Brake disc surface performance monitoring system and method

Abstract

The application discloses a brake disc surface performance monitoring system and method, which comprises a driving module for driving the brake disc to rotate; a speed detection module for detecting the rotating speed of the brake disc; a torque detection module for detecting the torque borne by the brake disc; a distance detection module comprising at least two detection probes oppositely arranged on both sides of the friction surface of the brake disc, the detection probes being used for detecting the distance between the detection probes and the side surface of the brake disc; a hardness detection module for detecting the hardness of the surface of the brake disc; a brake caliper module for braking the brake disc through hydraulic driving; and a hydraulic detection module for detecting the brake hydraulic pressure of the brake caliper assembly, wherein the data of the thickness, thickness change amount, end jump value, friction coefficient or surface hardness of the brake disc in real time are detected, the change trend of the parameters is judged, the service life of the brake disc meeting the use condition is tested, and the service life of the part is estimated according to the data change trend, so that the process monitoring of the performance change of the brake disc is realized.

Description

Technical Field

[0001] This invention relates to the technical field of vehicle braking testing, and in particular to a brake disc surface performance monitoring system and method. Background Technology

[0002] Currently, brake disc design is constantly improving, and more and more heat treatment processes from other fields are being applied to brake discs, such as nitriding and hot-dip chrome plating. These processes can significantly improve brake disc performance. However, because these technologies have not been used on brake discs for very long, there is insufficient experience in their application. Furthermore, brake discs are easily worn parts, and the service life of these treated brake discs has not been estimated. This means that when developing projects using these surface-treated brake discs, the performance of both the brake disc and the friction pads is affected by the amount of surface wear. Especially in friction pad tests with high wear intensity, the surface layer of the brake disc may be completely worn away, or even one friction material may come into contact with two different brake disc surfaces. While some equipment for testing brake disc performance has emerged, existing testing technologies cannot accurately measure different parameters of the brake disc in real time during braking, making it difficult to accurately obtain the trend of surface performance changes and estimate the service life of the surface layer. Summary of the Invention

[0003] This invention provides a brake disc surface performance monitoring system and method, which detects various parameters of the brake disc in real time during braking, and detects and records the changes in the performance of the brake disc as the number of braking cycles increases.

[0004] A brake disc surface performance monitoring system according to a first aspect of the present invention includes: The drive module is used to drive the brake disc to rotate; A speed detection module is used to detect the rotational speed of the brake disc; A torque detection module is used to detect the torque applied to the brake disc; The distance detection module includes at least two detection probes disposed opposite to each other on both sides of the friction surface of the brake disc, the detection probes being used to detect the distance between the detection probes and the side of the brake disc; The hardness testing module is used to test the hardness of the brake disc surface; The brake caliper module brakes the brake disc via hydraulic drive; A hydraulic testing module is used to detect the brake hydraulic pressure of the brake caliper assembly.

[0005] A method for testing the surface performance of a brake disc according to a second aspect of the present invention includes: The brake disc is cyclically braked by controlling the brake hydraulic pressure and the initial braking speed. The real-time thickness, thickness change, and end runout value of the brake disc are calculated by detecting the distance between the detection probe and the side surface of the brake disc in real time. Real-time braking pressure is obtained by calculating the braking hydraulic pressure in real time. Real-time detection of the braking torque applied to the brake disc; The real-time friction coefficient between the brake disc and the friction pad surface is calculated based on the braking pressure, the braking torque, and the effective radius of the brake caliper. Test the surface hardness of the brake disc; The thickness, thickness variation, end jump value, friction coefficient, and surface hardness of the brake disc are controlled by preset change thresholds. Cyclic braking is stopped when any one of the brake disc thickness, thickness variation, end jump value, friction coefficient, or surface hardness reaches the preset change threshold.

[0006] According to some embodiments of the present invention, the brake disc surface performance testing method further includes: The service life of the brake disc is estimated based on the thickness of the brake disc, the amount of thickness variation, the end runout value, the friction coefficient, or the trend of surface hardness variation.

[0007] According to some embodiments of the present invention, the cyclic braking of the brake disc by controlling the brake hydraulic pressure and the initial braking speed further includes: Real-time monitoring of brake disc temperature; setting a first preset temperature threshold and a second preset temperature threshold. When the temperature of the brake disc is higher than the first preset temperature threshold, cyclic braking stops, and cyclic braking resumes only after the brake disc cools down to below the second preset temperature threshold.

[0008] According to some embodiments of the present invention, the cyclic braking of the brake disc by controlling the brake hydraulic pressure and the initial braking speed further includes: The final braking speed for each braking cycle is controlled to be 0 km / h.

[0009] According to some embodiments of the present invention, the step of detecting the surface hardness of the brake disc further includes: Test the surface hardness of the brake disc after it stops rotating.

[0010] According to some embodiments of the present invention, the step of calculating the real-time thickness, thickness change, and end runout value of the brake disc by real-time detection of the distance between the distance sensor and the side surface of the brake disc further includes: Confirm that the distances between the detection probes on both sides of the brake disc and the surfaces on both sides of the brake disc are a1 and a2, respectively, and the distance between the two detection probes on both sides of the brake disc is L; The end jump values ​​on both sides of the brake disc are calculated by the changes in a1 and a2 respectively; The real-time thickness of the brake disc is obtained through the relation L-(a1+a2); The average thickness of each brake disc is calculated based on the set of real-time thicknesses for each brake disc. The thickness change of the brake disc in each revolution is obtained by measuring the difference between the maximum and minimum real-time thickness of the brake disc in each revolution.

[0011] According to some embodiments of the present invention, the step of calculating the real-time braking pressure by real-time detection of braking hydraulic fluid includes: Through relational formulas The calculation is performed, where P is the brake hydraulic pressure, S is the piston end face area of ​​the hydraulic cylinder in the brake caliper assembly, and F is the braking pressure provided by the brake caliper assembly to the brake disc.

[0012] According to some embodiments of the present invention, the calculation of the real-time friction coefficient between the brake disc and the friction pad surface based on the braking pressure, the braking torque, and the braking friction area includes: Through relational formulas The calculation is performed, where μ is the coefficient of friction between the brake disc and the friction pad surface, M is the real-time braking torque on the brake disc, F is the braking pressure provided by the brake caliper assembly to the brake disc, and r is the effective radius of the brake caliper.

[0013] According to some embodiments of the present invention, the brake disc surface performance monitoring system further includes: By detecting the braking speed of the brake disc in real time, the real-time deceleration is calculated, and the braking torque is controlled by controlling the brake hydraulic fluid to achieve constant deceleration.

[0014] According to an embodiment of the present invention, a brake disc surface performance monitoring system and method has at least the following beneficial effects: The present invention can determine the changing trends of these parameters based on the real-time data of brake disc thickness, thickness change, end runout, friction coefficient, or surface hardness. It can test the lifespan of the brake disc to meet the usage conditions and can also predict the lifespan of the parts based on the data changing trends. It realizes the process monitoring of brake disc performance changes and provides objective data supplements for the evaluation of brake disc performance during the development of braking systems, especially brake disc development.

[0015] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0016] The present invention will be further described below with reference to the accompanying drawings and embodiments, wherein: Figure 1 This is a partial front view of the brake disc surface performance monitoring system of the present invention; Figure 2 This is a side view of the brake disc surface performance monitoring system of the present invention; Figure 3 This is the control logic diagram of the brake disc surface performance monitoring method of the present invention; Figure 4 This is a control logic diagram of the brake disc surface performance monitoring method of the present invention, which controls the hydraulic pressure based on real-time deceleration.

[0017] Icon labels: Drive shaft 100; Brake caliper module 200; Speed ​​sensor 300; Torque sensor 400; Distance sensor 500; Detection probe 510; Hardness tester 600; Hydraulic sensor 700; Brake disc 800. Detailed Implementation

[0018] The reference numerals denote the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the invention, and should not be construed as limiting the invention.

[0019] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, etc., are based on the orientation or positional relationship shown in the drawings and are only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0020] In the description of this invention, "multiple" refers to two or more. The use of "first" and "second" is for distinguishing technical features only and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features or their sequential relationship.

[0021] In the description of this invention, unless otherwise explicitly defined, terms such as "set up," "install," and "connect" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this invention in conjunction with the specific content of the technical solution.

[0022] Reference Figure 1 and Figure 2 As shown, the brake disc surface performance monitoring system of this invention includes: a drive module, a speed detection module, a torque detection module, a distance detection module, a hardness detection module, a brake caliper module 200, and a hydraulic detection module.

[0023] The drive module in this embodiment is used to drive the brake disc 800 to rotate. The drive module includes a drive shaft 100. During the test, the brake disc 800 is clamped on the drive shaft 100, and the brake caliper module 200 is driven by hydraulic pressure. The brake caliper module 200 is connected to a hydraulic pipeline system, which is connected to a hydraulic cylinder on the brake caliper module 200. The hydraulic cylinder drives the brake caliper to achieve the braking action. Friction pads are installed on the brake caliper. The brake caliper drives the two friction pads on both sides of the brake disc 800 to move closer or further apart, so as to achieve braking of the brake disc 800.

[0024] The speed detection module of this embodiment is used to detect the rotational speed of the brake disc 800. The speed detection module of this embodiment includes a speed sensor 300 installed at the drive shaft 100 at the center of the brake disc 800.

[0025] The torque detection module in this embodiment is used to detect the torque on the brake disc 800. The torque detection module in this embodiment is installed at the torque sensor 400 on the drive shaft 100 at the center of the brake disc 800.

[0026] The distance detection module of this embodiment includes a distance sensor 500. Distance sensors 500 are provided on both sides of the friction surface of the brake disc 800, and each distance sensor 500 is provided with a detection probe 510. The detection probes 510 on both sides of the brake disc 800 are arranged opposite to each other along the axial direction of the brake disc 800. The detection probes 510 and the side surface of the brake disc 800 are provided with a gap, which is determined based on different brake discs 800. At the same time, the distance between the detection probes 510 on both sides of the brake disc 800 in this embodiment is also constant.

[0027] The hardness testing module of this embodiment is used to test the hardness of the surface of the brake disc 800. The hardness testing module includes a non-contact hardness tester 600 disposed on both sides of the brake disc 800.

[0028] The hydraulic detection module in this embodiment is used to detect the brake hydraulic pressure of the brake caliper assembly. The hydraulic detection module includes a hydraulic sensor 700 installed in the brake caliper oil inlet line.

[0029] The brake disc surface performance monitoring system of this embodiment also includes a data processor and a controller. The data processor is connected to the controller and is also connected to the drive module, speed detection module, torque detection module, distance detection module, hardness detection module, brake caliper module 200 and hydraulic detection module. like Figure 3 As shown, this embodiment also provides a method for testing the surface performance of a brake disc, including: Step S1: Install the brake disc 800. The detection probes 510 on the distance sensors 500 on both sides of the brake disc 800 measure the distances a1 and a2 to the two sides of the brake disc 800, respectively. The distance between the two detection probes 510 is L.

[0030] Step S2: Start the system to make the brake disc 800 rotate at the specified initial braking speed. The distance sensor 500 maintains the measurement state and records the values ​​of a1 and a2. The data processor then calculates the end jump values ​​b1 and b2 on both sides of the brake disc 800 based on the changes in a1 and a2, respectively. The real-time thickness of the brake disc 800 is obtained by L-(a1+a2). The average thickness δ of each circle of the brake disc 800 is calculated by the data processor, and the thickness change of each circle is obtained by the difference between the maximum and minimum values ​​of the real-time thickness of the brake disc 800.

[0031] Step S3: The data processor calculates the deceleration based on the speed change using the data detected by the speed sensor 300, and simultaneously monitors the brake hydraulic pressure p in real time using the hydraulic sensor 700, and calculates the deceleration using the relevant formula. The calculation is performed, where S is the area of ​​the piston end face of the hydraulic cylinder in the brake caliper assembly, and F is the braking pressure provided by the brake caliper assembly to the brake disc 800, in order to obtain the braking pressure. The area of ​​the piston end face of the hydraulic cylinder in the brake caliper assembly is a fixed value, which is known before the test.

[0032] Step S4: The torque sensor 400 detects the torque M on the brake disc 800 in real time during braking.

[0033] Step S5: The data processor, using the torque M detected by the torque sensor 400, the F calculated in step S3, and the effective radius r of the brake caliper, can then apply the formula... The coefficient of friction between the brake disc 800 and the friction pad surface is obtained. The effective radius of the brake caliper is a fixed value, which was known before the test.

[0034] Step S6: After the brake disc 800 stops rotating due to the braking force, use a hardness tester 600 to test the surface hardness H of the brake disc 800. In other words, control the final braking speed of each braking cycle to 0 km / h.

[0035] Step S7: Repeat steps S1 to S6, during which the temperature of the brake disc 800 is monitored by a temperature sensor. When the temperature of the brake disc 800 is higher than the first preset temperature threshold, stop the cyclic braking. After the brake disc 800 cools down to below the second preset temperature threshold, cyclic braking is resumed. The first preset temperature threshold is greater than the second preset temperature threshold. The first and second preset temperature thresholds are determined according to actual conditions. This mainly ensures that the brake disc 800 is tested within a reasonable temperature range to meet actual braking conditions.

[0036] Step S8: When the controller receives the friction coefficient μ, brake disc thickness δ, thickness change DTV, end jump value b1, b2 or surface hardness H output by the data processor and the value reaches the preset change threshold, the test is stopped after the cycle is completed.

[0037] Subsequently, the service life of the brake disc 800 can be estimated based on the changing trends of the friction coefficient μ, brake disc thickness δ, thickness change DTV, end jump values ​​b1, b2, or surface hardness H.

[0038] In some embodiments, different brake hydraulic pressures and initial braking speeds are controlled according to different brake discs 800 to perform cyclic braking. like Figure 4 As shown, this embodiment can also simulate different braking strategies in steps S3-S5 using data from the hydraulic sensor 700 and the speed sensor 300. For example, based on the deceleration detected and calculated by the speed sensor 300, the hydraulic pressure can be controlled to achieve constant deceleration by controlling the braking torque. Alternatively, based on the real-time deceleration calculated by detecting the braking speed of the brake disc 800, the braking torque can be controlled by controlling the braking hydraulic pressure to achieve constant deceleration.

[0039] This system can be added to other test benches to assist in the operation of control programs during experiments with other brake discs 800 or friction pads, and can control the state of the brake disc 800.

[0040] According to an embodiment of the present invention, a brake disc surface performance monitoring system and method has at least the following beneficial effects: The present invention can determine the changing trends of parameters such as the thickness, thickness change, end runout value, friction coefficient, or surface hardness of the brake disc 800 based on the detected real-time data. It can test the lifespan of the brake disc 800 to meet the usage conditions, and can also predict the lifespan of the parts based on the data changing trends. It realizes the process monitoring of the performance changes of the brake disc 800, and provides objective data supplements for the evaluation of the performance of the brake disc 800 during the development of the braking system, especially the development of the brake disc 800.

[0041] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. A method for testing the surface performance of a brake disc, characterized in that, It is applicable to brake disc surface performance monitoring systems, which include: The drive module is used to drive the brake disc to rotate; A speed detection module is used to detect the rotational speed of the brake disc; A torque detection module is used to detect the torque applied to the brake disc; The distance detection module includes at least two detection probes disposed opposite to each other on both sides of the friction surface of the brake disc, the detection probes being used to detect the distance between the detection probes and the side of the brake disc; The hardness testing module is used to test the hardness of the brake disc surface; The brake caliper module brakes the brake disc via hydraulic drive; A hydraulic detection module is used to detect the brake hydraulic pressure of the brake caliper assembly; The method for testing the surface performance of the brake disc includes: The brake disc is cyclically braked by controlling the brake hydraulic pressure and the initial braking speed. The real-time thickness, thickness change, and end runout value of the brake disc are calculated by detecting the distance between the detection probe and the side surface of the brake disc in real time. Real-time braking pressure is obtained by calculating the braking hydraulic pressure in real time. Real-time detection of the braking torque applied to the brake disc; The real-time friction coefficient between the brake disc and the friction pad surface is calculated based on the braking pressure, the braking torque, and the effective radius of the brake caliper. Test the surface hardness of the brake disc; The thickness, thickness variation, end jump value, friction coefficient, and surface hardness of the brake disc are controlled by preset change thresholds. Cyclic braking is stopped when any one of the brake disc thickness, thickness variation, end jump value, friction coefficient, or surface hardness reaches the preset change threshold.

2. The method for testing the surface performance of a brake disc according to claim 1, characterized in that: The method for testing the surface performance of the brake disc also includes: The service life of the brake disc is estimated based on the thickness of the brake disc, the amount of thickness variation, the end runout value, the friction coefficient, or the trend of surface hardness variation.

3. The method for testing the surface performance of a brake disc according to claim 1, characterized in that: The method of cyclically braking the brake disc by controlling the brake hydraulic pressure and the initial braking speed also includes: Real-time monitoring of brake disc temperature; setting a first preset temperature threshold and a second preset temperature threshold. When the temperature of the brake disc is higher than the first preset temperature threshold, cyclic braking stops, and cyclic braking resumes after the brake disc cools down to below the second preset temperature threshold.

4. The method for testing the surface performance of a brake disc according to claim 1, characterized in that: The method of cyclically braking the brake disc by controlling the brake hydraulic pressure and the initial braking speed also includes: The final braking speed for each braking cycle is controlled to be 0 km / h.

5. The method for testing the surface performance of a brake disc according to claim 4, characterized in that: The method of detecting the surface hardness of the brake disc also includes: Test the surface hardness of the brake disc after it stops rotating.

6. The method for testing the surface performance of a brake disc according to claim 1, characterized in that: The calculation of the real-time thickness, thickness change, and end runout value of the brake disc by real-time detection of the distance between the detection probe and the side surface of the brake disc also includes: Confirm that the distances between the detection probes on both sides of the brake disc and the surfaces on both sides of the brake disc are a1 and a2, respectively, and the distance between the two detection probes on both sides of the brake disc is L; The end jump values ​​on both sides of the brake disc are calculated by the changes in a1 and a2 respectively; The real-time thickness of the brake disc is obtained through the relation L-(a1+a2); The average thickness of each brake disc is calculated based on the set of real-time thicknesses for each brake disc. The change in brake disc thickness for each revolution is obtained by measuring the difference between the maximum and minimum values ​​of the real-time thickness of the brake disc for each revolution.

7. The method for testing the surface performance of a brake disc according to claim 1, characterized in that: The real-time braking pressure obtained by real-time detection of braking hydraulic fluid includes: Through relational formulas The calculation is performed, where P is the brake hydraulic pressure, S is the piston end face area of ​​the hydraulic cylinder in the brake caliper assembly, and F is the braking pressure provided by the brake caliper assembly to the brake disc.

8. The method for testing the surface performance of a brake disc according to claim 1, characterized in that: The real-time friction coefficient between the brake disc and the friction pad surface, calculated based on the braking pressure, the braking torque, and the braking friction area, includes: Through relational formulas The calculation is performed, where μ is the coefficient of friction between the brake disc and the friction pad surface, M is the real-time braking torque on the brake disc, F is the braking pressure provided by the brake caliper assembly to the brake disc, and r is the effective radius of the brake caliper.

9. The method for testing the surface performance of a brake disc according to claim 1, characterized in that: The method for testing the surface performance of the brake disc also includes: By detecting the braking speed of the brake disc in real time, the real-time deceleration is calculated, and the braking torque is controlled by controlling the brake hydraulic fluid to achieve constant deceleration.

Images