Full Stop – An Advanced Friction Braking System Designed For HEV and Autonomous Vehicles

“随着电动汽车的部署预计将继续呈现两位数的增长，汽车行业将经历一场根本性的变化，许多新的市场进入者受到2025年清洁空气倡议的进一步鼓励，以加强趋势。此外，自动化程度的提高和无人驾驶汽车的前景正在逼近，预计从2020年到2030年，主要原始设备制造商将推出首次产品。电动汽车和4级和5级全自动驾驶汽车（AV）将使用再生制动系统（RBS），该系统引入了一种全新的车辆减速方法。这意味着将动能转化为热能的需求大大减少，因此基础制动器可以从根本上重新设计。目前，绝大多数汽车使用的制动部件（卡钳和制动盘）都是由灰铸铁制成的，这种材料在过去80年里一直是汽车的选择，几乎所有的汽车都使用这种材料。唯一的替代方案是碳陶瓷技术，这种技术极其昂贵，需要数月的时间和大量的能源来制造。**Full-Stop**为市场提供了第三种选择，这是一种比铸铁轻得多的可行系统，但在所有行业标准测试中都具有匹配的性能，而且成本也相当，制造过程简单，快速清洁。Full-Stop利用最新的耐高温复合材料，提供了一个基础制动系统（卡钳/盘和垫），减轻了60%的重量，同时仍然具有这些安全关键部件的最高额定值。**Full- Stop**汇集了两个之前的Innovate-UK倡议- 1)BRAKETHRU，一个为期2年的计划，专注于复合制动盘，其中一个新的光盘架构诞生，现在正在申请专利。2) CABTEC——一项专注于开发聚合物复合卡钳和轻质刹车片的短期研究，其可行性已经得到验证，并在项目结束时（2018年3月）生产了第一个原型。目标是提高TRL水平，为商业化做准备。虽然BRAKETHRU的测试结果非常鼓舞人心，但还需要更广泛的长期测试计划，以及大量oem特定的环境测试，以确定在所有可行条件下的性能，并展示其在其他车型上的可扩展性，并研究噪音性能、耐腐蚀性和其他理想的商业方面。CABTEC需要进入一个完整的研发项目，包括对当前复合卡钳原型进行多次迭代，以及一个完整的车载测试项目。”

"The car industry is set to undergo a fundamental change as the deployment of EVs is expected to continue to show double digit growth, with multiple new market entrants, encouraged further by clean air initiatives from 2025 to reinforce trends. Additionally, greater automation and the prospect of the driverless car is looming, where from 2020- 2030 onwards initial offerings from major OEMs are expected.EVs and Level 4 &5 Fully Autonomous Vehicles (AV) will utilise Regenerative Braking Systems (RBS) which introduces a fundamentally new method of decelerating the vehicle. This means the need to convert kinetic into thermal energy is significantly reduced and foundation brakes can therefore, can be fundamentally re-designed. Right now, the vast majority of cars use braking components (calipers and discs) made from heavy grey cast iron -the material of choice for the last 80 years and deployed on almost all cars. The only alternative is carbon ceramic technology -- extremely expensive, taking months and vast amounts of energy to manufacture.**Full-Stop** offers the market a third alternative, -a viable system that is far lighter than cast iron but with matching performance in all industry standard tests, but also with comparable cost, -with a simple manufacturing process that's fast and clean. Full-Stop utilises the latest advances in high temperature tolerant composite materials, to deliver a foundation braking system (Callipers/discs and pads) with a 60% weight saving, whist still performing to the highest rating for these safety-critical components.**Full- Stop** brings together two preceding Innovate-UK initiatives -- 1) BRAKETHRU, a 2yr program focused on the composite brake disc, where a new disc architecture was born and is now being patented. 2) CABTEC -- a short study focused on developing polymer composite calipers and lightweight brake pads, where feasibility had been demonstrated and a first prototype produced by project end (March-2018).**The Full --Stop** objective is to raise the TRL level and prepare for commercialisation. Whilst the BRAKETHRU outcomes are extremely encouraging, a more extensive longer term testing programme is required, along with a whole raft of OEM-specific, and environmental testing in order to establish performance under all feasible conditions together with demonstrating the scalability to other vehicle types, and investigate noise performance, corrosion resistance and other desirable commercial aspects. CABTEC needs to progress into a full R&D program involving several more iterations of the current composite calliper prototype, and a full on-vehicle test programme."