Brake caliper unit and method for detecting brake pad and disc wear of a brake caliper unit of a disc brake

Abstract

The invention relates to a brake caliper unit (1, 1') of a disc brake, in particular for a rail vehicle, having two caliper arms (2, 3), a brake cylinder (8), an adjuster module (9), brake pads (4, 5) and a wear sensor device (11, 11', 11") having at least one sensor element (24, 24') and an evaluation unit (12). The wear sensor device (11, 11', 11") is articulated on the two caliper arms (2, 3) in a coupling axis parallel to the adjuster module (9) and / or the brake cylinder (8). The invention also relates to a method for determining the wear of brake pads (4, 5) and brake discs of a brake caliper unit (1, 1') of a disc brake.

Description

Technical Field

[0001] This invention relates to a brake caliper unit with a wear sensor device. The invention also relates to a method for detecting wear on the brake pads and brake disc of a brake caliper unit for a disc brake. Background Technology

[0002] This type of brake caliper unit is widely used in the railway industry due to its braking performance, especially in locomotives, trams, and multi-car train units.

[0003] During routine braking operation, brake pads and discs wear down. For safety reasons, the condition of the brakes must be checked regularly, and current inspection methods rely on visual inspection of the brake pads and discs by maintenance personnel. This is costly and requires highly trained maintenance staff.

[0004] For example, automatic wear detection of disc brakes is known from the document WO 2018 / 178018 A1. According to this document, a non-contact operating sensor is used on or in the brake pad retainer or on or in the brake caliper rod connected to the brake pad retainer. This sensor measures the distance from the side of the brake disc in order to calculate the wear of the brake pads. However, this arrangement is considered disadvantageous because it is susceptible to interference and therefore requires too much protection to operate robustly.

[0005] Furthermore, only the wear of the brake pads can be detected, but the wear of the brake disc cannot be determined. Summary of the Invention

[0006] The objective of this invention is to provide an improved brake caliper unit that features automatic wear detection for brake pads and brake discs, while reducing cost and maintenance time.

[0007] Another task is to propose an improved method for detecting wear of brake pads and brake discs in the brake caliper unit of a disc brake.

[0008] The task is accomplished by a brake caliper unit of a disc brake according to the present invention, the brake caliper unit having two caliper bars, a brake cylinder, an adjuster module, brake pads, and a wear sensor device, the wear sensor device having at least one sensor element and an evaluation unit, the wear sensor device being hinged to the two caliper bars in a connecting axis parallel to the adjuster module and / or the brake cylinder, the wear sensor device being hingedly mounted in the connecting axis of the connection point, the brake cylinder and / or the adjuster module being hinged in the connecting axis of the connection point, the connections being spaced apart from each other. The wear sensor device has a motion conversion unit that converts longitudinal motion, which is a change in distance between connection points, into rotational motion. The motion conversion unit of the wear sensor device includes a threaded tube with internal threads and a lead screw with external threads. The internal and external threads mesh to form a transmission thread. The wear sensor device includes a fixing element, a sensor housing for accommodating the at least one sensor element, a housing, and the at least one sensor element. The wear sensor device is hingedly mounted in the connecting axis of the connection point by means of a fixing element, and the housing tube of the housing and the threaded tube are telescopically arranged together, with the housing tube pushed onto the threaded tube.

[0009] The other task is accomplished by a method according to the invention for determining the wear of the brake pads and brake disc of the brake caliper unit of the disc brake according to the invention, characterized by the following method steps:

[0010] (VS1) detects the initial position and detects the change in the length of the distance between the connection points of the two calipers during braking using a wear sensor device, and converts the change in the length of the distance into a change in the rotation angle of the sensor element through a motion conversion unit;

[0011] (VS2) Generates a measurement signal based on the detected measurement value; and forwards the measurement signal to the evaluation unit;

[0012] (VS3) The measurement signal is evaluated by the evaluation unit to determine the wear value of the lining wear and disc wear of the brake caliper unit accumulated in the measurement signal.

[0013] Alternatively, according to the present invention, a method for determining the wear of brake pads and brake discs in a brake caliper unit of a disc brake is provided, the brake caliper unit having two caliper bars, a brake cylinder, brake pads, and a wear sensor device having an evaluation unit, characterized by the following method steps:

[0014] (VS1) The initial position is detected and the change in distance between the connection points of the two caliper bars during braking is detected by means of a wear sensor device. The change in distance is detected by measuring the distance between the sensor element of the non-contact ranging sensor and the reference section of the wear sensor device. The wear sensor device includes a fixing element, a housing tube, and at least one non-contact ranging sensor. The housing tube and the at least one non-contact ranging sensor are telescopically arranged together. The sensor element is an ultrasonic sensor that interacts with the inner side of the wall of a recess in the fixing plate of the first fixing element. The housing tube is fixed in the recess. The inner side of the wall serves as a reflective surface for the ultrasonic vibration of the sensor element and constitutes the reference section of the wear sensor device. The transmitter / receiver surface of the sensor element and the inner side of the wall are spaced apart by the distance. The wear sensor device is hingedly mounted in the connecting axis of the connection point by means of one of the fixing elements.

[0015] (VS2) Generates a measurement signal based on the detected measurement value; and forwards the measurement signal to the evaluation unit;

[0016] (VS3) The measurement signal is evaluated by the evaluation unit to determine the wear value of the lining wear and disc wear of the brake caliper unit accumulated in the measurement signal.

[0017] The present invention is based on detecting wear by means of at least one wear sensor device, which is mounted parallel to the brake cylinder and / or adjuster module of the brake caliper unit.

[0018] The brake caliper unit according to the invention, particularly for rail vehicles, comprises two caliper bars, a brake cylinder, an adjuster module, brake pads, and a wear sensor device having at least one sensor element and an evaluation unit. The wear sensor device is hinged to the two caliper bars in a connecting axis, parallel to the adjuster module and / or the brake cylinder.

[0019] In this way, a robust and simple wear sensor device can be realized, which can be installed and mounted in a simple manner.

[0020] The method according to the invention for determining the wear of the brake pads and brake disc of a brake caliper unit (which has two caliper bars, a brake cylinder, brake pads, and a wear sensor device having an evaluation unit) for disc brakes, particularly for rail vehicles, comprises the following steps: (VS1) detecting an initial position and detecting, by means of the wear sensor device, the change in length of the distance between the connection points of the two caliper bars during braking, wherein the change in length of the distance is converted into a change in the rotation angle of a rotation angle sensor by a motion conversion device, or the change in length of the distance is detected by measuring the distance between the sensor element of a contact or / and non-contact distance measuring sensor and a reference section of the wear sensor device; (VS2) generating a measurement signal based on the measured value thus detected; and forwarding the measurement signal to the evaluation unit; and (VS3) evaluating the measurement signal by the evaluation unit such that the wear value of the brake caliper unit's pad wear and disc wear accumulated in the measurement signal is determined.

[0021] One particular advantage is that it can easily and automatically determine not only liner wear, but also disc wear.

[0022] According to the present invention, the wear sensor device is hingedly mounted in the connecting axis of the connection point, and the brake cylinder and / or regulator module is hinged in the connecting axis of the connection point, the connection points being arranged at a distance from each other. The connection points already exist and can be utilized in a simple manner.

[0023] The wear sensor device has a motion conversion unit that converts longitudinal motion, which is a change in distance between connection points, into rotational motion. This achieves a compact and easily sealable advantageous structure.

[0024] The motion conversion unit of the wear sensor device according to the present invention includes a threaded tube with internal threads and a lead screw with external threads, and the internal and external threads mesh to form a transmission thread, which is advantageous for such a compact structure.

[0025] In another embodiment, the threaded tube is non-rotatably connected to the wear sensor device and the lead screw is rotatably supported and connected to the at least one sensor element; or the lead screw is non-rotatably connected to the wear sensor device and the threaded tube is rotatably supported and connected to the at least one sensor element. This structure is simple and compact.

[0026] It is advantageous if the at least one sensor element is a rotation angle sensor, because such a component is available on the market at low cost and of high quality.

[0027] Another embodiment specifies that the wear sensor device includes a fixing element, a sensor housing, a housing, a motion conversion unit, at least one bearing, and the at least one sensor element. The wear sensor device is hingedly mounted in the connecting axis of the connection point via a fixing element. This installation is simple and inexpensive.

[0028] Another embodiment specifies that the housing tube and the threaded tube are telescopically arranged together, with the housing tube pushed onto the threaded tube. This achieves an advantageous space-saving structure.

[0029] In an alternative embodiment, the wear sensor device has at least one non-contact ranging sensor. This allows for an advantageous, compact, and simple structure.

[0030] Advantageously, the at least one non-contact ranging sensor is an ultrasonic sensor, a radar sensor, and / or an optical ranging sensor. Commercially available components with integrated electronic measurement data processing circuitry can be used for this purpose.

[0031] Furthermore, if the wear sensor device has a fixing element, a housing tube, and the at least one non-contact ranging sensor, and the housing tube and the at least one non-contact ranging sensor are telescopically arranged together, it is advantageous for a compact and simple structure.

[0032] In another embodiment, the at least one non-contact ranging sensor interacts with a reference section of the wear sensor device and detects the distance between the sensor element and the reference section as a measure of the distance change between the connection points. This is advantageous because it requires only a small number of components.

[0033] The brake caliper unit is designed for pneumatic disc brakes. This advantageously expands the range of applications.

[0034] In one embodiment of the method, the non-contact ranging sensor is an ultrasonic sensor, a radar sensor, and / or an optical ranging sensor. These components are advantageously available on the market as ready-to-use functional components in a highly integrated design.

[0035] If the assessment unit compares the determined wear value with previously stored limits for brake pad replacement and / or brake disc replacement and outputs notifications, warnings, etc. on appropriate media based on the comparison results, maintenance time can be advantageously planned.

[0036] Another significant advantage is that the evaluation unit determines the wear of the brake pads and brake disc of the entire disc brake based on a comparison value, using all detected measurements and the wear values ​​determined therefrom. Attached Figure Description

[0037] Embodiments of the present invention are described below with reference to the accompanying drawings. The drawings are as follows:

[0038] Figure 1-2 A schematic top view showing conventional and compact brake caliper units;

[0039] Figure 3 A schematic cross-sectional view of a brake caliper unit according to the invention is shown, having a first embodiment of a wear sensor device according to the invention;

[0040] Figure 4 Showing according to Figure 3 A schematic enlarged cross-sectional view of the sensor housing;

[0041] Figure 5 Showing according to Figure 3 A cross-sectional view of a variation of a first embodiment of the wear sensor device;

[0042] Figure 6 Showing according to Figure 3 A cross-sectional view of a second embodiment of the wear sensor device;

[0043] Figure 7 A schematic diagram of the wear curve is shown; and

[0044] Figure 8 A schematic flowchart illustrating an embodiment of the method according to the present invention is shown. Detailed Implementation

[0045] The coordinates x, y, and z are used for orientation in the attached diagram. The x-coordinate extends along the longitudinal direction of the brake caliper unit 1, the y-coordinate is transverse to its extension, and the z-coordinate forms a vertical direction. Other positions of the brake caliper unit 1 are, of course, also possible.

[0046] Figure 1 A schematic top view of a conventional brake caliper unit 1 is shown. Figure 2 A schematic top view of a conventional so-called compact brake caliper unit 1' is shown.

[0047] Each brake caliper unit 1, 1' forms a disc brake for rail vehicles and includes a first caliper bar 2 and a second caliper bar 3, two brake pads 4, 5, a brake cylinder 8, and an adjuster module 9 for wear adjustment.

[0048] Brake caliper unit 1 includes a brake cylinder 8 with an integrated adjuster module 9, and another brake caliper unit 1' has a separate brake cylinder 8 and a separate adjuster module 9.

[0049] Two clamps 2 and 3 are pivotally mounted in corresponding hinges 2a and 3a about their respective rod axes along the Z direction, which will not be described in more detail here.

[0050] On one side of the caliper bars 2 and 3, brake pads 4 and 5 are pivotally mounted in hinges 2b and 3b via brake pad retainers on the free ends of the caliper bars 2 and 3. On the other free end of the caliper bars 2 and 3, according to... Figure 1 The brake cylinder 8, which has an integrated regulator module 9, in the brake caliper unit 1 is hinged to the connecting axis at connection points 6 and 7. According to... Figure 2 In the compact brake caliper unit 1', only the adjuster module 9 is hinged to the connection points 6 and 7.

[0051] The brake cylinder 8 may be driven pneumatically, hydraulically, electromechanically, or in a similar manner. Brake pads 4 and 5 are disposed on both sides of a brake disc, which is not shown here.

[0052] During braking, brake cylinder 8 is activated when the brake is applied, increasing the distance 10 in the y-direction between connection points 6 and 7. This causes brake pads 4 and 5 to move toward each other in the y-direction and thus press against the brake disc.

[0053] When the brake is released, the brake cylinder 8 is not activated, the distance 10 between the connection points 6 and 7 in the y direction decreases again, and the brake pads 4 and 5 move away from each other. The brake pads 4 and 5 then separate from the brake disc.

[0054] The use of regulator module 9 ensures that the brake pad gap (also known as the air gap) remains constant during operation when the brake is released. The air gap exists between the brake pads 4 and 5 and the brake disc.

[0055] During brake operation, the wear of brake pads 4 and 5 and brake disc increases, resulting in an increase in the distance 10 between connection points 6 and 7. During braking, the distance between brake pads 4 and 5 in the y direction decreases.

[0056] In this way, distance 10 forms a measure of wear on brake pads 4 and 5 and the brake disc. The dynamic change of distance 10 during braking also provides information about the function of the braking process.

[0057] Figure 3 A schematic cross-sectional view of a brake caliper unit 1' according to the invention is shown, which has a first embodiment of a wear sensor device 11 according to the invention. Figure 4 Showing according to Figure 3 A schematic enlarged cross-sectional view of the sensor housing 15.

[0058] The sectional view shows the brake caliper unit 1' in the x-direction (see...). Figure 2 ).

[0059] The brake caliper unit 1' according to the present invention also includes a wear sensor device 11.

[0060] The wear sensor device 11 is mounted parallel to the axis of the regulator module 9 at two points on the clamping bars 2 and 3, namely at connection points 6 and 7. That is, the sensor axis 11a of the wear sensor device 11 extends parallel to the axis 9a of the regulator module 9. During braking, the movement of the clamping bars 2 and 3 and the related changes in distance 10 are transmitted to the wear sensor device 11 through connection points 6 and 7.

[0061] In a first embodiment, the wear sensor device 11 includes an evaluation unit 12, fixing elements 13 and 14, a sensor housing 15, a housing 16, a motion conversion unit having a threaded tube 17 and a lead screw 18, a bellows 20, at least one bearing 21, and at least one sensor element 24, 24'.

[0062] The evaluation unit 12 is connected to the at least one sensor element 24, 24' via a connection path 12a (such as an electrical and / or optical transmission wire). It is also conceivable that a wireless transmission path, such as radio, infrared, or ultrasonic, can be used instead of the wire connection path 12a.

[0063] The wear sensor device 11 is secured to the coupling points 6 and 7 on the clamp bars 2 and 3 by fixing elements 13 and 14, which are configured as angle brackets. This will be explained further below.

[0064] The change in distance 10 between connection points 6 and 7 is transmitted to the wear sensor device 11 via fixing elements 13 and 14. During braking, connection points 6 and 7 move on arcs, the center of which is the axis of the corresponding hinges 2a and 3a of the corresponding clamps 2 and 3. The axes of connection points 6 and 7 and hinges 2a and 3a extend parallel to each other in the z-direction. Fixing elements 13 and 14 allow linear movement of the wear sensor device 11 in the y-direction.

[0065] The sensor housing 15 is used to accommodate the at least one sensor element 24. The sensor housing 15 has a surrounding wall 15a, which is closed by means of an end plate 15b. The end plate 15b and the wall 15a define an internal space 15c, the opening 15d of which is provided with a radially outwardly projecting, surrounding flange 15e.

[0066] The sensor housing 15 is fixed to the mounting plate 13a of the first fixing element 13 by its surrounding flange 15e and is sealed to the atmosphere by means of a seal 15f, such as an O-ring. The first fixing element 13 thus forms the mounting portion of the wear sensor device 11 at the connection point 6 of the first clamp 2.

[0067] Additionally, the sensor housing 15 is connected to the bearing housing 16a of the housing 16 via a fixing plate 13a. The bearing housing 16a is fixed in the opening 13b of the fixing plate 13a via a shoulder 16c. The housing 16 also has a housing tube 16b. The sensor housing 15, bearing housing 16a, and housing tube 16b are arranged coaxially with the sensor axis 11a in sequence.

[0068] This example illustrates one possibility in which the housing tube 16b extends almost entirely along the entire length of the distance 10 between connection points 6 and 7. Of course, the length of the housing tube 16b can also have other dimensions. The housing tube 16b and the threaded tube 17 are telescopically arranged together, with the housing tube 16b fitting over the threaded tube 17. The threaded tube 17 has an internal thread 19a and a smooth outer surface.

[0069] exist Figure 3 In the initial position of the wear sensor device 11 shown, the free end 17a of the threaded tube 17 is a short distance away from the bearing housing 16a. The other end 17b of the threaded tube 17 is constructed as a flange, by means of which the threaded tube 17 is mounted on the fixing plate 14a of the second fixing element 14. The second fixing element 14 forms another mounting part of the wear sensor device 11 at the connection point 7 of the second clamp 3.

[0070] The motion conversion unit includes a lead screw 18 with external threads 19 and a threaded tube 17 with internal threads 19a. In this example, the internal thread 19a is formed in a section of the free end 17a of the threaded tube 17. The lead screw 18 is disposed in the threaded tube 17, and the external thread 19 of the lead screw 18 engages with the internal thread 19a of the threaded tube 17. The external thread 19 and the internal thread 19a here form a drive thread with a corresponding pitch.

[0071] The lead screw 18 is positioned in the threaded tube 17 such that the first lead screw end 18a protrudes from the threaded tube 17 toward the bearing housing 16a. In the initial position of the wear sensor device 11, the second free lead screw end 18b remains within the end 17b of the threaded tube 17.

[0072] The first lead screw end 18a of the lead screw 18 is connected to the bearing section 18c. The bearing 21—here, for example, an auto-centering ball bearing—is disposed on the bearing section 18c with its inner ring and housed in the bearing housing 16a with its outer ring. The bearing 21 forms a rotating bearing for the lead screw 18 about the sensor axis 11a.

[0073] The threaded tube 17 is mounted on the fixing plate 14a of the fixing element 14 with its end 17b in a non-rotatable manner.

[0074] A seal is installed on the section of the housing tube 16b and the threaded tube 17 that protrudes from the housing tube with end 17b. This seal is a bellows 20, which is fixed to the housing tube 16b in the connection area between the bearing housing 16a and the housing tube 16b with a first sealing end section 20a. A second sealing end section 20b is fixed to the section of the threaded tube 17 at end 17b.

[0075] Furthermore, the bearing section 18c of the lead screw 18 is connected to the sensor element 24 via a transmission mechanism 23 through a rotating connector. The transmission mechanism 23 is, for example, a planetary gear transmission mechanism. The sensor element 24 detects the rotation angle of the lead screw 18 about the sensor axis 11a. The sensor element 24 is a rotation angle sensor, such as a potentiometer or a Hall sensor. Of course, optical and / or capacitive angle sensors are also possible.

[0076] During braking, the movement of caliper bars 2 and 3 causes a change in distance 10, which is transmitted as longitudinal motion to wear sensor device 11. Wear sensor device 11 can be extended or retracted. Since the threaded tube 17 of the motion conversion unit is non-rotatably mounted on the second fixed element 14, when the length of distance 10 changes, the lead screw 18 rotates about sensor axis 11a based on the drive thread—formed by the external thread 19 of the lead screw 18 engaging with the internal thread 19a of the threaded tube 17. In this way, the motion conversion unit converts the longitudinal motion of the changing distance 10 into rotational motion.

[0077] By rotating the connecting member 22, the sensor element 24 subsequently rotates and thus detects the rotation angle proportional to the change in length of distance 10. The evaluation unit 12 determines the wear values ​​of the brake pads 4, 5 and the brake disc from the signal transmitted for this purpose from the sensor element 24. Furthermore, the evaluation unit 12 can monitor the braking process based on the detected change in length of distance 10 caused by motion, for example, by comparing it with a predetermined value.

[0078] The following text will combine Figure 7 The evaluation of the signal will be explained in more detail.

[0079] Figure 5 Showing according to Figure 3 A cross-sectional view of a variation of a first embodiment of the wear sensor device 11.

[0080] according to Figure 5 The wear sensor device 11' in the variant and according to Figure 3 The difference in the first embodiment of the wear sensor device 11 lies in the shape of the housing 16, the arrangement of the internal thread 19a in the other end 17b of the threaded tube 17, and the arrangement of the threaded tube 17 and the lead screw 18.

[0081] The bearing housing 16a is fixed to the opening of the intermediate plate 16d by a shoulder 16c. The intermediate plate 16d is fixed to the fixing plate 13a and is fixed to the opening 13b of the fixing plate 13a of the fixing element 13 by a shoulder. The sensor housing 15 is fixed to the fixing plate 13a by its surrounding flange 15e and is sealed to the atmosphere by means of a seal 15f.

[0082] The bearing housing 16a has a bearing 21, which, unlike the first embodiment, is disposed on the end 17a of the threaded tube 17 with its inner ring. In this variation, the threaded tube 17 is rotatably supported by means of the bearing 21.

[0083] The length of the housing tube 16b is approximately one-quarter the length of the threaded tube 17. The threaded tube 17 extends over the entire length of the lead screw 18.

[0084] In this variant, the lead screw 18 is mounted on the fixing plate 14a of the second fixing element 14 by means of the retaining plate 18e via the bracket 18d, which prevents relative rotation.

[0085] The bellows 20 is fixed to the housing tube 16b with the first sealed end section 20a and to the bracket 18d of the lead screw 18 with the second sealed end section 20b.

[0086] In contrast to the first embodiment, in this variant, the rotating connector 22 of the transmission mechanism 23 connecting the sensor element 24 is connected to the rotatable threaded tube 17 via a synchronizing member 22a. The synchronizing member 22a is inserted into the hole at the first end 17a of the threaded tube 17 and is non-rotatably connected to the threaded tube 17, for example, by screwing, clamping, etc.

[0087] During braking, the movement of caliper bars 2 and 3 causes a change in distance 10, which is transmitted to the wear sensor device 11. Here, the wear sensor device can be extended or retracted. This longitudinal movement is converted into rotational movement of the threaded tube 17 and transmitted to the sensor element 24 via the transmission threads (external thread 19 of the lead screw 18 and internal thread 19a of the threaded tube 17).

[0088] Figure 6 Showing according to Figure 3 A cross-sectional view of a second embodiment of the wear sensor device 11.

[0089] according to Figure 6 The second embodiment of the wear sensor device 11'' includes fixing elements 13, 14, a bellows 20, a housing tube 25, and a non-contact ranging sensor.

[0090] The non-contact ranging sensor is mounted on the second fixed element 14 by means of a bracket 26 and has at least one sensor element 24'.

[0091] The non-contact distance sensor interacts with the reference section of the wear sensor device 11'' and detects the distance 10' between the sensor element 24' and the reference section. Changes in this distance 10' correspond to changes in the distance 10 between connection points 6 and 7. Changes in distance 10' can also be proportional to changes in the distance 10 between connection points 6 and 7. Calculations of the actual distance or associated wear are performed by the evaluation unit 12.

[0092] The housing tube 25 is fixed at its end 25a in a recess 13c in the fixing plate 13a of the first fixing element 13. The recess 13c is closed by a wall 13d. The end 25a rests against the inner side 13e of the wall 13d.

[0093] The housing tube 25 extends over approximately two-thirds of the distance along the y-direction between the fixing plate 13a of the first fixing element 13 and the fixing plate 14a of the second fixing element 14, and has a free tube end 25b.

[0094] Coaxial with the housing tube 25 and the sensor axis 11a, the bracket 26 is mounted on the mounting plate 14a of the second mounting element 14 with a fixed end 26a. The bracket 26 is constructed as a tube that extends from the mounting plate 14a into the space between the mounting plate 13a of the first mounting element 13 and the mounting plate 14a of the second mounting element 14 with a free bracket end 26b. In the initial position of the wear sensor device 11'' shown here, the free bracket end 26b extends into the second end 25b of the housing tube 25.

[0095] The rod-shaped sensor housing 27 is inserted into the bracket 26 via a fixed section 27a, which is also rod-shaped, through the free end 26b of the bracket. The insertion depth can be adjusted by the adjustable stop element 27b of the sensor housing 27.

[0096] A sensor element 24' is disposed in the section of the sensor housing 27 that extends into the housing tube 25. The housing tube 25 and the sensor housing 27 with the sensor element 24' are telescopically mounted on the bracket 26. In other words, the housing tube 25 and the non-contact ranging sensor are telescopically mounted together.

[0097] The sensor element 24' here is an ultrasonic sensor, which interacts with the inner side 13e of the wall 13d of the recess 13b in the fixing plate 13a of the first fixing element 13. The inner side 13e of this wall 13d serves as a reflective surface for the ultrasonic vibrations of the sensor element 24', forming a reference section of the wear sensor device 11''. The transmitter / receiver surface 24'a of the sensor element 24' and the inner side 13e of the wall 13d are spaced apart by a distance 10'. The change in this distance 10' is a measure of the change in distance 10 between connection points 6 and 7. In this way, the wear sensor device 11'', having an ultrasonic sensor as the sensor element 24', can detect changes in distance 10.

[0098] The bellows 20 is fixed to the first pipe end 25a region of the housing pipe 25 with its first sealing end section 20a and to the fixed end 26a region of the bracket 26 with its second sealing end section 20b. The pipe end 25a is here constructed as a thickened flange.

[0099] During braking, the movement of caliper bars 2 and 3 causes a change in distance 10, which is transmitted to the wear sensor device 11''. Here, the wear sensor device can be extended or retracted. Consequently, the distance 10' between the transmitter / receiver surface 24'a of sensor element 24' and the inner side 13e of wall 13d changes in the same manner as distance 10. This change is detected by an ultrasonic sensor having sensor element 24'.

[0100] An ultrasonic sensor with sensor element 24' forms a non-contact ranging sensor. Connection path 12a, such as a wire for power supply and signal transmission, is connected to evaluation unit 12.

[0101] In one embodiment, instead of a non-contact ranging sensor, a contact ranging sensor with at least one electromechanical contact can also be provided. Depending on whether the contact is designed to be normally open or normally closed, the contact closes or opens when a distance corresponding to a specific, for example, maximum wear value is reached.

[0102] In another embodiment, however, such a contact can also be an electromechanical contact within the sensor housing 27, which is actuated by an actuator at a pre-set distance corresponding to a specific wear value. Such an electromechanical contact can be, for example, a so-called snap-action switch, a microswitch, or a limit switch.

[0103] Multiple contacts can also be set, which are assigned to different wear levels, such as: a) indicating impending wear, b) indicating wear requires replacement, and c) warning that the wear threshold has been reached and the vehicle can no longer be driven.

[0104] The actuator may be, for example, a rod fixedly connected to the tube 25 or a switch cam disposed on the inside of the tube 25.

[0105] These mechanical contacts can also be provided as additional redundant components.

[0106] Figure 7 A schematic diagram SB shows the wear curves of brake caliper units 1 and 1'.

[0107] The measurement signals S from one or more sensor elements 24, 24' of the wear sensor devices 11, 11', 11'' of the brake caliper units 1, 1' are plotted as a function of time t. The measurement signals S are received, amplified, and evaluated by the evaluation unit 12. The evaluation results are forwarded by the evaluation unit 12 to a suitable display, data processing, and storage device.

[0108] The measurement signal S shows the change in distance 10 and corresponds to the wear of brake pads 4 and 5, the wear of the brake disc, and the total air gap.

[0109] The lining wear curve 28 rises like a trigonometric function until the maximum wear value of lining wear 29, and then the replacement of brake linings 4 and 5 occurs at this maximum value 30.

[0110] The disc wear curve 31 has a long, serrated profile. After multiple liner replacements 30, the brake disc needs to be replaced (disc replacement 32) only when the maximum disc wear 33 is reached.

[0111] Total wear 34 includes the sum of liner wear 29 and disc wear 33.

[0112] The shape of the measurement signal 3 for brake pad wear 29 is also a sawtooth profile, but brake pads 4 and 5 must be replaced more frequently than brake discs.

[0113] By continuously detecting measurement signals corresponding to wear, the specific characteristics of wear can be monitored sustainably and events such as early or abnormal wear can be quickly identified.

[0114] Figure 8 A schematic flowchart of an embodiment of a method for detecting wear of brake pads 4, 5 and brake disc in brake caliper units 1, 1' according to the present invention is shown.

[0115] In the first method step VS1, the initial position is detected and the change in distance 10 between the connection points 6 and 7 of the caliper bars 2 and 3 during braking is detected by means of at least one wear sensor device 11, 11', 11''.

[0116] The at least one wear sensor device 11, 11' is a rotation angle sensor and detects a rotation angle change that is proportional to the length change of the distance 10 between the connection points 6, 7 of the clamps 2, 3.

[0117] The at least one wear sensor device 11'' may also have a non-contact ranging sensor that detects the length change of the distance 10' between the sensor element 24' of the non-contact ranging sensor and the reference section of the wear sensor device 11''.

[0118] Sensor element 24' is an ultrasonic sensor that interacts with the inner side 13e of the wall 13d of the recess 13b in the fixing plate 13a of the first fixing element 13, in which the housing tube 25 is fixed. The inner side 13e of this wall 13d serves as a reflective surface for the ultrasonic vibrations of sensor element 24', forming a reference section for the wear sensor device 11''. The transmitter / receiver surface 24'a of sensor element 24' and the inner side 13e of wall 13d are spaced apart by a distance 10'. Variations in this distance 10' are a measure of variations in the distance 10 between connection points 6 and 7.

[0119] In the second method step VS2, the at least one wear sensor device 11, 11', 11'' generates a measurement signal S based on the detected measurement value and forwards it to the evaluation unit 12.

[0120] In the third method step VS3, the evaluation unit 12 evaluates the measurement signal S in such a way that the wear values ​​of the lining wear and disc wear of the brake caliper unit 1 accumulated in the measurement signal S are determined.

[0121] The wear value is then compared with previously stored limits for liner and disc replacement. Based on the comparison result, notifications, warnings, etc., are output on appropriate media.

[0122] Furthermore, the measurement signal can be evaluated in such a way that information about the route or sine curve that causes the train wheelset to deflect continuously from its initial position can be determined.

[0123] When two or more wear sensor devices 11, 11', 11'' are set up, their measurement signals can be used to verify the reliability of the determined wear value.

[0124] In addition, the measurement signals provided by the wear sensor devices 11, 11', 11'' can also be used to detect the loss of brake pads 4, 5 and / or check whether brake caliper units 1, 1' have been operated or released.

[0125] The evaluation unit 12 can also determine the wear of the entire brake caliper unit 1, 1' based on the comparison value of all detected measurements and the wear values ​​determined therefrom.

[0126] Wear sensor devices 11, 11', 11'' can be installed according to Figure 1On the traditional brake caliper unit 1, it can also be installed according to Figure 2 It is mounted on the so-called compact brake caliper unit 1'. It can also be retrofitted into both types of brake caliper units 1 and 1'.

[0127] The present invention is not limited to the embodiments given above, but can be modified within the scope of the claims.

[0128] For example, it is conceivable that instead of the ultrasonic sensor in the second embodiment, a radar sensor and / or an optical ranging sensor, such as an infrared ranging sensor, could be used.

[0129] Another alternative is to adjust the depth measurement solution of the vernier caliper.

[0130] List of reference numerals

[0131] 1 Brake Caliper Unit

[0132] 2, 3 clamps

[0133] 2a, 3a; 2b, 3b hinges

[0134] 4, 5 brake pads

[0135] 6 and 7 connecting shafts

[0136] 8 brake cylinders

[0137] 9 Regulator Module

[0138] 10, 10' distance

[0139] 11, 11', 11'' wear sensor device

[0140] 11a sensor axis

[0141] 12 assessment units

[0142] 12a connecting wire

[0143] 13, 14 Fixing elements

[0144] 13a, 14a fixing plates

[0145] 13b opening

[0146] 13c notch

[0147] 13d wall

[0148] 13e inner side

[0149] 15 Sensor Housing

[0150] Wall 15a

[0151] 15b end plate

[0152] 15c interior space

[0153] 15d opening

[0154] 15e flange

[0155] 15f seal

[0156] 16-shell

[0157] 16a bearing housing

[0158] 16b shell tube

[0159] 16c protruding shoulders

[0160] 16D intermediate board

[0161] 17 threaded pipe

[0162] Ends of 17a and 17b

[0163] 18 lead screw

[0164] 18a, 18b lead screw ends

[0165] 18c bearing section

[0166] 18D bracket

[0167] 18e retaining plate

[0168] 19 External Thread

[0169] 19a internal thread

[0170] 20 corrugated pipe

[0171] 20a, 20b Sealed end sections

[0172] 21 bearing

[0173] 22 Rotary connector

[0174] 22a Synchronization Component

[0175] 23 Transmission Mechanism

[0176] 24, 24' sensor elements

[0177] 24'a Transmitter / Receiver Surface

[0178] 25 tubes

[0179] 25a and 25b pipe ends

[0180] 26 stents

[0181] 26a Fixed end

[0182] 26b support end

[0183] 27 Sensor Housing

[0184] 27a Fixed Section

[0185] 28 Liner Wear Curve

[0186] 29 Liner Wear

[0187] Replacement of 30 Liners

[0188] 31 disc wear curves

[0189] 32 disks replaced

[0190] 33 discs worn

[0191] 34 Total Wear

[0192] S measurement signal

[0193] SB diagram

[0194] t time

[0195] VS1, VS2, VS3 method steps

[0196] x, y, z coordinates

Claims

1. A brake caliper unit (1, 1') for a disc brake, the brake caliper unit having two caliper bars (2, 3), a brake cylinder (8), an adjuster module (9), brake pads (4, 5), and a wear sensor device (11, 11', 11''), the wear sensor device having at least one sensor element (24, 24') and an evaluation unit (12), the wear sensor device (11, 11', 11'') being hinged to the two caliper bars (2, 3) in a connecting axis parallel to the adjuster module (9) and / or the brake cylinder (8), characterized in that, The wear sensor devices (11, 11', 11'') are hingedly mounted in the connecting axis of the connection points (6, 7), and the brake cylinder (8) and / or the regulator module (9) are hinged in the connecting axis of the connection points. The connection points (6, 7) are spaced apart from each other by a distance (10). The wear sensor device (11, 11') has a motion conversion unit that converts longitudinal motion, which is a change in the distance (10) between the connection points (6, 7), into rotational motion. The motion conversion unit of the wear sensor device (11, 11') includes a threaded tube (17) with an internal thread (19a) and a lead screw (18) with an external thread (19). The internal thread (19a) and the external thread (19) mesh to form a transmission thread. The wear sensor device (11, 11') includes a fixing element (13; 14), a sensor housing (15) for accommodating the at least one sensor element, a housing (16), and the at least one sensor element (24). The wear sensor devices (11, 11') are hingedly mounted in the connecting axis of the connection point (6, 7) by means of a fixing element (13; 14), and the housing tube (16b) of the housing (16) and the threaded tube (17) are telescopically arranged together, with the housing tube (16b) pushed onto the threaded tube (17).

2. The brake caliper unit (1, 1') according to claim 1, characterized in that, The threaded tube (17) is non-rotatably connected to the wear sensor device (11, 11'), and the lead screw (18) is rotatably supported and connected to the at least one sensor element (24), or The lead screw (18) is non-rotatably connected to the wear sensor device (11, 11') and the threaded tube (17) is rotatably supported and connected to the at least one sensor element (24).

3. The brake caliper unit (1, 1') according to claim 2, characterized in that, The at least one sensor element (24) is a rotation angle sensor.

4. The brake caliper unit (1, 1') according to claim 1, characterized in that, The wear sensor device (11, 11') also includes at least one bearing (21) that forms a rotating bearing for a lead screw (18) or a threaded tube (17).

5. The brake caliper unit (1, 1') according to any one of claims 1 to 4, characterized in that, The brake caliper unit (1, 1') is configured for a pneumatic disc brake.

6. The brake caliper unit (1, 1') according to any one of claims 1 to 4, characterized in that, This brake caliper unit is designed for disc brakes on rail vehicles.

7. A method for determining the wear of the brake pads (4, 5) and the brake disc of a brake caliper unit (1, 1') of a disc brake according to any one of claims 1 to 6, characterized in that... The following are the steps: (VS1) detects the initial position and detects the change in length of the distance (10) between the connection points (6, 7) of the two caliper bars (2, 3) during braking by means of wear sensor devices (11, 11', 11''), and converts the change in length of the distance (10) into the change in the rotation angle of the sensor element by the motion conversion unit; (VS2) Generates a measurement signal (S) based on the detected measurement value; and forwards the measurement signal to the evaluation unit (12); (VS3) The measurement signal (S) is evaluated by the evaluation unit (12) to determine the wear value of the lining wear and disc wear of the brake caliper unit (1, 1') accumulated in the measurement signal (S).

8. A method for determining the wear of brake pads (4, 5) and brake disc of a brake caliper unit (1, 1') of a disc brake, said brake caliper unit having two caliper bars (2, 3), a brake cylinder (8), brake pads (4, 5) and a wear sensor device (11, 11', 11''), the wear sensor device having an evaluation unit (12), characterized in that The following are the steps: (VS1) The initial position is detected and the change in length of the distance (10) between the connection points (6, 7) of the two caliper bars (2, 3) during braking is detected by means of a wear sensor device (11, 11', 11''). The change in length of the distance (10) is detected by measuring the distance (10') between the sensor element (24') of the non-contact rangefinder and the reference section of the wear sensor device (11''). The wear sensor device (11'') includes a fixing element (13, 14), a housing tube (25), and at least one non-contact rangefinder. The housing tube (25) and the at least one non-contact rangefinder are telescopically arranged together, and the sensor element (24') is ultrasonic. The ultrasonic sensor interacts with the inner side (13e) of the wall (13d) of the recess (13b) in the fixing plate (13a) of the first fixing element in the fixing element. The housing tube (25) is fixed in the recess. The inner side (13e) of the wall (13d) serves as a reflective surface for the ultrasonic vibration of the sensor element (24') and constitutes a reference section of the wear sensor device (11''). The transmitter / receiver surface (24'a) of the sensor element (24') and the inner side (13e) of the wall (13d) are spaced apart by the distance (10'). The wear sensor devices are respectively hinged in the connecting axis of the connection point (6, 7) by means of one of the fixing elements (13; 14). (VS2) Generates a measurement signal (S) based on the detected measurement value; and forwards the measurement signal to the evaluation unit (12); (VS3) The measurement signal (S) is evaluated by the evaluation unit (12) to determine the wear value of the lining wear and disc wear of the brake caliper unit (1, 1') accumulated in the measurement signal (S).

9. The method according to claim 7 or 8, characterized in that, The evaluation unit (12) compares the determined wear value with the previously stored limit values ​​for liner replacement and disc replacement and outputs a notification or warning on a suitable medium based on the comparison result.

10. The method according to claim 7 or 8, characterized in that, The evaluation unit (12) determines the wear of the brake pads (4, 5) and brake disc (13, 13') of the entire disc brake based on the comparison value of all detected measurements and the wear values ​​determined therefrom.

11. The method according to claim 7 or 8, characterized in that, This brake caliper unit is designed for disc brakes on rail vehicles.

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