Abstract: Systems and methods of making an enhanced brake rotor having enhanced wear resistance are provided. The systems and methods provide a vehicular rotor comprising a base comprising iron (Fe). The base comprises an outer surface having a laser-hardened portion thereon. The laser-hardened portion comprises martensite and having a thickness of between 10 and 100 microns of the outer surface to define the enhanced brake rotor with enhanced wear resistance.

Abstract: Systems and methods of making an enhanced vehicular brake rotor having improved wear and corrosion resistance are provided. The enhanced vehicular brake rotor comprises a brake rotor comprising a base comprised of iron (Fe). The base comprises an outer surface having open pores formed thereon. The rotor has a steam-treated layer formed on the outer surface and in the open pores. The steam-treated layer is comprised of iron oxide (Fe3O4) and has a thickness of between 10 and 50 microns for enhanced wear and corrosion resistance to define the enhanced vehicular rotor.

Abstract: Systems and methods of making an enhanced brake rotor having enhanced wear resistance are provided. The systems and methods provide a vehicular rotor comprising a base comprising iron (Fe). The base comprises an outer surface having a laser-hardened portion thereon. The laser-hardened portion comprises martensite and having a thickness of between 10 and 100 microns of the outer surface to define the enhanced brake rotor with enhanced wear resistance.

Abstract: A method for manufacturing a ferrous rotational member including the steps of turning a first portion of the friction surface at a sufficient feed rate to provide a first deformed layer on the first portion of the friction surface; fine turning a second portion of the friction surface at a sufficient feed rate to provide a second deformed layer on the second portion of the friction surface; burnishing the first and second portions of the friction surface to achieve a predetermined roughness; and nitrocarburizing the rotational member at a time and temperature sufficient for the diffusion of nitrogen atoms and carbon atoms through the deformed layer to form hardened casings having variable thickness. The ferrous rotational member may be that of a brake rotor having a hub surface and a friction surface, where the hub surface and friction surface have a variable thickness hardened casing.

Abstract: An exemplary method for determining a remaining life expectancy of a brake component includes the steps of providing vehicle parameters that identify operating conditions of a vehicle, using the vehicle parameters to determine work done by a brake of the vehicle as brake work, using the brake work to determine brake rotor temperature, using the brake rotor temperature to determine a fatigue damage of the brake component, accumulating the fatigue damage to determine a cumulative fatigue damage of the brake component, and comparing the cumulative fatigue damage to a damage limit to provide an estimation of the remaining life expectancy of the brake component.

Abstract: A shield assembly is employed for a friction brake used to decelerate a road wheel of a vehicle. The vehicle has a body with a first body end configured to face an incident ambient airflow, a second body end opposite of the first body end, and an underbody section spanning a distance between the first and second ends. The shield assembly includes a first shield component arranged proximate the brake and rotationally fixed relative to the vehicle body. The shield assembly also includes a second shield component operatively connected to the first shield component for shifting relative thereto. The shield assembly additionally includes an actuator employing a shape memory alloy element to shift the second shield component relative to the first shield component in response to a temperature of the brake to thereby direct at least a portion of the airflow to the brake and control temperature thereof.

Abstract: A shield assembly is employed for a friction brake used to decelerate a road wheel of a vehicle. The vehicle has a body with a first body end configured to face an incident ambient airflow, a second body end opposite of the first body end, and an underbody section spanning a distance between the first and second ends. The shield assembly includes a first shield component arranged proximate the brake and rotationally fixed relative to the vehicle body. The shield assembly also includes a second shield component operatively connected to the first shield component for shifting relative thereto. The shield assembly additionally includes an actuator employing a shape memory alloy element to shift the second shield component relative to the first shield component in response to a temperature of the brake to thereby direct at least a portion of the airflow to the brake and control temperature thereof.

Abstract: A shield assembly is employed for a friction brake used to decelerate a road wheel of a vehicle. The vehicle has a body with a first body end configured to face an incident ambient airflow, a second body end opposite of the first body end, and an underbody section spanning a distance between the first and second ends. The shield assembly includes a first shield component arranged proximate the brake and rotationally fixed relative to the vehicle body. The shield assembly also includes a second shield component operatively connected to the first shield component for shifting relative thereto. The shield assembly additionally includes an actuator employing a shape memory alloy element to shift the second shield component relative to the first shield component in response to a temperature of the brake to thereby direct at least a portion of the airflow to the brake and control temperature thereof.

Abstract: An exemplary method for determining a remaining life expectancy of a brake component includes the steps of providing vehicle parameters that identify operating conditions of a vehicle, using the vehicle parameters to determine work done by a brake of the vehicle as brake work, using the brake work to determine brake rotor temperature, using the brake rotor temperature to determine a fatigue damage of the brake component, accumulating the fatigue damage to determine a cumulative fatigue damage of the brake component, and comparing the cumulative fatigue damage to a damage limit to provide an estimation of the remaining life expectancy of the brake component.

Abstract: A method for manufacturing a ferrous rotational member including the steps of turning a first portion of the friction surface at a sufficient feed rate to provide a first deformed layer on the first portion of the friction surface; fine turning a second portion of the friction surface at a sufficient feed rate to provide a second deformed layer on the second portion of the friction surface; burnishing the first and second portions of the friction surface to achieve a predetermined roughness; and nitrocarburizing the rotational member at a time and temperature sufficient for the diffusion of nitrogen atoms and carbon atoms through the deformed layer to form hardened casings having variable thickness. The ferrous rotational member may be that of a brake rotor having a hub surface and a friction surface, where the hub surface and friction surface have a variable thickness hardened casing.

Abstract: A brake temperature monitoring system configured to monitor at least one of a rotor and hydraulic fluid of a brake mechanism for a vehicle. The system including a controller including a processor and an electronic storage medium, a vehicle velocity sensor, an ambient temperature sensor, and a pre-programmed module. The vehicle velocity sensor is configured to output a velocity signal to the processor. The ambient temperature sensor is configured to output an ambient temperature signal to the processor. The model is pre-programmed into the electronic storage medium, and is adapted to estimate the temperature of at least one of the rotor and the hydraulic fluid. The estimation is based on an ambient air temperature, and a pre-established relationship between a conductive heat transfer factor and a convective heat transfer factor. The convective heat transfer factor is a function of vehicle velocity.

Abstract: Technical solutions are described to for determining thickness of a vehicle brake rotor. An example method includes providing vehicle parameters that identify operating conditions of a vehicle, and using the vehicle parameters to determine work done by a brake of the vehicle as brake-work. Further, the method includes using the brake work to determine brake rotor temperature, and using the brake rotor temperature to determine brake rotor wear. The method further includes accumulating the brake rotor wear to provide an estimation of the thickness of the vehicle brake rotor.

Abstract: A shield assembly is employed for a friction brake used to decelerate a road wheel of a vehicle. The vehicle has a body with a first body end configured to face an incident ambient airflow, a second body end opposite of the first body end, and an underbody section spanning a distance between the first and second ends. The shield assembly includes a first shield component arranged proximate the brake and rotationally fixed relative to the vehicle body. The shield assembly also includes a second shield component operatively connected to the first shield component for shifting relative thereto. The shield assembly additionally includes an actuator employing a shape memory alloy element to shift the second shield component relative to the first shield component in response to a temperature of the brake to thereby direct at least a portion of the airflow to the brake and control temperature thereof.

Abstract: A system for determining thickness of a brake pad includes a controller configured to provide a total braking energy of a vehicle with a regenerative energy braking system, and a rotor braking system that includes a plurality of brake pads. The system controller determines the work done by the brake pads as a combination of front brake pad work and rear brake pad work, then accumulates the brake pad wear to provide an estimation of the brake pad thickness using the front brake pad work and the rear brake pad work.

Abstract: A brake rotor comprising a brake pad wear surface; a hat surface; and a decorative insert comprising an insert material, the decorative insert disposed on the brake pad wear surface, the hat surface, or both; wherein at least one of a friction coefficient between the decorative insert and a brake pad is substantially the same as a friction coefficient between the brake pad wear surface and the brake pad, a wear rate of the decorative insert is substantially the same as or greater than a wear rate of the brake pad wear surface, or a wear rate of the decorative insert is substantially the same as or greater than a wear rate of the hat surface; and at least a portion of the decorative insert is visible on the brake pad wear surface, the hat surface, or both.

Abstract: An electromechanical brake system includes a caliper, an electric motor mounted to the caliper, a gear element mechanically connected to the electric motor, an actuator supported by the caliper, the actuator including an actuation member, and a controller operatively connected to the actuator. The controller is operable to selectively engage the actuation member with the gear element to positionally lock the first caliper member relative to the second caliper member.

Abstract: A system for determining thickness of a brake pad includes a controller configured to provide a total braking energy of a vehicle with a regenerative energy braking system, and a rotor braking system that includes a plurality of brake pads. The system controller determines the work done by the brake pads as a combination of front brake pad work and rear brake pad work, then accumulates the brake pad wear to provide an estimation of the brake pad thickness using the front brake pad work and the rear brake pad work.

Abstract: Technical solutions are described to for determining thickness of a vehicle brake rotor. An example method includes providing vehicle parameters that identify operating conditions of a vehicle, and using the vehicle parameters to determine work done by a brake of the vehicle as brake-work. Further, the method includes using the brake work to determine brake rotor temperature, and using the brake rotor temperature to determine brake rotor wear. The method further includes accumulating the brake rotor wear to provide an estimation of the thickness of the vehicle brake rotor.

Abstract: A number of variations may include a ferritically nitrocarburized vehicle component comprising a compound zone and a friction surface at an outer edge of the compound zone wherein the friction surface is configured for engagement with a corresponding friction material, and wherein the compound zone comprises a nitride layer comprising epsilion iron nitride, Fe3N and gamma prime iron nitride Fe4N.

Abstract: A brake rotor comprising a brake pad wear surface; a hat surface; and a decorative insert comprising an insert material, the decorative insert disposed on the brake pad wear surface, the hat surface, or both; wherein at least one of a friction coefficient between the decorative insert and a brake pad is substantially the same as a friction coefficient between the brake pad wear surface and the brake pad, a wear rate of the decorative insert is substantially the same as or greater than a wear rate of the brake pad wear surface, or a wear rate of the decorative insert is substantially the same as or greater than a wear rate of the hat surface; and at least a portion of the decorative insert is visible on the brake pad wear surface, the hat surface, or both.