Disk Brake

The disc brake system is an effective braking mechanism that slows and stops a vehicle by clamping brake pads mounted in a caliper against a rotating disc (rotor) attached to the wheel hub. This system converts kinetic energy into thermal energy through friction and is commonly used on front wheels, with increasing adoption on all four wheels.

Structure and Operating Principle

The disc brake mechanism consists of a brake disc (rotor), caliper assembly, brake hydraulic cylinder/piston, brake pads (friction element), and connecting components. When the brake pedal is pressed, hydraulic pressure activates the caliper or pistons, causing the brake pads to clamp the disc from both sides, generating friction that slows the disc’s rotation.

Components and Characteristics

• Brake Disc (Rotor): A rotating component attached to the wheel hub by bolts. There are two types: ventilated discs, which cool rapidly during rotation due to a fan-like effect; and solid discs, which are simpler and more durable.
• Caliper: Composed of brake pads, pistons, and a housing. Both fixed and sliding types are available.
• Brake Pads: The friction element that contacts the disc surface. Their thickness decreases with wear; therefore, automatic clearance adjustment systems or adaptive piston seal designs are used to maintain optimal contact.

Advantages

Disc brakes provide reliable braking performance at high speeds due to their resistance to high temperatures and rapid heating and cooling characteristics. They also require less maintenance and offer advantages in terms of cleanliness of the disc-pad contact surfaces.

Maintenance and Failure Indicators

• Braking distance increases when brake pads become thin.
• Vibration is felt due to scratches, damage, or deformation on the disc surface.
• Excessive dust accumulation on brake pads and sticking of caliper pistons may occur.
• In some systems, brake pad fatigue can cause the brake pedal to remain depressed.

During periodic maintenance, brake pad thickness should be checked, the disc surface should be inspected for wear, and caliper piston movement should be verified for free operation.