Online dragging detection mechanism for brake caliper

Abstract

The invention relates to an online dragging detection mechanism for a brake caliper. The online dragging detection mechanism comprises an air pressure pressurization module, a dragging detection module, an online control module and a feedback and alarm module, the air pressure pressurization module is used for applying air pressure to the brake caliper and simulating pressure change in the braking process; the dragging detection module is connected with the air pressure pressurization module and is used for evaluating the dragging condition; the online control module receives the air pressure value of the air pressure increasing module and the dragging torque analysis result of the dragging detection module, automatically judges the detection result and outputs the judgment result to the feedback and alarm module. By adopting the air pressure pressurization module and the on-line detection module, 100% detection of dragging of the brake caliper is realized, the detection frequency and efficiency are improved, hydraulic pressurization is replaced by air pressure, the problem that a brake is scrapped after hydraulic detection is avoided, the detection cost is reduced, and the utilization rate of a production line is improved.

Description

Technical Field

[0001] The invention belongs to the technical field of brake systems, and in particular relates to an online drag detection mechanism for a brake caliper. Background Art

[0002] Caliper drag refers to the phenomenon in the vehicle braking system that when the driver releases the brake pedal, the brakes cannot be released immediately or completely, and the wheels are still applied with braking force. This phenomenon will cause the vehicle to slow down even after the brakes are released, and the brake pads will overheat or even burn. Caliper drag not only affects the fuel consumption and driving comfort of the vehicle, but may also cause vehicle shaking, abnormal braking noise, and in severe cases may even cause the vehicle to lock, affecting driving safety.

[0003] The drag of the brake caliper affects the cruising range of the vehicle. Reducing the drag by 1N.m can increase the cruising range of the vehicle by 20-30 kilometers. Currently, most of the drag detection is hydraulic testing in the laboratory. Due to the limitations of hydraulic testing (the brake cannot be delivered to the OEM after the test is hydraulically connected), the detection frequency is usually low (once or several times a year), and the actual production level of the production line cannot be monitored in time.

[0004] In summary, the existing technologies are mostly hydraulic detection, and the detection frequency is low and cannot timely monitor the actual production level of the production line to ensure production quality, resulting in the problem of brake caliper drag affecting the vehicle's endurance. Summary of the invention

[0005] The purpose of this section is to summarize some aspects of the embodiments of the present invention and briefly introduce some preferred embodiments. Some simplifications or omissions may be made in this section and the specification abstract and the invention title of the present invention to avoid blurring the purpose of this section, the specification abstract and the invention title, and such simplifications or omissions cannot be used to limit the scope of the present invention.

[0006] Therefore, the purpose of the present invention is to provide an online drag detection mechanism for a brake caliper, which can solve the problem that the existing technology is mostly hydraulic detection, and the detection frequency is low and the actual production level of the production line cannot be monitored in time to ensure the production quality, resulting in brake caliper drag affecting the endurance of the whole vehicle. The present invention provides an online drag detection mechanism for a brake caliper, which includes an air pressure pressurization module, a drag detection module, an online control module and a feedback and alarm module; the air pressure pressurization module is used to apply air pressure to the brake caliper to simulate the pressure change during the braking process; the drag detection module is connected to the air pressure pressurization module to evaluate the drag situation; the online control module receives the air pressure value of the air pressure pressurization module and the drag torque analysis result of the drag detection module to automatically determine the detection result, and output the determination result to the feedback and alarm module.

[0007] Optionally, the air pressure pressurization module includes an air pressure source, the air pressure source is connected to an air pressure control valve, the other side of the air pressure control valve is connected to an air pressure sensor, and the drag detection module is connected to the other side of the air pressure sensor.

[0008] Optionally, the air pressure source is an air compressor or a nitrogen cylinder.

[0009] Optionally, the drag detection module includes a servo motor, the servo motor and the torque sensor are connected via a coupling, the other side of the torque sensor is connected to a bearing via the coupling, and the other side of the bearing is connected to a simulated brake disc.

[0010] Optionally, there is a detection fixture between the bearing and the simulated brake disc, and the top of the detection fixture is connected to the brake caliper through a caliper fastening bolt, and the brake caliper and the simulated brake disc are adapted to each other.

[0011] Optionally, the online control module includes a data acquisition and analysis module, an automatic control module, and a result judgment module; the data acquisition and analysis module is used to collect air pressure values ​​and torque data in real time; the automatic control module is used to receive data and perform automatic control according to preset detection processes and parameters; the result judgment module is used to automatically determine the detection results based on the analysis results, and output the determination results to the feedback and alarm module.

[0012] Optionally, the controller used by the automation control module of the online control module is a programmable logic controller (PLC) or an industrial computer as a core controller.

[0013] Optionally, the air pressure control valve is a high-precision air pressure control valve.

[0014] Optionally, the servo motor is a high-performance servo motor.

[0015] Optionally, the feedback and alarm module includes an alarm module and a detection result feedback module; the alarm module is used to start when it detects that the drag exceeds a set threshold, and emit an audible and visual alarm signal; the detection result feedback module is used to display the detection results in digital or graphical form on the operation interface, and at the same time feed back the detection results to the production management personnel through the production line integration system.

[0016] In summary, the present invention includes at least one of the following beneficial effects: The present invention adopts an air pressure module and an online detection module to achieve 100% inspection of brake caliper drag, improve the detection frequency and efficiency, and use air pressure instead of hydraulic pressure to avoid the scrapping problem of the brake after hydraulic detection, reduce the detection cost, and improve the utilization rate of the production line.

[0017] The present invention can timely discover and correct the drag problem through the online detection module, thereby ensuring the quality stability and consistency of the brake caliper. The detection mechanism of the present invention is easy to integrate with the existing production line to realize automatic detection, thereby reducing manual intervention and errors. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0019] Figure 1 A schematic structural diagram of an online brake caliper drag detection mechanism of the present invention; Figure 2 It is a schematic diagram of a drag detection module of an online drag detection mechanism of a brake caliper of the present invention; Figure 3 A control flow chart of a line control module of a brake caliper online drag detection mechanism of the present invention; Figure 4 It is a schematic diagram of the structure of a detection tooling of a brake caliper online drag detection mechanism of the present invention; List of illustration symbols: 1. Air pressure pressurization module; 2. Drag detection module; 3. Online control module; 4. Feedback and alarm module; 5. Detection tooling; 6. Simulated brake disc; 101. Air pressure source; 102. Air pressure source control valve; 103. Air pressure sensor; 201. Servo motor; 202. Torque sensor; 203. Coupling; 204. Bearing; 7. Brake caliper; 8. Caliper fastening bolts. DETAILED DESCRIPTION

[0020] The following is combined with Figure 1-4 The present invention is described in further detail.

[0021] Embodiment 1, refer to Figure 1-4 In order to solve the problem that the existing technology is mostly hydraulic detection, and the detection frequency is low and the actual production level of the production line cannot be monitored in time to ensure the production quality, resulting in brake caliper drag and affecting the endurance of the whole vehicle, the present invention discloses a brake caliper online drag detection mechanism, including an air pressure pressurization module 1, a drag detection module 2, an online control module 3 and a feedback and alarm module 4; the air pressure pressurization module 1 is used to apply air pressure to the brake caliper 7 to simulate the pressure change during braking; the drag detection module 2 is connected to the air pressure pressurization module 1 to evaluate the drag situation; the online control module 3 receives the air pressure value of the air pressure pressurization module 1 and the drag torque analysis result of the drag detection module 2 to automatically determine the detection result, and outputs the determination result to the feedback and alarm module 4.

[0022] The air pressure module 1 includes an air pressure source 101, an air pressure control valve 102 and an air pressure sensor 103; Air pressure source 101: First, select an air source device that can provide stable air pressure, such as an air compressor or a nitrogen cylinder, to ensure the stability and reliability of the air pressure source 101.

[0023] Air pressure control valve 102: A high-precision air pressure control valve is installed between the air pressure source and the brake caliper 7. The valve can receive instructions from the online control system and accurately adjust the air pressure value applied to the brake caliper 7. By adjusting the opening of the control valve, the air pressure can be accurately controlled.

[0024] Air pressure sensor 103: An air pressure sensor 103 is installed on the pipeline between the air pressure control valve 102 and the brake caliper 7 to monitor the air pressure value in real time and transmit the data to the online control system. The sensor has high sensitivity and high precision, which can ensure accurate measurement of the air pressure value.

[0025] The drag detection module 2 includes a servo motor 201, a coupling 203, a torque sensor 202, a bearing 204, a detection tool 5 and a simulated brake disc 6; Servo motor 201: A high-performance servo motor is selected and connected to the simulated brake disc 6 through a coupling 203. The servo motor 201 can run at a preset speed and torque to simulate the working state of the brake caliper 7 during the actual braking process.

[0026] Coupling 203 and bearing 204: Coupling 203 is used to connect servo motor 201 and simulated brake disc 6 to ensure the coaxiality and transmission stability between the two. Bearing 204 is used to support simulated brake disc 6.

[0027] Simulated brake disc 6: The simulated brake disc 6 is designed to meet the specifications of the actual brake caliper 7 and is used to contact the friction pad of the brake caliper 7. The material and surface treatment of the simulated brake disc 6 should be similar to those of the actual brake disc to ensure the accuracy of the test results.

[0028] Testing tool 5: A special testing tool is designed, and the professional testing tool 5 fixes and connects the brake caliper 7 to the drag detection module 2 through the upper caliper fastening bolts 8. The testing tool 5 ensures the stability and accuracy of the brake caliper 7 during the installation process.

[0029] Torque sensor 202: A torque sensor 202 is installed between the servo motor 201 and the simulated brake disc 6 to measure and record the torque change of the brake caliper 7 under the action of air pressure in real time. The torque measurement device should have high accuracy and fast response capabilities to accurately evaluate the drag situation.

[0030] The online control module 3 includes an automatic control module, a data acquisition and analysis module, and a test result determination module; Automatic control module: uses a programmable logic controller (PLC) or an industrial computer as the core controller, receives data from the air pressure sensor 103 and the torque sensor 202, and by comparing the preset drag threshold and the actual measured torque value, it can determine whether the brake caliper 7 has a drag problem and perform automatic control.

[0031] Data acquisition and analysis module: collects the air pressure value of the air pressure sensor 103 and the torque data of the torque sensor 202 in real time.

[0032] Detection result determination module: The online control system automatically determines the detection result according to the analysis result, and outputs the determination result to the feedback and alarm module 4.

[0033] The feedback and alarm module 4 includes an alarm module and a detection result feedback module; Alarm module: When the drag is detected to exceed the set threshold, the alarm device will automatically start and send out sound and light alarm signals to alert the operator.

[0034] Test result feedback module: The test results are displayed in digital or graphical form on the operation interface, and the test results are fed back to the production management personnel through the production line integration system. The management personnel can take corrective measures in time according to the test results.

[0035] Specific implementation principle: Before using the present invention, the contact surface state of the simulated brake disc 6-detection tool 5 is manually adjusted on the detection tool 5 to make the end face runout of the simulated brake disc 6 reach the detection requirement range. At the same time, the detection tool 5 ensures the stability and accuracy of the brake caliper 7 during the installation process. When the present invention is used, the air pressure source control valve 102 is opened so that the gas in the air pressure source 101 is transmitted to the air pressure sensor 103. The data acquisition and analysis module collects the air pressure value on the air pressure sensor 103 and transmits it to the automation control module. The automation control module automatically adjusts the air pressure source control valve 102 by judging whether the air pressure is within the set range. When the air pressure is within the set range, the drag detection module 2 is started. The torque data detected by the torque sensor 202 on the drag detection module 2 is collected by the data acquisition and analysis module and transmitted to the automation control module. The automation control module determines whether to start the alarm module of the feedback and alarm module 4 by judging whether the torque is within the preset range. If it is within the range, the detection is terminated. If it is not within the range, the detection result feedback module is started and the alarm module is also started, so that the operator knows the drag at the first time, and feedback is given through numbers or graphics on the operation interface and corresponding measures are taken.

[0036] The above are all preferred embodiments of the present invention, and are not intended to limit the protection scope of the present invention. Therefore, any equivalent changes made according to the structure, shape, principle, and method of the present invention should be included in the protection scope of the present invention.

Claims

1. A brake caliper online drag detection mechanism, characterized in that: The invention comprises an air pressure pressurizing module (1), a drag detection module (2), an online control module (3) and a feedback and alarm module (4); the air pressure pressurizing module (1) is used to apply air pressure to the brake caliper (7) to simulate the pressure change during the braking process; the drag detection module (2) is connected to the air pressure pressurizing module (1) to evaluate the drag situation; the online control module (3) receives the air pressure value of the air pressure pressurizing module (1) and the drag torque analysis result of the drag detection module (2) to automatically determine the detection result, and outputs the determination result to the feedback and alarm module (4).

2. A brake caliper online drag detection mechanism according to claim 1, characterized in that: The air pressure pressurizing module (1) comprises an air pressure source (101), the air pressure source (101) is connected to an air pressure control valve (102), the other side of the air pressure control valve (102) is connected to an air pressure sensor (103), and the drag detection module (2) is connected to the other side of the air pressure sensor (103).

3. The brake caliper online drag detection mechanism according to claim 2, characterized in that: The air pressure source (101) is an air compressor or a nitrogen cylinder.

4. The brake caliper online drag detection mechanism according to claim 1, characterized in that: The drag detection module (2) comprises a servo motor (201), the servo motor (201) and a torque sensor (202) are connected via a coupling (203), the other side of the torque sensor (202) is connected to a bearing (204) via the coupling (203), and the other side of the bearing (204) is connected to a simulated brake disc (6).

5. The brake caliper online drag detection mechanism according to claim 4, characterized in that: A detection fixture (5) is provided between the bearing (204) and the simulated brake disc (6); the top of the detection fixture (5) is connected to the brake caliper (7) via a caliper fastening bolt (8); and the brake caliper (7) and the simulated brake disc (6) are adapted to each other.

6. The brake caliper online drag detection mechanism according to claim 1, characterized in that: The online control module (3) comprises a data acquisition and analysis module, an automatic control module, and a result determination module; the data acquisition and analysis module is used to collect air pressure values ​​and torque data in real time; the automatic control module is used to receive data and perform automatic control according to preset detection processes and parameters; The result determination module is used to automatically determine the detection result according to the analysis result, and output the determination result to the feedback and alarm module (4).

7. The brake caliper online drag detection mechanism according to claim 1, characterized in that: The controller used by the automation control module of the online control module (3) is a programmable logic controller (PLC) or an industrial computer as a core controller.

8. The brake caliper online drag detection mechanism according to claim 2, characterized in that: The air pressure control valve (102) is a high-precision air pressure control valve.

9. The brake caliper online drag detection mechanism according to claim 4, characterized in that: The servo motor (201) is a high-performance servo motor.

10. The brake caliper online drag detection mechanism according to claim 1, characterized in that: The feedback and alarm module (4) comprises an alarm module and a detection result feedback module; the alarm module is used to start when detecting that the drag exceeds a set threshold value, and emit an audible and visual alarm signal; the detection result feedback module is used to display the detection result in digital or graphical form on the operation interface, and at the same time feed back the detection result to the production management personnel through the production line integration system.

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