Electromagnetic and friction integrated disc brake device and method

Abstract

The invention discloses an electromagnetism and friction integrated disc brake device and method. A rotor winding and a brake disc are coaxially fixed, a plurality of N and S poles which are arranged in a staggered mode are arranged in the circumferential direction of the rotor winding, the rotor winding is powered on through an electric brush unit, a stator is fixed in a brake caliper body, and the rotating rotor winding is powered on and then acts with the stator to generate electromagnetic braking force. Electromagnetic braking and friction braking are integrated into the disc type braking device, and the disc type braking device has the advantages of high control precision, high response speed, good braking efficiency and high heat dissipation capacity of a disc type brake and non-contact braking of an electromagnetic brake. When the brake load is large, the electromagnetic brake participates in work, the friction brake load is shared, and the dangerous heat fading phenomenon caused by the fact that the temperature of a friction brake component is too high can be effectively prevented.

Description

Technical Field

[0001] The invention relates to an electromagnetic and friction integrated disc brake device and method. Background Art

[0002] The brake device is a component on a car that generates a force to stop the movement or movement trend of the car. Its working performance has an important impact on the driving safety of the car. At present, the automobile brake device mainly includes two types: disc brake and drum brake. Compared with drum brakes, disc brakes have the advantages of high control accuracy, fast response speed, good braking performance, strong heat dissipation capacity, light weight and small size. Therefore, disc brakes are more and more widely used in automobiles, and many trucks, (semi) trailers and other models have also begun to use disc brakes. However, due to the large vehicle mass of trucks, (semi) trailers and other models, the burden of disc brakes is heavy under continuous braking, frequent braking and other working conditions, which will cause the temperature of the brake friction parts to be too high, and dangerous brake thermal decay will occur. Electromagnetic brakes are one of the auxiliary brake devices of automobiles, which can generate electromagnetic braking torque through contactless eddy current effect. Therefore, a disc brake device integrating electromagnetic braking, friction braking and cooling functions will be one of the preferred ways to solve the above problems. Until now, electromagnetic and friction integrated disc brake devices with cooling and temperature control functions have rarely been mentioned. Summary of the invention

[0003] The present invention provides an electromagnetic and friction integrated disc brake device and method in order to solve the above problems in the prior art.

[0004] The technical solutions adopted in the present invention are: An electromagnetic and friction integrated disc brake device comprises a brake disc, a brake caliper body, a friction plate and a brake piston, wherein one end of the brake disc is placed in the brake caliper body, two friction plates are respectively arranged on both sides of the brake disc, and one friction plate is fixed to the brake caliper body, and the other friction plate is fixed to the brake piston. The device also comprises a stator, a rotor winding and a brush unit. The rotor winding is coaxially fixed to the brake disc, and a plurality of staggered N and S poles are arranged in the circumferential direction of the rotor winding. The rotor winding is powered through the brush unit, and the stator is fixed in the brake caliper body. After the rotating rotor winding is powered, it acts on the stator and generates electromagnetic braking force.

[0005] Furthermore, the brake disc is provided with two pieces, which are respectively fixed on the two end surfaces of the rotor winding center frame.

[0006] Furthermore, the center portion of the brake disc is a through hole. After the brake disc and the rotor winding frame are fixed by bolts, the through hole at the center portion of the brake disc forms a heat dissipation hole.

[0007] Furthermore, a plurality of limiting bosses are evenly distributed on the side surface of the rotor winding skeleton, and a limiting groove matched with the limiting bosses is provided on the inner end surface of the brake disc.

[0008] Furthermore, the stator is made of electrical pure iron or low carbon steel, and a copper coating is provided on the outer wall surface of the stator.

[0009] Furthermore, the brush unit comprises a conductive shaft, a brush holder and a brush, wherein the conductive shaft is coaxially fixed with the rotor winding, the brush holder is arranged on one side of the conductive shaft, and the brush is arranged on the brush holder and elastically abuts against the conductive shaft.

[0010] Furthermore, the brush holder is provided with a slide groove, the brush is inserted in the slide groove, a spring is provided in the slide groove, the spring abuts against the brush and enables the brush to elastically abut against the conductive shaft.

[0011] Furthermore, the brake caliper body is provided with a piston cavity and a cooling channel, the brake piston is placed in the piston cavity, and flowing coolant is injected into the cooling channel to cool the stator and the friction plate.

[0012] Furthermore, a condenser and an electric circulating pump are provided on the outer wall of the brake caliper body, and the cooling channel, the condenser and the electric circulating pump are used for the circulation and cooling of the coolant.

[0013] Furthermore, temperature sensors are provided on the friction plate, and on the liquid inlet and liquid outlet of the cooling channel.

[0014] The present invention also discloses a braking method, when the braking intensity of the automobile is less than 0.2, the duration is less than 30 seconds, and the temperature of the friction plate does not reach the first threshold value, only the friction brake is used to provide braking torque, the electromagnetic brake does not work, and the vehicle is in a traditional disc friction braking state; When the vehicle braking intensity is greater than or equal to 0.2 or the continuous braking time is greater than or equal to 30 seconds, the friction brake works first. When the friction plate temperature reaches the first threshold value, the electromagnetic brake participates in the work. At this time, the friction brake and the electromagnetic brake work at the same time; if the friction plate temperature rises further and reaches the second threshold value, the friction brake stops working and the electromagnetic brake provides the braking torque independently. At the same time, the cooling system is controlled by temperature sensors at the inlet and outlet of the cooling channel. The higher the inlet temperature, the greater the driving current of the electric circulation pump, the faster the coolant flows, and the stronger the cooling effect.

[0015] Furthermore, the cooling system works as follows: The control unit obtains the liquid inlet temperature according to the temperature sensor of the liquid inlet of the cooling channel, and compares it with the cooling system startup threshold. If it is lower than the startup threshold, the electric circulation pump does not work; otherwise, the electric circulation pump and the entire cooling system start to work, and the higher the liquid inlet temperature, the greater the driving current of the electric circulation pump, the faster the electric circulation pump rotates, and the stronger the system cooling effect; If the electric circulation pump is already at maximum power and the outlet temperature of the cooling channel is higher than the stop threshold, the control unit sends an alarm signal to the driver, reminding the driver to stop the vehicle in time to cool down or repair the system.

[0016] The present invention has the following beneficial effects: (1) Electromagnetic brake and friction brake are integrated into a disc brake device, which has the advantages of high control accuracy, fast response speed, good braking efficiency, strong heat dissipation capacity of disc brake and non-contact braking of electromagnetic brake.

[0017] (2) When the braking load is large, the electromagnetic brake takes part in the work and shares the friction braking load, which can effectively prevent the friction brake components from overheating and causing dangerous thermal decay.

[0018] (3) The integrated disc brake device is equipped with cooling channels, condensers, and electric circulation pumps, which can force cooling of the electromagnetic brake stator, brake caliper body, and the entire brake device, further improving the brake device's resistance to thermal degradation.

[0019] (4) A liquid inlet temperature sensor, a liquid outlet temperature sensor and a friction plate temperature sensor are respectively provided on the liquid inlet, the liquid outlet and the brake disc. The driving current of the electric circulation pump is adjusted according to actual working needs to save the power consumption of the cooling system. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 This is a structural diagram of the present invention.

[0021] Figure 2 This is the assembly drawing of the rotor winding and brake disc.

[0022] Figure 3 This is the assembly drawing of the brake disc and rotor winding disc.

[0023] Figure 4 This is the structural diagram of the brush unit.

[0024] Figure 5 This is the structural diagram of the brush. DETAILED DESCRIPTION

[0025] The present invention will be further described below in conjunction with the accompanying drawings.

[0026] like Figure 1The present invention discloses an electromagnetic and friction integrated disc brake device, comprising a brake disc 1, a brake caliper body 2, a friction plate 3, a brake piston 4, a stator 5, a rotor winding 6 and a brush unit 7.

[0027] One end of the brake disc 1 is placed in the brake caliper body 2, and two friction plates 3 are respectively arranged on both sides of the brake disc 1, and one friction plate 3 is fixed to the brake caliper body 2, and the other friction plate 3 is fixed to the brake piston 4. The brake piston 4 is placed in the piston cavity 21. When the vehicle brakes (i.e., the brake pedal is stepped on), the pressure in the piston cavity 21 increases, pushing the brake piston 4 and the friction plate 3 on one side to press against the brake disc 1. At the same time, the brake caliper body 2 drives the friction plate 3 on it to press against the brake disc 1, and the friction plates 3 on both sides and the brake disc 1 generate friction force to implement vehicle braking.

[0028] The rotor winding 6 is coaxially fixed to the brake disc 1, and a plurality of staggered N poles and S poles are arranged circumferentially of the rotor winding 6. The rotor winding 6 is powered through the brush unit 7, and the stator 5 is fixed in the brake caliper body 2. After being powered, the rotating rotor winding 6 acts with the stator 5 and generates electromagnetic braking force.

[0029] like Figure 2 The rotor winding 6 in the present invention is a spoke-type structure, and the brake disc 1 is provided with two pieces, which are respectively fixed on the two end surfaces of the skeleton in the rotor winding 6.

[0030] like Figure 3 In order to ensure the heat dissipation effect of the rotor winding 6 and the brake disc 1, a through hole is provided at the center of the brake disc 1. After the brake disc 1 and the skeleton of the rotor winding 6 are fixed by bolts, the through hole at the center of the brake disc 1 forms a heat dissipation hole, and the spokes of the rotor winding 6 are leaked out of the heat dissipation hole to achieve a good heat dissipation effect.

[0031] In order to ensure the assembly reliability of the brake disc 1 and the rotor winding 6, a plurality of limiting bosses 61 are evenly distributed on the side of the frame of the rotor winding 6, and a limiting groove matching the limiting boss 61 is provided on the inner end surface of the brake disc 1. After the brake disc 1 and the frame of the rotor winding 6 are fixed by bolts, reliable assembly is achieved through the cooperation between the limiting boss 61 and the limiting groove.

[0032] The stator 5 is made of electrical pure iron or low carbon steel, and a copper coating 51 is provided on the outer wall surface of the stator 5. The copper coating 51 can improve the eddy current effect of electromagnetic braking and increase the electromagnetic braking torque.

[0033] The brush unit 7 in the present invention comprises a conductive shaft 71, a brush holder 72 and a brush 73. The conductive shaft 71 is coaxially fixed with the rotor winding 6. The coil on the rotor winding 6 is connected to the conductive shaft 71. The conductive shaft 71 is made of a conductive material. The brush holder 72 is arranged on one side of the conductive shaft 71. The brush 73 is arranged on the brush holder 72 and elastically abuts against the conductive shaft 71.

[0034] Two mutually insulated collector rings are provided on the conductive shaft 71 . The two collector rings are respectively connected to the two ends of the rotor winding 6 . Two brushes are respectively in contact with the two collector rings and are externally connected to a power supply, thereby supplying power to the rotor winding 6 .

[0035] A slide groove is provided on the brush holder 72, and the brush 73 is inserted in the slide groove. A spring 74 is provided in the slide groove. A cover plate is fixed at the top of the slide groove. The top end of the spring 74 abuts against the cover plate, and the bottom end abuts against the brush 73 so that the brush 73 elastically abuts against the conductive shaft 71.

[0036] Since heat energy is generated during electromagnetic braking, a cooling channel 22 is provided on the brake caliper body 2 to cool the entire device. A flowing coolant is injected into the cooling channel 22 to cool the stator 5 and the friction plate 3 .

[0037] A condenser 23 and an electric circulating pump 24 are provided on the outer wall of the brake caliper body 2. The cooling channel 22, the condenser 23 and the electric circulating pump 24 are used for the circulation and cooling of the coolant.

[0038] In order to better monitor the temperature, temperature sensors are provided on the friction plate 3 and the liquid inlet and outlet of the cooling channel 22 .

[0039] When the braking load of the car is small, that is, the braking intensity is small and the duration is short (the braking intensity is less than 0.2 and the duration is less than 30 seconds), and the friction plate temperature has not reached the first threshold value (for example: 120°C), only the friction brake is involved in the work to provide braking torque, the electromagnetic brake does not work, and it is in the traditional disc friction braking state.

[0040] When the vehicle braking load is large (braking intensity is greater than or equal to 0.2) or the duration is too long (greater than or equal to 30 seconds), the friction brake works first. When the friction plate temperature reaches the first threshold value (for example: 120°C), the electromagnetic brake participates in the work. At this time, the friction brake and the electromagnetic brake work at the same time; if the friction plate temperature rises further and reaches the second threshold value (for example: 200°C), the friction brake quits working, and the electromagnetic brake provides the braking torque independently. At the same time, the control unit controls the cooling system according to the inlet sensor and the outlet sensor. The higher the inlet temperature, the greater the driving current of the electric circulation pump, the faster the coolant flows, and the stronger the cooling effect of the cooling system.

[0041] The working process of the cooling system is as follows: the control unit obtains the liquid inlet temperature according to the liquid inlet sensor and compares it with the cooling system start threshold (for example: 40°C). If it is lower than the start threshold, the electric circulation pump will not work; otherwise, the electric circulation pump and the entire cooling system will start to work, and the higher the liquid inlet temperature, the greater the electric circulation pump drive current, the faster the electric circulation pump rotates, and the stronger the system cooling effect. If the electric circulation pump is at maximum power and the liquid outlet temperature is higher than the stop threshold (for example: 60°C), the control unit will send an alarm signal to the driver to remind the driver to stop the car in time to cool down the system or repair it.

[0042] The first threshold value, the second threshold value, the start threshold value and the stop threshold value are set according to specific use requirements. The braking intensity can also be set according to specific use requirements.

[0043] The above description is only a preferred embodiment of the present invention. It should be pointed out that a person skilled in the art can make several improvements without departing from the principle of the present invention, and these improvements should also be regarded as within the protection scope of the present invention.

Claims

1. An electromagnetic and friction integrated disc brake device, comprising a brake disc (1), a brake caliper body (2), a friction plate (3) and a brake piston (4), wherein one end of the brake disc (1) is placed in the brake caliper body (2), two friction plates (3) are respectively arranged on both sides of the brake disc (1), and one friction plate (3) is fixed to the brake caliper body (2), and the other friction plate (3) is fixed to the brake piston (4), characterized in that: The invention also comprises a stator (5), a rotor winding (6) and a brush unit (7); the rotor winding (6) is coaxially fixed to the brake disc (1); a plurality of staggered N and S poles are arranged in the circumferential direction of the rotor winding (6); the rotor winding (6) is powered via the brush unit (7); the stator (5) is fixed in the brake caliper body (2); and the rotating rotor winding (6) acts on the stator (5) after being powered to generate electromagnetic braking force.

2. The electromagnetic and friction integrated disc brake device according to claim 1, characterized in that: The brake disc (1) is provided with two pieces, which are respectively fixed on the two end surfaces of the central frame of the rotor winding (6); the stator (5) is made of electrical pure iron or low-carbon steel, and a copper coating (51) is provided on the outer wall surface of the stator (5).

3. The electromagnetic and friction integrated disc brake device according to claim 1, characterized in that: The center portion of the brake disc (1) is a through hole. After the brake disc (1) and the frame of the rotor winding (6) are fixed by bolts, the through hole at the center portion of the brake disc (1) forms a heat dissipation hole.

4. The electromagnetic and friction integrated disc brake device according to claim 1, characterized in that: A plurality of limiting bosses (61) are evenly distributed on the side surface of the skeleton of the rotor winding (6), and a limiting groove matched with the limiting bosses (61) is provided on the inner end surface of the brake disc (1).

5. The electromagnetic and friction integrated disc brake device according to claim 1, characterized in that: The brush unit (7) comprises a conductive shaft (71), a brush holder (72) and a brush (73); the conductive shaft (71) is coaxially fixed with the rotor winding (6); the brush holder (72) is arranged on one side of the conductive shaft (71); and the brush (73) is arranged on the brush holder (72) and elastically contacts the conductive shaft (71).

6. The electromagnetic and friction integrated disc brake device according to claim 5, characterized in that: The brush holder (72) is provided with a slide groove, the brush (73) is inserted into the slide groove, a spring is provided in the slide groove, the spring abuts against the brush (73) and enables the brush (73) to elastically abut against the conductive shaft (71).

7. The electromagnetic and friction integrated disc brake device according to claim 1, characterized in that: The brake caliper body (2) is provided with a piston cavity (21) and a cooling channel (22); the brake piston (4) is disposed in the piston cavity (21); flowing coolant is injected into the cooling channel (22) to cool the stator (5) and the friction plate (3).

8. The electromagnetic and friction integrated disc brake device according to claim 1, characterized in that: The outer wall of the brake caliper body (2) is provided with a cooling system having a condenser (23) and an electric circulation pump (24), and the cooling flow channel (22), the condenser (23) and the electric circulation pump (24) are used for circulation and cooling of the coolant; Temperature sensors are provided on the friction plate (3) and on the liquid inlet and liquid outlet of the cooling channel (22).

9. A braking method according to any one of claims 1 to 8, characterized in that: When the vehicle braking intensity is less than 0.2, the duration is less than 30 seconds, and the friction plate temperature does not reach the first threshold value, only the friction brake is used to provide braking torque, the electromagnetic brake does not work, and the vehicle is in the traditional disc friction brake state; When the vehicle braking intensity is greater than or equal to 0.2 or the duration is greater than or equal to 30 seconds, the friction brake works first. When the friction plate temperature reaches the first threshold value, the electromagnetic brake participates in the work. At this time, the friction brake and the electromagnetic brake work at the same time; if the friction plate temperature rises further and reaches the second threshold value, the friction brake stops working and the electromagnetic brake provides the braking torque independently. At the same time, the cooling system is controlled by temperature sensors at the inlet and outlet of the cooling channel. The higher the inlet temperature, the greater the driving current of the electric circulation pump, the faster the coolant flows, and the stronger the cooling effect.

10. The electromagnetic and friction integrated disc brake method according to claim 9, characterized in that: The working process of the cooling system is: The control unit obtains the temperature of the liquid inlet through the temperature sensor of the liquid inlet of the cooling channel (22), and compares it with the cooling system start threshold. If the temperature is lower than the start threshold, the electric circulation pump does not work; otherwise, the electric circulation pump and the entire cooling system start working, and the higher the temperature of the liquid inlet, the greater the driving current of the electric circulation pump, the faster the electric circulation pump rotates, and the stronger the cooling effect of the system. If the electric circulation pump is already at maximum power and the outlet temperature of the cooling channel is higher than the stop threshold, the control unit sends an alarm signal to the driver, reminding the driver to stop the vehicle in time to cool down or repair the system.

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