.21 no.10
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• pp.581-588
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• 2020

This study examined a brake pad wear compensation method for an Electro-Mechanical Brake (EMB) using the braking test device. A three-phase Interior Permanent Magnet Synchronous Motor (IPMSM) was applied to drive the actuator of an EMB. Current control, speed control, and position control were used to control the clamping force of the EMB. The wear compensation method was performed using a software algorithm that updates the motor model equation by comparing the motor output torque current with a reference current. In addition, a simple first-order motor model equation was applied to estimate the output clamping force. The operation time to the maximum clamping force increased within 0.1 seconds compared to the brake pad in its initial condition. The experiment verified that the reference operating time was within 0.5 seconds, and the maximum value of the clamping force was satisfied under the wear condition. The wear compensation method based on the software algorithm in this paper can be performed in the pre-departure test of rolling stock.

• Journal of Advanced Navigation Technology
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• v.27 no.6
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• pp.821-827
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• 2023

In this study, the aircraft technical standards of the Korea and the United States were analyzed to derive the dynamometer test procedure required to prove the compatibility for flight test certification of the metal brake pad for transport aircraft. Since the design modification of the brake systems is classified as a major change, the STC(Supplemental Type Certificate) and the PMA(Parts Manufacturer Approval) are required. In accordance with the TSO-C135a, the technical standard order for brake system in the United States, the design landing-stop test, accelerate-stop test, and most severe landing stop test were selected among the test items for flight test. The conditions for the dynamometer test are determined according to the specifications provided by aircraft manufacturer, and the brake pad condition, deceleration, and the number of test are defined according to the TSO-C135a.

• Journal of Advanced Navigation Technology
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• v.27 no.5
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• pp.621-628
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• 2023

This study derived a reverse engineering procedure for verifying the design identity of original parts and developed parts for PMA(Parts Manufacturer Approval) and STC(Supplemental Type Certificate) of metal brake pads for transport aircraft, which are critical parts among aircraft parts and equipment. In Korea, the regulations for reverse engineering procedures are regulated by the Parts Manufacturer Approval Guidelines, and in the United States, AC No. 21. 303-4. In the reverse engineering for the brake pad, the detailed procedures for each component were determined by selecting verification test items to confirm identity based on sample quantity, dimensional tolerance, mechanical property measurement, material, weight and volume characteristics for each component. In addition, as a result of analyzing the regulation of Korea and United States, in the case of Korea, it is necessary to establish technical standards for braking systems for transport aircraft and regulations related to flight tests.

• Journal of the Korean Society for Railway
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• v.14 no.2
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• pp.100-108
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• 2011

This paper investigates the structural stability and reliability on improving performance of flexible brake pad used in high speed train. To this end, an improved model of flexible pad was obtained through structural analysis. Brake pad specimens were subjected to modal, stroke and endurance tests to examine the dynamic characteristics and mechanical stability. The hot spot generation with increasing rotational speed was observed on chassis dynamometer equipment and then the structurally uniform contact between the disc and pad was achieved. The temperature distribution of flexible pad was measured using the infrared camcorder. Hence, the proposed flexible pad showed the better structural stability and thermal energy emission.

• Transactions of the Korean Society for Noise and Vibration Engineering
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• v.24 no.12
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• pp.954-961
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• 2014

Brake squeal noise of KTX is very uncomfortable to passengers and workers in stations. A lot of study has been conducted to inquire into the mechanism of the squeal noise. But understanding of the brake squeal noise is still challenging. In this study, we developed a full-scale tester equipped with a KTX mechanical brake unit. And we measured the vibrational characteristics of each component of the brake unit and compared them with frequency response functions of brake squeal noise measured also in the tester. It was found that the brake squeal noise was more closely related to the vibrational characteristics of the brake pads and hangers in friction condition than those of free components.

• Tribology and Lubricants
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• v.30 no.3
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• pp.177-182
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• 2014

To stop a high speed train running at the speed of 300 km/h, the disc brake for the train should be able to dissipate enormous kinetic energy of the train into frictional heat energy. Sintered pin-type metals are mostly used for friction materials of high speed brake pads. A pad comprises several friction pins, and the topology, length, flexibility, composition, etc. have a great influence on the tribological properties of the disc brake. In this study, the topology of the friction pins in a pad was our main concern. We presented the optimization of the topology of a railcar brake pad with nine-pin-type friction materials by thermo-mechanical contact analysis. We modeled the brake pad with/without a back plate. To simulate a continuous braking, the pad or friction materials were rotated at constant velocity on the friction surface of the disc. We varied the positions of the nine friction materials to compare the temperature distributions on the disc surface. In a non-optimized brake pad, the distance between two neighboring friction materials in the radial direction from the rotational center of the disc was not equal. In an optimized pad, the distance between two neighboring friction materials in the radial direction was equal. The temperature distribution on the disc surface fluctuated more for the former than the latter. Optimizing the pad reduced the maximum temperature of the brake disc by more than 10%.