A caliper assembly with a friction plate wear monitoring function and its wear alarm, runout detection, and brake failure compensation methods

Abstract

The present invention provides a caliper assembly with a function of monitoring the wear of friction plates, as well as a wear alarm method, a runout detection method, and a braking failure compensation method thereof, belonging to the field of automotive disc caliper brakes. It solves the problem that the existing caliper assembly cannot monitor the state of the friction plates in real time. The caliper assembly includes a caliper bracket, a caliper body, a sensor link, a friction plate, and a displacement sensor. The caliper bracket is connected to the caliper body. The friction plate is arranged inside the caliper body. The number of displacement sensors is multiple, and the multiple displacement sensors are respectively connected to the inner and outer ends of the friction plate through the sensor links. It is mainly used for real-time monitoring of the friction plates in the caliper assembly.

Description

Technical Field

[0001] The present invention belongs to the field of automotive disc caliper brakes, and particularly relates to a caliper assembly with a function of monitoring the wear of friction pads and its wear alarm, runout detection, and brake failure compensation methods. Background Art

[0002] Currently, the commonly used caliper assemblies do not have friction pad displacement sensors, so the usage status of the friction pads cannot be monitored in real time, and they cannot be replaced in time in the later stage of the use of the friction pads or after the performance of the friction pads deteriorates. Only when it is found that the braking performance deteriorates or the braking fails, it is found that the friction pads have been worn out, but at this time, the braking failure has already occurred. Summary of the Invention

[0003] In order to solve the problems in the prior art, the present invention provides a caliper assembly with a function of monitoring the wear of friction pads and its wear alarm, runout detection, and brake failure compensation methods.

[0004] To achieve the above object, the present invention adopts the following technical solutions: A caliper assembly with a function of monitoring the wear of friction pads, which includes a caliper bracket, a caliper body, a sensor link, a friction pad, and a displacement sensor. The caliper bracket is connected to the caliper body. The friction pad is arranged inside the caliper body. The number of displacement sensors is multiple, and multiple displacement sensors are respectively connected to the inner and outer ends of the friction pad through the sensor link.

[0005] Further, the number of displacement sensors is four.

[0006] Further, the displacement sensors are fixed on the caliper bracket.

[0007] Further, the displacement sensor includes a housing, a secondary coil, a primary coil, an armature, a measuring rod, and a return spring. The number of secondary coils is two, and the two secondary coils are symmetrically arranged on both sides of the primary coil. The secondary coil and the primary coil are both wound on the housing. An armature is arranged inside the secondary coil and the primary coil. The armature is connected to the measuring rod, and the measuring rod is connected to the return spring.

[0008] Further, the measuring rod is connected to the sensor link.

[0009] Further, the displacement sensor is connected to the vehicle-mounted control system of the vehicle through a wire harness.

[0010] Further, the vehicle-mounted control system is connected to an alarm and a vehicle electronic stability system.

[0011] The present invention also provides a wear alarm method for a caliper assembly with a friction plate wear monitoring function: Four displacement sensors measure the internal and external displacement values when the friction plate presses against the brake disc, and compare and calculate them with the standard displacement values when the vehicle leaves the factory. The difference is the internal and external wear amounts of the friction plate. Whether the friction plate is unevenly worn or the uneven wear is within the standard requirements is judged by the wear amounts at both ends of the friction plate. If it exceeds the standard requirement range, the instrument will give an alarm to remind the driver to check the friction plate; The average wear amount of the friction plate can be obtained by taking the average of the wear amounts at both ends of the friction plate. By comparing the wear amounts of the inner and outer friction plates, it can be judged whether the uneven wear of the inner or outer friction plate exceeds the standard requirements. If it exceeds the standard requirements, the instrument will give an alarm to remind the driver to check the friction plate.

[0012] The present invention also provides a runout detection method for a caliper assembly with a friction plate wear monitoring function: Calculate the difference between the brake disc clamping state and the initial contact state between the brake disc and the friction plate. The difference is the maximum end face runout of the brake disc. If the maximum value exceeds the permitted value, it is judged as abnormal.

[0013] The present invention also provides a brake failure compensation method for a caliper assembly with a friction plate wear monitoring function: When the vehicle has a situation where the brake piston fails to clamp in place, the displacement sensor connected to the friction plate feeds back the position of the friction plate to the vehicle's on-vehicle control system. The on-vehicle control system judges the driver's braking intention according to the opening degree and position of the brake pedal, and judges whether the actual wheel cylinder pressure reaches the braking requirement according to the displacement amount of the friction plate. If it does not reach, the on-vehicle control system issues an active increase request, and the electronic stability program of the vehicle body responds to the request and actively pressurizes to achieve the driver's intention.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows: The present invention solves the problem that the existing caliper assembly cannot monitor the state of the friction plate in real time. By detecting the real-time state of the friction plate, functions such as wear alarm, uneven wear alarm, brake disc runout out-of-tolerance alarm, and active compensation for caliper failure are realized. The present invention can not only feedback the wear state of the friction plate in real time, but also detect the uneven wear of the friction plate in time. By comparing with the standard use state of the friction plate, it can be judged whether the actual state of the friction plate meets the design requirements. By monitoring the position state of the friction plate in real time and comparing it with the driver's braking intention, the problem that the brake has no response after the driver steps on the pedal can be avoided in time, improving the safety performance of the vehicle. Brief Description of the Drawings

[0015] Figure 1 is a front view structural schematic diagram of a caliper assembly with a friction plate wear monitoring function according to the present invention;

[0016] Figure 2 is a top view structural schematic diagram of a caliper assembly with a friction plate wear monitoring function according to the present invention;

[0017] Figure 3 Structural schematic diagram of the displacement sensor according to the present invention;

[0018] Figure 4 Flowchart of the wear alarm method for a caliper assembly with a friction plate wear monitoring function according to the present invention;

[0019] Figure 5 Flowchart of the runout detection method for a caliper assembly with a friction plate wear monitoring function according to the present invention;

[0020] Figure 6 Flowchart of the brake failure compensation method for a caliper assembly with a friction plate wear monitoring function according to the present invention;

[0021] 1 - Caliper bracket, 2 - Caliper body, 3 - Sensor link, 4 - Friction plate, 5 - Displacement sensor, 6 - Wiring harness, 51 - Housing, 52 - Secondary coil, 53 - Primary coil, 54 - Armature, 55 - Measuring rod, 56 - Return spring. Specific embodiments

[0022] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention.

[0023] See Figure 1-3 In this embodiment, a caliper assembly with a friction plate wear monitoring function is described. It includes a caliper bracket 1, a caliper body 2, a sensor link 3, a friction plate 4, and a displacement sensor 5. The caliper bracket 1 is connected to the caliper body 2. The friction plate 4 is arranged inside the caliper body 2. The number of displacement sensors 5 is multiple, and multiple displacement sensors 5 are respectively connected to the inner and outer ends of the friction plate 4 through the sensor link 3.

[0024] In this embodiment, the number of displacement sensors 5 is four. The displacement sensors 5 are fixed on the caliper bracket 1. The displacement sensor 5 includes a housing 51, a secondary coil 52, a primary coil 53, an armature 54, a measuring rod 55 and a return spring 56. The number of secondary coils 52 is two. The two secondary coils 52 are symmetrically arranged on both sides of the primary coil 53. The secondary coil 52 and the primary coil 53 are both wound on the housing 51. An armature 54 is arranged inside the secondary coil 52 and the primary coil 53. The armature 54 is connected to the measuring rod 55. The measuring rod 55 is connected to the return spring 56. The measuring rod 55 is connected to the sensor link 3. The displacement sensor 5 is connected to the vehicle's on-vehicle control system through a wire harness 6. The on-vehicle control system is connected to the alarm and the electronic stability program of the vehicle body. Through the sensor link 3, the position of the friction plate 4 is transmitted into the displacement sensor 5 and is transmitted to the on-vehicle control system of the vehicle through the wire harness 6. A rod-shaped armature 54 that can move freely is arranged inside the secondary coil 52 and the primary coil 53. When the armature 54 is in the middle position, the induced electromotive forces generated by the two secondary coils 52 are equal, and the output voltage is 0 at this time. When the armature 54 moves inside the coil and deviates from the center position, the induced electromotive forces generated by the two secondary coils 52 are not equal, and there is a voltage output. The magnitude of the voltage depends on the magnitude of the displacement, thereby realizing signal output.

[0025] Displacement sensors 5 are arranged at both the inner and outer ends of the friction plate 4. Through the position monitoring of the displacement sensors 5, the position state of the friction plate 4 is fed back in real time. By judging the position state of the friction plate 4, the state of the friction plate 4 and the runout state of the brake disc can be inferred. By comparing with the pedal signal, the state of the braking system can be monitored, and the transmission failure of the braking intention can be detected in time and certain measures can be taken for compensation.

[0026] This embodiment is a wear alarm method for a caliper assembly with a friction plate wear monitoring function, as Figure 4 shown, four displacement sensors 5 measure the inner and outer displacement values when the friction plate 4 presses against the brake disc, and compare and calculate them with the calibrated displacement values when the vehicle leaves the factory. The difference is the inner and outer wear amounts of the friction plate 4. By the wear amounts at both ends of the friction plate 4, it is judged whether the friction plate 4 is unevenly worn or whether the uneven wear is within the standard requirements. If it exceeds the standard requirement range, the instrument will alarm to remind the driver to check the friction plate 4; the average value of the wear amounts at both ends of the friction plate 4 is taken to obtain the average wear amount of the friction plate 4. By comparing the wear amounts of the inner and outer friction plates 4, it can be judged whether the uneven wear of the inner or outer friction plate 4 exceeds the standard requirements. If it exceeds the standard requirements, the instrument will alarm to remind the driver to check the friction plate 4.

[0027] This embodiment is a runout detection method for a caliper assembly with a friction plate wear monitoring function, as Figure 5As shown, the difference is obtained between the brake disc clamping state and the initial contact state between the brake disc and the friction plate 4. The difference is the maximum end face runout of the brake disc. If the maximum value exceeds the permitted value, it is judged as abnormal. The maximum value exceeding the permitted value will cause problems such as braking torque fluctuation and braking NVH.

[0028] This embodiment is a braking failure compensation method for a caliper assembly with a friction plate wear monitoring function. As Figure 6 shown, when the vehicle is braking during a turn or passing over a Belgian road surface and the brake piston fails to clamp properly, the displacement sensor 5 connected to the friction plate 4 feeds back the position of the friction plate 4 to the vehicle's on-vehicle control system. The on-vehicle control system judges the driver's braking intention based on the opening degree and position of the brake pedal, and judges whether the actual wheel cylinder pressure reaches the braking requirement based on the displacement of the friction plate 4. If not, the on-vehicle control system issues an active increase request, and the electronic stability program of the vehicle body responds to the request to actively pressurize to achieve the driver's intention.

[0029] The above has introduced the patent name provided by the present invention in detail. Specific examples are used in this article to elaborate on the principle and implementation manner of the present invention. The description of the above embodiments is only used to help understand the method and its core idea of the present invention; at the same time, for those of ordinary skill in the art, based on the idea of the present invention, there will be changes in the specific implementation manner and application scope. In summary, the content of this specification should not be construed as a limitation to the present invention.

Claims

1. A caliper assembly with a friction plate wear monitoring function, characterized in that: It includes a caliper bracket (1), a caliper body (2), a sensor link (3), a friction plate (4), and a displacement sensor (5). The caliper bracket (1) is connected to the caliper body (2). The friction plate (4) is arranged inside the caliper body (2). The number of displacement sensors (5) is multiple. The multiple displacement sensors (5) are respectively connected to the inner and outer ends of the friction plate (4) through the sensor link (3). The displacement sensor (5) includes a housing (51), a secondary coil (52), a primary coil (53), an armature (54), a measuring rod (55), and a return spring (56). The number of secondary coils (52) is two. The two secondary coils (52) are symmetrically arranged on both sides of the primary coil (53). The secondary coil (52) and the primary coil (53) are both wound on the housing (51). An armature (54) is arranged inside the secondary coil (52) and the primary coil (53). The armature (54) is connected to the measuring rod (55). The measuring rod (55) is connected to the return spring (56). The displacement sensor (5) is connected to the vehicle's on-board control system through a wire harness (6). The on-board control system is connected to an alarm and an electronic stability program of the vehicle body.

2. The caliper assembly with a friction plate wear monitoring function according to claim 1, characterized in that: The number of the displacement sensors (5) is four.

3. The caliper assembly with a friction plate wear monitoring function according to claim 1, characterized in that: The displacement sensor (5) is fixed on the caliper bracket (1).

4. A caliper assembly with a friction plate wear monitoring function according to claim 1, characterized in that: The measuring rod (55) is connected to the sensor link (3).

5. A wear alarm method for a caliper assembly with a friction plate wear monitoring function as described in claim 1, characterized in that: Four displacement sensors (5) measure the inner and outer displacement values when the friction plate (4) presses the brake disc, and compare and calculate with the calibrated displacement values when the vehicle leaves the factory. The difference is the inner and outer wear amounts of the friction plate (4). Whether the friction plate (4) is unevenly worn or the uneven wear is within the standard requirements is judged by the wear amounts at the left and right ends of the friction plate (4). If it exceeds the standard requirement range, the instrument alarms to remind the driver to check the friction plate (4). By taking the average of the wear amounts at both ends of the friction plate (4), the average wear amount of the friction plate (4) can be obtained. By comparing the wear amounts of the inner and outer friction plates (4), it can be judged whether the uneven wear of the inner or outer friction plate (4) exceeds the standard requirements. If it exceeds the standard requirements, the instrument alarms to remind the driver to check the friction plate (4).

6. A method for detecting the runout of a caliper assembly with a friction plate wear monitoring function according to claim 1, characterized in that: Find the difference between the brake disc clamping state and the initial contact state between the brake disc and the friction plate (4). The difference is the maximum end face runout of the brake disc. If the maximum value exceeds the allowable value, it is judged as abnormal.

7. A braking failure compensation method for a caliper assembly with a friction plate wear monitoring function as described in claim 1, characterized in that: When the vehicle has a situation where the brake piston fails to clamp in place, the displacement sensor (5) connected to the friction plate (4) feeds back the position of the friction plate (4) to the vehicle's on-board control system. The on-board control system judges the driver's braking intention based on the opening and position of the brake pedal, and judges whether the actual wheel cylinder pressure reaches the braking requirement according to the displacement amount of the friction plate (4). If not, the on-board control system issues an active increase request, and the electronic stability program of the vehicle body responds to the request to actively pressurize to achieve the driver's intention.

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