DE102022202788A1 - Coated brake disc for a vehicle and method for producing such a coated brake disc for a vehicle - Google Patents

Abstract

The invention relates to a coated brake disc (2) for a vehicle, which can be rotated about an axis of rotation (4), with at least one base body (6), with at least one friction layer (8) which is subject to wear and which is attached to the base body (6) as an additional coating is fixed and which has a braking surface (10) on the side facing away from the base body (6), on which a braking agent is in contact when braking the vehicle and causes wear, and with at least one wear progress indicator (12), which has at least one critical wear indicator (14 ), which is arranged in the braking surface (10) of the friction layer (8), which is visually perceptible until the friction layer (8) reaches or falls below a critical friction layer thickness, at which the friction layer (8) is almost removed, and the is abraded from reaching or falling below the critical friction layer thickness of the friction layer (8), and which comprises at least one intermediate level wear indicator (16) which is arranged in the braking surface (10) of the friction layer (8), which until it reaches or falls below a Intermediate friction layer thickness of the friction layer (8), which is greater than the critical friction layer thickness, is visually perceptible and which is worn off when the intermediate friction layer thickness of the friction layer (8) is reached or falls below.

Description

The invention relates to a coated brake disc for a vehicle and a method for producing such a coated brake disc for a vehicle.

Coated brake discs are known from the prior art, in which a base body, which consists, for example, of gray cast iron, is coated with a friction layer made of hard material and/or a similar material. The friction layer serves as a friction surface on which a braking agent can be placed in contact when the vehicle is braked.

The friction layer thickness of coated brake discs is very small and is approx. 100-300 µm.

Due to the very thin friction layer, it is difficult to determine whether this friction layer is worn out and the brake disc needs to be replaced or reconditioned or whether the brake disc can still be used. For this purpose, a very precise measuring tool must be used, such as a micrometer screw or a similarly precise measuring tool. This turns out to be time-consuming and complicated.

If the friction layer is removed, the braking agent lies directly on the base body, which means that the braking behavior of the brake disc is unfavorably changed.

One object of an exemplary embodiment of the invention is to propose a coated brake disc for a vehicle and a method for producing such a coated brake disc for a vehicle, in which checking whether there is a sufficient friction layer thickness is simplified.

This object is achieved by a coated brake disc for a vehicle, which is rotatable about an axis of rotation, with at least one base body, with at least one friction layer which is subject to wear, which is fixed to the base body as an additional coating and which has a braking surface on the side facing away from the base body , on which a braking agent is in contact when braking the vehicle and causes wear, and with at least one wear progress indicator, which includes at least one critical wear indicator, which is arranged in the braking surface of the friction layer, which until the friction layer reaches or falls below a critical friction layer thickness, in which the friction layer is almost worn away, is visually perceptible and which is worn off once the critical friction layer thickness of the friction layer is reached or falls below, and which comprises at least one intermediate wear indicator which is arranged in the braking surface of the friction layer, which until it is reached or falls below an intermediate friction layer thickness of the friction layer which is greater than the critical friction layer thickness, is visually perceptible and which is worn off when the intermediate friction layer thickness of the friction layer is reached or falls below.

Because the coated brake disc includes a wear progress indicator that includes at least one critical wear indicator, it is quickly and easily visually detectable during an inspection of the vehicle whether the coated brake disc needs to be replaced or reconditioned. Because the wear progress indicator includes at least one intermediate wear indicator, which is visually perceptible when the intermediate friction layer thickness of the friction layer is reached or falls below, which is greater than the critical friction layer thickness, an inspection interval or a checking interval can be planned.

A check interval can be planned based on the material thickness between the intermediate friction layer thickness and the critical friction layer thickness as well as an average removal of the friction layer in relation to the kilometers driven by the motor vehicle.

Coated brake discs include friction layers with friction layer thicknesses of approx. 100-300 µm.

In a coated brake disc, the base body and friction layer comprise components that are joined together. In particular, the friction layer comprising a hard material or stainless steel is applied as a coating, which is joined to the base body in particular by means of laser deposition welding. The critical friction layer thickness can be 20 µm for coated brake discs.

The fact that the coated brake disc includes a wear progress indicator means that there is no need to laboriously measure the already very thin friction layer.

The wear progress indicator can be provided easily and inexpensively if the critical wear indicator and/or at least one of the at least one intermediate level wear indicator comprises at least one recess in the friction layer, which extends from the braking surface of the friction layer parallel to the axis of rotation in the direction of the base body and onto the reason The side facing away from the body is open to the outside, wherein the recess of the critical wear indicator parallel to the axis of rotation comprises a depth which corresponds to the distance from the braking surface to the critical friction layer thickness and / or wherein the recess of the intermediate level wear indicator parallel to the axis of rotation comprises a depth which corresponds to the distance from the braking surface to the intermediate friction layer thickness.

Because the critical wear indicator and/or at least one of the at least one intermediate level wear indicator comprises at least one recess in the friction layer, the respective wear indicator can be easily designed. As the friction layer is removed over the life cycle of the brake disc, the depth of the recess in the respective wear indicator becomes steadily smaller until the respective wear indicator is completely removed. Accordingly, due to the shallower depth of its recess, the intermediate wear indicator is already removed before the critical wear indicator is removed.

In a further development of the last-mentioned embodiment, it proves to be advantageous if the recesses of the critical wear indicator and the recess of the at least one intermediate level wear indicator each comprise a cross section transverse to the axis of rotation which has a width that is proportional to the depth of the recess, the recess with the greatest depth has the greatest width and the recess with the smallest depth has the smallest width.

Because the width of the respective recess of the respective wear indicator is proportional to the respective depth of the recess, it can be quickly determined during a visual inspection of the brake disc that the wear indicator is the critical wear indicator or an intermediate level wear indicator.

In addition, if several intermediate wear indicators are provided, each of which is assigned to different layer thicknesses of the friction layer, progress in wear of the friction layer of the brake disc can be recorded in a simplified manner.

In one embodiment of the brake disc, it proves to be advantageous if the recess forming the critical wear indicator and/or the at least one intermediate level wear indicator, which is arranged in the friction layer, is designed like a groove and, when viewed transversely to the axis of rotation, surrounds an area filled with friction layer material in sections or in its entirety or if the recess forming the critical wear indicator and/or the intermediate level wear indicator, which is arranged in the friction layer, comprises a material-free recess.

If the critical wear indicator and/or at least one of the at least one intermediate level wear indicator is groove-like, the braking surface of the friction layer available for braking is maximum.

If the critical wear indicator and/or at least one of the recess forming at least one intermediate level wear indicator comprises a material-free recess, the risk of the recess becoming clogged by contamination is reduced and the optical detection of the respective wear indicator is improved.

In order to further improve the visual detectability of the wear progress indicator, in one embodiment of the brake disc it is provided that the critical wear indicator and / or at least one of the at least one intermediate wear indicator is a polygonal, in particular triangular or square, a rounded, in particular circular or elliptical , a dot-like, a line-like or an arrow-like cross section or that the critical wear indicator and / or at least one of the at least one intermediate wear indicator in cross section includes a representation, such as a logo.

This further improves the ability to distinguish the respective wear indicator from the surface of the friction layer.

The critical wear indicator and at least one of the at least one intermediate level wear indicator can be arranged anywhere on the braking surface of the friction layer. For example, the critical wear indicator can be arranged at a first position and at least one of the at least one intermediate wear indicator can be arranged on the braking surface of the friction layer offset by an angle with respect to the axis of rotation.

The condition of the brake disc can be determined in a simplified manner if the at least one critical wear indicator and at least one of the at least one intermediate level wear indicator are arranged on the same radial through the axis of rotation and on the same side and surface of the brake disc with respect to the axis of rotation.

In this case, the critical wear indicator and at least one of the at least one intermediate wear indicator can be arranged on an optical line. This makes it possible to quickly determine whether there is already any intermediate level wear indicators have been removed and, for example, only the critical wear indicator is visually perceptible.

In principle, it is conceivable that the wear progress indicator only has the critical wear indicator and a single intermediate wear indicator. In such a case, the intermediate wear indicator is designed in such a way that, based on statistical experience, the brake disc will definitely still have a sufficient friction layer until the next inspection, when the intermediate wear indicator is still visually perceptible.

In order to be able to detect and observe increasing wear on the friction layer of the brake disc, it proves to be advantageous if the wear progress indicator comprises at least two intermediate level wear indicators, with a first intermediate level wear indicator optically until the friction layer reaches or falls below a first intermediate level friction layer thickness is perceptible, which is greater than the critical friction layer thickness and which is abraded from reaching or falling below the first intermediate friction layer thickness of the friction layer and wherein a second intermediate level wear indicator is visually perceptible until a second intermediate friction layer thickness of the friction layer is reached or fallen below, which is greater than the first intermediate friction layer thickness and which is rubbed off when the friction layer reaches or falls below the second intermediate friction layer thickness.

The different friction layer thicknesses can be so different that they correspond to normal vehicle maintenance intervals. For example, a first intermediate wear indicator can include such a first intermediate friction layer thickness that the first intermediate wear indicator has worn off after 40,000 km. Accordingly, the second intermediate wear indicator can include such a second intermediate friction layer thickness that the second intermediate wear indicator has worn off after 80,000 km of mileage.

The critical wear indicator and at least one of the at least one intermediate level wear indicator can be arranged anywhere on the braking surface of the friction layer with regard to their distance from the axis of rotation. In order to further facilitate visual detection, it proves to be advantageous if the critical wear indicator covers the smallest or the largest distance from the axis of rotation with respect to the at least one intermediate wear indicator.

In this case, an inspection makes it quick and easy to see which of the wear indicators includes a critical wear indicator and an intermediate wear indicator.

In a further development of the last-mentioned embodiment, it proves to be advantageous if the respective distance that the wear indicators of the wear progress indicator have to the axis of rotation is sorted from wear indicators with the greatest friction layer thickness, from which the corresponding wear indicator is rubbed off when it is reached or falls below, to wear indicators with the smallest friction layer thickness , from which the corresponding wear indicator is rubbed off if it is reached or fallen below.

This means that the wear indicators are sorted from the inside to the outside or from the outside to the inside. If all wear indicators are on the same radial with respect to the axis of rotation, wear progress can be quickly visualized. As a result of increasing wear, the innermost or outermost intermediate wear indicator, the adjacent wear indicator and finally the critical wear indicator disappear.

In order to further improve the ability to detect the condition of the friction layer of the brake disc, in one embodiment of the brake disc it is provided that at least three wear progress indicators are arranged on, on or in each friction layer.

This can reduce the risk that the wear progress indicator cannot be detected immediately, for example due to partial or area contamination of the braking surface of the friction layer.

If several wear progress indicators are arranged on or in the friction layer, these can in principle be arranged anywhere on the braking surface of the friction layer. In order to ensure a uniform distribution of the wear progress indicator, in a further development of the last-mentioned embodiment it is provided that the wear progress indicators are arranged in the friction layer with respect to the axis of rotation at the same or different angles to one another, evenly or unevenly distributed.

The brake disc can comprise a friction layer on a single surface of the base body that runs transversely to the axis of rotation. In addition, coated brake discs include a friction layer on both sides, i.e. on both surfaces of the base body that run transversely to the axis of rotation. Who can never be completely ruled out? Since the two surfaces running transversely to the axis of rotation can be worn differently over the course of a life cycle of the brake disc, it proves to be advantageous if a friction layer with at least one wear progress indicator is arranged on each surface of the base body running transversely to the axis of rotation.

In principle, it is conceivable that the friction layer is applied directly to the base body. In addition, an adhesive layer to which the friction layer is applied can be applied to the base body. In addition, it is conceivable that the brake discs include several friction layers that are worn one on top of the other. In this case, the wear indicators can extend through several of these layers and the friction layer thickness can be composed of the sum of the individual friction layers stacked on top of each other.

In addition, embodiments of the brake disc are conceivable in which the base body is made of gray cast iron with a friction layer thickness of 1.0 mm to 1.5 mm and/or in which the friction layer is made of stainless steel, an oxide, such as a ceramic-metal composite material, or a carbide with a friction layer thickness of 100 µm to 300 µm or a stainless steel with a friction layer thickness of 100 µm to 1.5 mm.

In addition, it proves to be advantageous if at least one of the at least one friction layer applied to the base body has a friction layer thickness of 100 µm to 300 µm, and if the critical wear indicator of the wear progress indicator is worn off when the layer thickness falls below a critical layer thickness of 20 µm.

Finally, the object is achieved by a method for producing a coated brake disc for a vehicle, according to at least one of the aforementioned features, in which at least one friction layer is applied to a base body without a friction layer or to the section of a base body without a friction layer until a predeterminable or predetermined friction layer thickness is reached, in particular by means of Laser deposition welding, is applied, wherein a critical wear indicator arranged in the friction layer and at least one intermediate level wear indicator is formed when the friction layer is applied, in particular by material release, or wherein a critical wear indicator arranged in the friction layer and at least one intermediate level wear indicator after the friction layer has been applied to the Base body is formed by removing material, such as turning, milling, eroding, lasering or grinding.

Further features, details and advantages of the invention result from the attached patent claims, from the graphic representation and the following description of a preferred embodiment of the brake disc.

• 1 Eine Draufsicht auf ein Ausführungsbeispiel einer beschichteten Bremsscheiben;
• 2 Eine geschnittene Ansicht entlang der Linie AA gemäß 1 sowie Detailvergrößerungen.

In the drawing shows:

• 1 A top view of an embodiment of a coated brake disc;
• 2 A sectional view along line AA according to 1 as well as enlargements of details.

The figures show a coated brake disc for a vehicle, provided overall with the reference number 2. The coated brake disc 2 can be rotated about an axis of rotation 4. The coated brake disc 2 comprises a base body 6, in which, in the exemplary embodiment shown in the figures, a friction layer 8 which is subject to wear is arranged on both surfaces running transversely to the axis of rotation 4. The friction layer 8 is fixed to the base body 6 as an additional coating. On the side facing away from the base body 6, the friction layers 8 each comprise a braking surface 10. When the vehicle is braked, a braking agent is in contact with the braking surfaces 10 and causes wear (not shown in the figures).

The coated brake disc 2 also includes several wear progress indicators 12, each of which includes a critical wear indicator 14, which is arranged on the braking surface 10 of the friction layer 8, which until the friction layer 8 reaches or falls below a critical friction layer thickness, at which the friction layer 8 is almost worn away is, is visually perceptible and which is rubbed off when the critical friction layer thickness of the friction layer 8 is reached or falls below.

In addition, the wear progress indicators 12 in the exemplary embodiment shown in the figures each include two intermediate wear indicators 16, which are arranged in the braking surface 10 of the friction layer 8, which until the intermediate friction layer thickness of the friction layer 8 is reached or falls below, which is greater than that critical friction layer thickness, are visually perceptible and which are rubbed off when the friction layer 8 reaches or falls below the intermediate level friction layer thickness.

The figures show an exemplary embodiment of the coated brake disc 2, in which the critical wear indicator 14 and the intermediate wear indicators 16 are formed by recesses which are parallel to the axis of rotation 4 the braking surface 10 of the friction layer 8 extend in the direction of the base body 6.

In the exemplary embodiment shown in the figures, the critical wear indicators 14 of the wear progress indicators 12 and the intermediate wear indicators 16 of the wear progress indicator 12 comprise a rounded, in particular circular, cross section transverse to the axis of rotation 4. In addition, the recesses include material-free depressions.

The wear progress indicators 12 are designed in such a way that the critical wear indicator 14 and the two intermediate wear indicators 16 are arranged on the same radial with respect to the axis of rotation 4 and on the same side and surface of the brake disc 2. The critical wear indicators 14 each comprise the smallest distance with respect to the axis of rotation 4 in the wear progress indicators 12 shown.

The wear progress indicators 12 include two intermediate wear indicators 16. Of these, a first intermediate wear indicator 18 includes a first intermediate friction layer thickness of the friction layer 8, which is greater than the critical friction layer thickness 8. A second intermediate wear indicator 20 includes a second intermediate friction layer thickness of the friction layer 8, which is larger than the first intermediate level wear indicator 16 comprising the second intermediate level friction layer thickness of the friction layer 8.

In the exemplary embodiment shown in the figures, the critical wear indicator 14 of the wear progress indicator 12 comprises the smallest distance to the axis of rotation 4. This is followed by the first intermediate level wear indicator 18 and then the second intermediate level wear indicator 20. Over the course of a life cycle of the coated brake disc 2, at in which the friction layer 8 is subject to wear and is continually removed, in this case the second intermediate friction layer thickness of the friction layer 8 will initially be reached and fallen below, i.e. the second intermediate wear indicator 20 will no longer be visually perceptible.

This is followed by the disappearance of the first intermediate level wear indicator 18 when the first intermediate level friction layer thickness is reached or fallen below.

Finally, the critical wear indicator 14 will no longer be visually perceptible when the critical friction layer thickness of the friction layer 8 has been reached or fallen below, i.e. the friction layer 8 has almost been removed.

In the exemplary embodiment shown in the figures, the coated brake disc 2 comprises three wear progress indicators 12 on both sides. These are arranged evenly distributed on the braking surface 10 of the friction layer 8, in particular spaced apart from one another at an angle of 120 degrees with respect to the axis of rotation 4.

The features of the invention disclosed in the above description, in the claims and in the drawing can be essential both individually and in any combination in the implementation of the invention in its various embodiments.

Reference symbol list

2

coated brake disc

4

Axis of rotation

6

Basic body

8th

friction layer

10

braking surface

12

Wear progress indicator

14

critical wear indicator

16

Intermediate wear indicator

18

first intermediate wear indicator

20

second intermediate wear indicator

Claims (15)

Coated brake disc (2) for a vehicle, which can be rotated about an axis of rotation (4), with at least one base body (6), with at least one friction layer (8) which is subject to wear and which is fixed to the base body (6) as an additional coating and which on the side facing away from the base body (6) has a braking surface (10), on which a braking agent is in contact when braking the vehicle and creates wear, and with at least one wear progress indicator (12), which includes at least one critical wear indicator (14). is arranged in the braking surface (10) of the friction layer (8), which is visually perceptible until a critical friction layer thickness of the friction layer (8) is reached or falls below, at which the friction layer (8) is almost removed, and which is from reaching or falling below the critical friction layer thickness of the friction layer (8) is abraded, and which comprises at least one intermediate level wear indicator (16), which is arranged in the braking surface (10) of the friction layer (8), which until an intermediate level friction layer thickness is reached or fallen below Friction layer (8), which is larger than the critical friction layer thickness, is visually perceptible and which is worn off once the friction layer (8) reaches or falls below the intermediate level friction layer thickness. Brake disc (2). Claim 1 , characterized in that the critical wear indicator (14) and / or at least one of the at least one intermediate wear indicator (16) comprises at least one recess in the friction layer (8), which is parallel to the braking surface (10) of the friction layer (8). extends to the axis of rotation (4) in the direction of the base body (6) and is open to the outside on the side facing away from the base body (6), the recess of the critical wear indicator (14) parallel to the axis of rotation (4) comprising a depth that corresponds to the distance the braking surface (10) corresponds to the critical friction layer thickness and/or wherein the recess of the intermediate level wear indicator (16) parallel to the axis of rotation (4) has a depth which corresponds to the distance between the braking surface (10) up to the intermediate level friction layer thickness. Brake disc (2). Claim 2 , characterized in that the recesses of the critical wear indicator (14) and the recess of the at least one intermediate wear indicator (16) each comprise a cross section transverse to the axis of rotation (4) which has a width that is proportional to the depth of the recess, where the recess with the greatest depth has the greatest width and the recess with the smallest depth has the smallest width. Brake disc (2). Claim 2 or 3 , characterized in that the recess forming the critical wear indicator (14) and/or the at least one intermediate level wear indicator (16), which is arranged in the friction layer (8), is groove-like and viewed transversely to the axis of rotation (4). area filled with friction layer material circumferentially in sections or in its entirety or that the recess forming the critical wear indicator (14) and/or the intermediate level wear indicator (16), which is arranged in the friction layer (8), comprises a material-free recess. Brake disc (2) according to one of the preceding claims, characterized in that the critical wear indicator (14) and / or at least one of the at least one intermediate wear indicator (16) is a polygonal, in particular triangular or square, a rounded, in particular circular or elliptical, a point-like, a line-like or an arrow-like cross section or that the critical wear indicator (14) and / or at least one of the at least one intermediate level wear indicator (16) includes a representation, such as a logo, in cross section. Brake disc (2) according to one of the preceding claims, characterized in that the at least one critical wear indicator (14) and at least one of the at least one intermediate wear indicator (16) on the same radial through the axis of rotation (4) and with respect to the axis of rotation (4) are arranged on the same side and surface of the brake disc (2). Brake disc (2) according to one of the preceding claims, characterized in that the wear progress indicator (12) comprises at least two intermediate wear indicators (16), wherein a first intermediate wear indicator (18) reaches or falls below a first intermediate friction layer thickness Friction layer (8) is visually perceptible, which is greater than the critical friction layer thickness and which is abraded from reaching or falling below the first intermediate level friction layer thickness of the friction layer (8) and wherein a second intermediate level wear indicator (20) until it reaches or falls below one second intermediate friction layer thickness (20) of the friction layer (8) is visually perceptible, which is greater than the first intermediate friction layer thickness and which is worn off when the second intermediate friction layer thickness (20) of the friction layer (8) is reached or falls below. Brake disc (2) according to one of the preceding claims, characterized in that the critical wear indicator (14) comprises the smallest or the largest distance from the axis of rotation (4) with respect to the at least one intermediate wear indicator (16). Brake disc (2). Claim 8 , characterized in that the respective distance that the wear indicators of the wear progress indicator (12) have to the axis of rotation (4) is sorted from wear indicators with the greatest friction layer thickness, from which the corresponding wear indicator is rubbed off when it is reached or falls below, to wear indicators with the smallest friction layer thickness, from which the corresponding wear indicator is rubbed off when it is reached or fallen below. Brake disc (2) according to one of the preceding claims, characterized in that at least three wear progress indicators (12) are arranged on, on or in each friction layer (8). Brake disc (2). Claim 10 , characterized in that the wear continues Step displays (12) with respect to the axis of rotation (4) are arranged in the friction layer (8) at the same or different angles to one another, evenly or unevenly distributed. Brake disc (2) according to one of the preceding claims, characterized in that a friction layer (8) with at least one wear progress indicator (12) is arranged on each surface of the base body (4) running transversely to the axis of rotation (4). Brake disc (2) according to one of the preceding claims, characterized in that the base body (6) is a gray cast iron with a friction layer thickness of 1.0 mm to 1.5 mm and / or that the friction layer (8) is a stainless steel, an oxide , such as ceramic-metal composite material, or a carbide with a friction layer thickness of 100 µm to 300 µm or a stainless steel with a friction layer thickness of 100 µm to 1.5 mm. Brake disc (2) according to one of the preceding claims, characterized in that at least one of the at least one friction layer (8) applied to the base body (6) has a friction layer thickness of 100 µm to 300 µm, and that the critical wear indicator (14) of the wear progress indicator (12) is rubbed off when the layer thickness falls below a critical layer of 20 µm. Method for producing a coated brake disc (2) for a vehicle, according to one of Claims 1 until 14 , in which at least one friction layer (8) is applied to a friction layer-free base body (6) or to the friction layer-free section of a base body (6) until a predetermined or predetermined friction layer thickness is reached, in particular by means of laser deposition welding, one arranged in the friction layer (8). critical wear indicator (14) and at least one intermediate wear indicator (16) is formed when the friction layer (8) is applied, in particular by material release, or wherein a critical wear indicator (14) arranged in the friction layer (8) and at least one intermediate wear indicator (16) after applying the friction layer (8) to the base body (6) by removing material, such as turning, milling, eroding, lasering or grinding.

Images