AKEBONO REPORT 2012

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12 AKEBONO REPORT 2012 Akebono Brake Industry Co. Ltd.Kinetic energy is translated into heat energy:The sudden application of brakes when a vehicle is travelling at100km/h generates enough heat to raise the temperature of twoliters of water from 0°C to boiling (100°C).What is a brake?◆ A device that causes a vehicle to decelerate and/or ceasemotion by converting kinetic energy into heat energy utilizingfriction◆ An important security component that brings a vehicle to a haltsafelyWhen brake pedal is pressed:1. The hydraulic pressure of the brake fluid builds2. The pressure is transferred into the brake mechanism3. The transferred pressure causes:Disc brake: the pads clamp the rotorDrum brake: the lining (friction material lining the shoe) ispushed into and applies pressure to the drum4. Friction due to the above process converts kinetic energy intoheat thereby causing the vehicle to decelerate and eventuallystop moving.How brake pads are made: The manufacture of a brake entails a seven-step production process.1. Compounding andstirringVarious materials arecompounded in certainproportions and stirredtogether.The compounded material ismeasured out and poured intoa metallic mold. The mold andmaterial are then subjected topressure to form a preliminarydough.3. FormingA pressure plate thatserves as a mounting forthe pad is inserted intothe metallic mold alongwith the preliminarydough. After heat andpressure are applied adough is formed.4. HeatingThe dough is placed in afurnace until it is heatedthrough. Then it becomesa pad.5. GrindingThe corners of the padare chamfered andgrooves are cut into it.6. Surface hardeningIn some cases the surfaceof the pad is hardenedusing a gas burner.7. PaintingAfter rust-proofing andwater-repellent paint areapplied an identificationnumber is etched into thepad and its surfaceMiniature Brake Pad Manufacturing LineACW has a miniature brake pad manufacturingline on exhibit at its premises alongwith similar manufacturing line for brakecalipers. These lines were produced inhouseby young Akebono associates andare superbly detailed for example thebefore and after examples of the pressureplates used in the forming processare different colors just like a real line.All the mechanisms that comprise theline are driven by a single motor that ispowered by solar cells.The photos illustrating steps 2 4 and 5 are all from theminiature manufacturing lineCalipersRotorPadsFront tire brakesRear tire brakesBrake pipes> >> >>>>>>> >>>> > >>>>>>2. PreformingJig in a furnacecleaned.Rotor(rotating body)Pads(frictionmaterials)Pistons(pressingmechanism)Lining(frictionmaterial)Drum(rotating body)Pistons(pressingmechanism)Disc brakes (usually used in passenger cars)Pads clamp rotor stopping its spinningDrum brakes (usually used in buses and trucks)Lining is pushed into the drum from the inside stopping its spinningDisc brakeDrum brake②⑤④⑦Brakes fall roughly into two categories namely disc brakes and drum brakes. Disc brakes deliver a stable braking force for high-speed running.Drum brakes are best suited to bringing heavier automobiles to a halt.Front tires: disc brakesRear tires: drum brakesFront tires: disc brakesRear tires: disc brakes（1）（2）（3）（4）Each of the four tires of a vehicle is equipped with brakes.PadsRotorLiningDrumHydraulic pressure pistonHydraulic pressure piston② ③ ②③Brakes save lives: absolute safety① ①Brake Systems That Bring Vehicles to a Halt SafelyOur Products

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