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Optimizing durability – ensuring the reliability of Knorr-Bremse’s ACR system under harsh vibration loads

Knorr-Bremse uses HBK strain gauges for vibration tests and nCode GlyphWorks for fatigue life prediction, optimizing ACR to reduce residual brake torque.

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Optimise the ACR (system for reduction of residual brake torques), to withstand harsh vibration loads, ensuring consistent performance and maintaining reliability in demanding operating environments for commercial vehicle braking systems.

Strain measurement using HBK strain gauges during vibration tests, followed by fatigue life prediction with nCode GlyphWorks. Data enabled statistical root cause analysis to identify critical design factors affecting ACR lifespan under vibration stress.

Key design factors were identified using advanced analysis methods to ensure maximum robustness of the ACR against harsh vibration loads. As a result, the ACR has been successfully operating in serial production for several years.

Ensuring Robustness Against Vibration Loads

Knorr-Bremse introduced the ACR System to improve the efficiency and durability of commercial vehicle disc brakes by reducing residual drag torque. This innovation minimizes fuel consumption and brake pad wear, extending the lifespan of braking systems. However, to ensure long-term reliability, it was essential to optimize the ACR’s design to withstand harsh vibration loads encountered during real-world operation.

Strain Measurement and Statistical Analysis

Using HBK strain gauges, vibration loads were applied to the ACR under different design conditions. Fatigue life predictions were performed with nCode GlyphWorks, and the resulting data formed the foundation for a statistical root cause analysis, identifying the critical design factors that would maximize the system’s durability under vibration loading.

Reliable Performance in Serial Production

The analysis successfully pinpointed the design factors that contribute to the ACR’s robustness, ensuring consistent performance under demanding conditions. As a result, the ACR has been operating reliably in serial production for several years, enhancing the efficiency and durability of Knorr-Bremse’s latest brake generations - proving its reliability and longevity in commercial vehicle applications. With HBK’s advanced technology and mission to empower the innovators, and Knorr-Bremse’s commitment to innovation and excellence, Knorr-Bremse won a 2022 AUTOMECHANIKA Innovation Award.

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