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

“汽车行业将发生根本性的变化，因为电动汽车的部署预计将继续呈现两位数的增长，多个新的市场进入者将受到2025年清洁空气倡议的进一步鼓励，以加强趋势。此外，更高的自动化和无人驾驶汽车的前景正在逼近，预计从2020- 2030年起，主要原始设备制造商将首次提供电动汽车和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。这意味着将动能转换为热能的需求大大减少，因此可以从根本上重新设计基础制动器。目前，绝大多数汽车使用的制动部件（卡钳和制动盘）由重型灰铸铁制成，这种材料在过去80年中一直是首选，几乎所有汽车都采用了这种材料。唯一的替代方案是碳陶瓷技术-非常昂贵，需要数月和大量的能源来制造。Full-Stop** 为市场提供了第三种选择-一种可行的系统，比铸铁轻得多，但在所有行业标准测试中具有匹配的性能，而且成本相当-具有快速清洁的简单制造工艺。Full-Stop采用耐高温复合材料的最新进展，提供重量减轻60%的基础制动系统（卡钳/制动盘和制动片），同时这些安全关键部件的性能仍然达到最高等级。Full- Stop** 结合了之前的两项创新英国计划- 1）BRAKETHRU，一项为期2年的计划，专注于复合制动盘，一种新的制动盘结构诞生了，现在正在申请专利。2)CABTEC --一项短期研究，重点是开发聚合物复合材料卡钳和轻质刹车片，其可行性已得到证明，并在项目结束时（2018年3月）生产出第一个原型。Full -Stop** 的目标是提高TRL水平并为商业化做好准备。虽然BRAKETHRU的结果非常令人鼓舞，但需要更广泛的长期测试计划，沿着一系列OEM特定的环境测试，以便在所有可行条件下建立性能，并证明可扩展到其他车辆类型，并调查噪音性能，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计划，包括对目前的复合材料卡钳原型进行几次迭代，以及一个完整的车载测试计划。"

"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."