Our Products Brake Systems That Bring Vehicles to a Halt Safely Brakes save lives: absolute safety What is a brake? ◆ A device that causes a vehicle to decelerate and/or cease Front tires: disc brakes motion by converting kinetic energy into heat energy utilizing Rear tires: drum brakes friction Drum brake ◆ An important security component that brings a vehicle to a halt safely Disc brake When brake pedal is pressed: （3） 1. The hydraulic pressure of the brake fluid builds 2. The pressure is transferred into the brake mechanism Rear tire brakes > 3. The transferred pressure causes: （1） > > > > Disc brake: the pads clamp the rotor > Drum brake: the lining (friction material lining the shoe) is > > > > > > Calipers pushed into and applies pressure to the drum > > > > 4. Friction due to the above process converts kinetic energy into > > > > Brake pipes heat, thereby causing the vehicle to decelerate and eventually Pads （4） > Rotor stop moving. Front tire brakes Kinetic energy is translated into heat energy: Front tires: disc brakes Rear tires: disc brakes The sudden application of brakes when a vehicle is travelling at （2） 100km/h, generates enough heat to raise the temperature of two liters of water from 0°C to boiling (100°C). Each of the four tires of a vehicle is equipped with brakes. Disc brakes (usually used in passenger cars) Drum brakes (usually used in buses and trucks) Pads clamp rotor, stopping its spinning Lining is pushed into the drum from the inside, stopping its spinning ③ ② ② Pads Pistons ③ (friction (pressing Drum materials) Pads mechanism) Lining (friction Pistons ① material) ① (pressing Rotor mechanism) Drum (rotating body) Hydraulic pressure piston Rotor Hydraulic pressure piston (rotating body) Lining Brakes 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. How brake pads are made: The manufacture of a brake entails a seven-step production process. ② ④ Jig in a furnace 2. Preforming The compounded material is measured out and poured into 4. Heating a metallic mold. The mold and The dough is placed in a 6. Surface hardening material are then subjected to furnace until it is heated In some cases, the sur- pressure to form a preliminary through. Then it becomes face of the pad is hard- Miniature Brake Pad Manufacturing Line dough. a pad. ened using a gas burner. ACW has a miniature brake pad manufac- turing line on exhibit at its premises along 1. Compounding and 3. Forming 5. Grinding 7. Painting with similar manufacturing line for brake stirring A pressure plate that The corners of the pad After rust-proofing and Various materials are serves as a mounting for are chamfered and water-repellent paint are calipers. These lines were produced in- compounded in certain the pad is inserted into grooves are cut into it. applied, an identification house by young Akebono associates and proportions and stirred the metallic mold along number is etched into the are superbly detailed, for example, the together. with the preliminary pad and its surface before and after examples of the pres- dough. After heat and cleaned. ⑦ pressure are applied, a sure plates used in the forming process dough is formed. are different colors, just like a real line. All the mechanisms that comprise the line are driven by a single motor that is powered by solar cells. ⑤ The photos illustrating steps 2, 4 and 5 are all from the miniature manufacturing line 12 AKEBONO REPORT 2012 Akebono Brake Industry Co., Ltd. Our Products Achieving Inspiring Technology That Delivers Safety and Security Grand Prix Racing Since 2007, Akebono has been supplying brake calipers and brake master cylinders to the “Vodafone McLaren Mercedes” team as an official supplier. In Grand Prix racing, which is the world’s most prestigious racing, brakes must be specifically tailored to high-speed running. For example, when a racing car is approaching a turn at a speed of 300km/h and has to decelerate to 80km/h within a mere three seconds, the braking for the deceleration heats the rotor almost instantly to about 800°C. To create brakes that are always reliable and stable under such condi- tions, Akebono continually strives to enhance all aspects of its products, MP4-27 (2012) including structure, materials and surface finishing. Mountain Bike Racing and Motorcycle Racing In 2002, Akebono entered the world of mountain bike downhill racing and in 2003 began supplying a team in the All Japan Road Race Championship in the JSB 1000 class that captured the title thanks to brilliant performances. Road racing requires high-perfor- mance brakes that enable a rider to quickly decelerate his motorcycle from a speed of 300km/h using just one finger. Riders also demand extreme responsiveness. Since 2011, Akebono has been providing braking systems to “MUSASHI RT HARC-PRO,” one of Japan’s leading road racing teams. All Japan Road Race Championship 2012: Takumi Takahashi riding HONDA CBR1000RR equipped with an Akebono brake system AKEBONO REPORT 2012 Akebono Brake Industry Co., Ltd. 13 Our Products Main Products ■ Products for Automobiles • Disc brake calipers • Disc brake pads • Drum brakes • Drum brake shoes • Brake linings • Disc rotors • Brake drums Drum brake shoe Disc rotor ■Disc brake ■Drum brake Brake lining Disc brake caliper Disc brake pads Brake drum Main components of disc brakes (type AD) Main components of drum brake (type LT) 1234 9 E 8 0 7 6 1 2 3 B A B C 4 H E 5 5 I D 6 F J 9 K 7 P G 0 O L N D A 8 M C Q 1 Piston seal 0 Pin boot 1 Bolt D Adjuster screw 2 Piston A Pads 2 Bleeding screw E Adjuster nut 3 Piston boot B Shims 3 Bleeding cap F Adjuster socket 4 Boot ring C Pad clips 4 Check hole cover G Adjuster lever 5 Bleed screw cap D Mounting bracket 5 Back plate H ‌‌ Shoe hold down spring 6 Bleed screw E Rotor 6 Wheel cylinders body I Shoe hold down cup 7 Cylinder body 7 Wheel cylinder cup J Shoe hold down pin 8 Lock pin 8 Wheel cylinder boot K Parking brake lever 9 Guide pin 9 Piston L Lining 0 Retainer M Shoe A Retainer spring N Rivet B‌ Return‌ spring O Anchor plate (shoe to shoe spring) P Wire guide C‌ Return‌ spring Q Drum (shoe to lever spring) 14 AKEBONO REPORT 2012 Akebono Brake Industry Co., Ltd. ■ Products for Rolling Stock ■ Products for Industrial Machinery • Bullet train disc brake calipers • Forklift brakes • Bullet train disc brake linings • Disc brakes for wind power generators • Brake linings for rolling stock • Disc brakes for rough terrain cranes • Brakes for maglev trains ■ Spindle brake N700 series bullet train ■Bullet train disc brake ■Railroad train brake shoes Wind power generator ■ Disk brake for a ■ Drum brake for forklifts wind power generator ■ Bullet train disc brake pads ■ Maglev train brake ■ Disc brake caliper for rough ■ Wet brake for forklifts terrain cranes ■ Products for Motorcycles • Disc brake calipers • Master cylinders • Disc brake pads ■ Other Products ■ Brake caliper for touring ■ Brake caliper for car endurance racing motorcycle racing ■ Concrete pouring detection Disc brake Master cylinder ■Sensor cluster system AKEBONO REPORT 2012 Akebono Brake Industry Co., Ltd. 15.