A low-drag brake caliper assembly based on grating displacement sensor measurement

Abstract

This invention discloses a low-drag brake caliper assembly based on a grating displacement sensor, relating to the field of vehicle braking systems. It includes a motor assembly, a caliper body, and a caliper body bracket. The caliper body contains a piston cylinder with a self-adjusting nut inside. A drive shaft is sleeved within the self-adjusting nut. A guide platform is located on the lower outer periphery of the self-adjusting nut, and a first grating displacement sensor is mounted on the guide platform. This sensor monitors the displacement distance of the self-adjusting nut and transmits this distance to the vehicle control system. The vehicle control system generates a control signal based on the displacement distance of the self-adjusting nut, which controls the rotational speed of the motor assembly. By using the first grating displacement sensor to monitor the displacement distance of the self-adjusting nut and uploading this information to the vehicle control system to calculate the required brake fluid volume, precise control of the brake fluid volume is achieved, reducing brake caliper drag torque and increasing the range of the electric vehicle.

Description

Technical Field

[0001] This invention relates to the field of vehicle braking systems, and in particular to a low-drag brake caliper assembly based on grating displacement sensor measurement. Background Technology

[0002] With the rapid development of new energy vehicles, the energy efficiency and precise control of braking systems have become core challenges. Traditional hydraulic brake calipers rely on a fixed hydraulic transmission ratio, requiring excessive brake fluid filling to compensate for line expansion, which increases drag torque and reduces the range of electric vehicles. Friction pad reset relies on the rebound of rubber seals, which are prone to residual drag due to thermal deformation or contamination. Although existing electronic control systems reduce the amount of brake fluid required through electronic control, drag optimization relies on passive mechanical design and cannot adapt to low / high temperature operating conditions. Summary of the Invention

[0003] To address the above-mentioned deficiencies or improvement needs of existing technologies, this invention provides a low-drag brake caliper assembly based on grating displacement sensor measurement, which solves the problems of traditional hydraulic brake calipers where excessive brake fluid filling leads to increased drag torque, and friction pad reset relies on rubber seals for rebound, which is prone to residual drag due to thermal deformation or contamination.

[0004] To achieve the above objectives, the present invention provides the following technical solution:

[0005] A low-drag brake caliper assembly based on grating displacement sensor measurement includes a motor assembly, a caliper body and a caliper body bracket. The caliper body is located below the motor assembly. The caliper body and the caliper body bracket are connected by a first flange bolt and a second flange bolt.

[0006] The caliper body is equipped with a piston cylinder, and the piston cylinder is equipped with a self-adjusting nut. A drive shaft is sleeved inside the self-adjusting nut. A guide platform is set on the outer periphery of the lower end of the self-adjusting nut. A first grating displacement sensor is set on the guide platform. The first grating displacement sensor is used to monitor the displacement distance of the self-adjusting nut and send the displacement distance of the self-adjusting nut to the vehicle control system.

[0007] The vehicle control system generates a control signal based on the displacement distance of the self-adjusting nut. The control signal is used to control the speed of the motor assembly, which in turn controls the rotation of the drive shaft. The rotation of the drive shaft drives the self-adjusting nut to move, which in turn drives the piston cylinder to move, thus enabling the friction pads to engage with the brake disc and complete braking.

[0008] Preferably, the vehicle control system generates a control signal based on the displacement distance of the self-adjusting nut, including:

[0009] The required brake fluid volume V is calculated using equation (1): (1)

[0010] Where V represents volume, S represents the cross-sectional area of ​​the piston cylinder, and H represents the displacement distance of the self-adjusting nut;

[0011] A control signal is generated based on the liquid volume V.

[0012] Preferably, the inner friction pad assembly is provided with a first reset spring on both sides. One end of the first reset spring is connected to both sides of the inner friction pad assembly, and the other end is engaged with the upper end of the caliper body bracket. The first reset spring is used to automatically return the inner friction pad assembly away from the brake disc by its own elasticity after the vehicle braking ends.

[0013] Preferably, a second reset spring is provided on both sides of the outer friction pad assembly. One end of the second reset spring is connected to both sides of the outer friction pad assembly, and the other end is engaged with the lower end of the caliper body bracket. The second reset spring is used to automatically return the outer friction pad assembly away from the brake disc by its own elasticity after the vehicle braking ends.

[0014] The bottom of the outer friction pad assembly is provided with a third reset spring. The third reset spring consists of three reset springs. One end of the third reset spring is connected to the bottom of the outer friction pad assembly, and the other end is snapped into the bottom of the caliper body. The third reset spring is used to automatically return the outer friction pad assembly away from the brake disc by its own elasticity after the vehicle braking ends.

[0015] Preferably, a return spring is installed on both sides of the inner friction plate assembly and the outer friction plate assembly between them and the caliper body bracket. A retaining ring is provided at the upper and lower ends of the return spring. The return spring is used to apply an outward force through the retaining ring to move the inner friction plate assembly and the outer friction plate assembly away from the brake disc.

[0016] Preferably, an inner friction pad assembly is embedded in the upper end of the caliper body bracket, and an outer friction pad assembly is embedded in the lower end of the caliper body bracket. A second grating displacement sensor is provided on the side of the caliper body bracket near the outer friction pad assembly. The second grating displacement sensor is used to monitor the distance between the outer friction pad assembly and the brake disc after braking and send the distance between the outer friction pad assembly and the brake disc to the vehicle control system.

[0017] The vehicle control system calculates the speed at which the outer friction pad assembly separates from the brake disc based on the distance between the outer friction pad assembly and the brake disc received at different times.

[0018] The reset performance of the second reset spring, the third reset spring, and the reset spring is determined based on the separation speed.

[0019] Preferably, the caliper body has a first circular through hole and a second circular through hole on its left and right sides, respectively, and the caliper body bracket has a third circular through hole and a fourth circular through hole on its left and right sides, respectively. A first flange bolt passes through and connects the first circular through hole and the third circular through hole, and a second flange bolt passes through and connects the second circular through hole and the fourth circular through hole. The caliper body and the caliper body bracket are connected by the first flange bolt and the second flange bolt.

[0020] Preferably, the first reset spring, the second reset spring, the third reset spring, and the reset spring are made of ceramic-aluminum shape memory alloy.

[0021] Compared with the prior art, the beneficial effects of the present invention are:

[0022] By setting a first grating displacement sensor to monitor the displacement distance of the self-adjusting nut, the required amount of brake fluid is calculated, eliminating redundant fluid filling, reducing brake caliper drag torque, and increasing the electric vehicle's range. By setting a first, second, and third reset spring and a reset leaf spring, the gap between the friction pads and the brake disc is better controlled, further reducing brake caliper drag. By setting a second grating displacement sensor to monitor the distance between the outer friction pad assembly and the brake disc after braking, the reset performance of the second, third, and reset spring springs can be judged. A threshold can be set based on the reset performance, and the reset components can be replaced promptly when the separation speed of the outer friction pad assembly from the brake disc falls below the set threshold. Attached Figure Description

[0023] Figure 1 This is a three-dimensional structural diagram of the present invention;

[0024] Figure 2 This is an exploded view of the three-dimensional structure of the present invention;

[0025] Figure 3 This is a schematic diagram of the planing of piston cylinder 6 of the present invention;

[0026] Figure 4 This is a schematic diagram showing the position of the second grating displacement sensor 12 of the present invention;

[0027] Figure 5 This is a schematic diagram of the installation of the first reset spring 701, the second reset spring 801, and the third reset spring 802 of the present invention;

[0028] Figure 6 This is a schematic diagram of the installation of the reset spring 14 of the present invention;

[0029] In the diagram: 1. Motor assembly; 2. Caliper body; 201. First circular through hole; 202. Second circular through hole; 3. Caliper body bracket; 301. Third circular through hole; 302. Fourth circular through hole; 4. First flange bolt; 5. Second flange bolt; 6. Piston cylinder; 7. Inner friction plate assembly; 701. First reset spring; 8. Outer friction plate assembly; 801. Second reset spring; 802. Third reset spring; 9. Drive shaft; 10. Self-adjusting nut; 11. First grating displacement sensor; 12. Second grating displacement sensor; 13. Guide platform; 14. Reset spring; 1401. Snap ring. Detailed Implementation

[0030] The term “exemplary” as used herein means “serving as an example, embodiment, or illustration.” Any embodiment illustrated herein as “exemplary” is not necessarily to be construed as superior to or better than other embodiments.

[0031] Furthermore, to better illustrate this disclosure, numerous specific details are set forth in the following detailed description. Those skilled in the art will understand that this disclosure can be practiced without certain specific details. In some instances, methods, means, components, and circuits well known to those skilled in the art have not been described in detail in order to highlight the main points of this disclosure.

[0032] like Figures 1-6 As shown, the present invention provides a technical solution: including a motor assembly 1, a caliper body 2 and a caliper body bracket 3, the caliper body 2 is provided below the motor assembly 1, and the caliper body 2 and the caliper body bracket 3 are connected by a first flange bolt 4 and a second flange bolt 5;

[0033] The caliper body 2 is equipped with a piston cylinder 6, and a self-adjusting nut 10 is provided inside the piston cylinder 6. A drive shaft 9 is sleeved inside the self-adjusting nut 10. A guide platform 13 is provided on the lower outer periphery of the self-adjusting nut 10. A first grating displacement sensor 11 is provided on the guide platform 13. The first grating displacement sensor 11 is used to monitor the displacement distance of the self-adjusting nut 10 and send the displacement distance of the self-adjusting nut 10 to the vehicle control system.

[0034] The vehicle control system generates a control signal based on the displacement distance of the self-adjusting nut 10. The control signal is used to control the speed of the motor assembly 1. The motor assembly 1 is used to control the rotation of the drive shaft 9. The rotation of the drive shaft 9 drives the self-adjusting nut 10 to move. The movement of the self-adjusting nut 10 drives the piston cylinder 6 to move, so as to realize the friction pad and the brake disc to make braking.

[0035] The vehicle control system generates a control signal based on the displacement distance of the self-adjusting nut 10, including:

[0036] The required brake fluid volume V is calculated using equation (1): (1)

[0037] Where V represents volume, S represents cross-sectional area of ​​piston cylinder 6, and H represents displacement distance of self-adjusting nut 10;

[0038] Based on the fluid volume V, a control signal is generated. First, the required fluid volume of the pipeline and brake caliper during braking needs to be collected. Then, the displacement distance of the self-adjusting nut 10 is monitored by the first grating displacement sensor 11, and the displacement distance of the self-adjusting nut 10 is sent to the vehicle control system. The vehicle control system calculates the required braking fluid volume according to the formula V (volume) = S (cross-sectional area of ​​piston cylinder 6) · H (displacement), where the cross-sectional area S is set to a uniform specification, such as φ20mm. The required fluid volume of the pipeline and brake caliper during braking, plus the calculated required braking fluid volume, is sent to the motor assembly 1. The motor assembly 1 controls the drive shaft 9 to rotate. The drive shaft 9 and the self-adjusting nut 10 drive the self-adjusting nut 10 to move through the threaded transmission. The movement of the self-adjusting nut 10 drives the piston cylinder 6 to move, so that the friction pads and brake discs are in contact to complete the braking.

[0039] like Figure 5 As shown, the present invention provides a technical solution: a first reset spring 701 is provided on both sides of the inner friction pad assembly 7. One end of the first reset spring 701 is connected to both sides of the inner friction pad assembly 7, and the other end is engaged with the upper end of the caliper body bracket 3. The first reset spring 701 is used to make the inner friction pad assembly 7 automatically return to its original position away from the brake disc by its own elasticity after the vehicle braking ends.

[0040] The outer friction pad assembly 8 is provided with a second reset spring 801 on both sides. One end of the second reset spring 801 is connected to both sides of the outer friction pad assembly 8, and the other end is engaged with the lower end of the caliper body bracket 3. The second reset spring 801 is used to automatically return the outer friction pad assembly 8 away from the brake disc by its own elasticity after the vehicle braking ends.

[0041] The bottom of the outer friction pad assembly 8 is provided with a third reset spring 802. The third reset spring 802 is composed of three reset springs. One end of the third reset spring 802 is connected to the bottom of the outer friction pad assembly 8, and the other end is snapped into the bottom of the caliper body 2. The third reset spring 802 is used to automatically return the outer friction pad assembly 8 away from the brake disc by its own elasticity after the vehicle braking ends.

[0042] Through the above technical solution, after braking, the first reset spring 701 uses its own elasticity to lift the inner friction pad assembly 7 upward away from the brake disc, and the second reset spring 801 and the third reset spring 802 use their own elasticity to lower the outer friction pad assembly 8 downward away from the brake disc, further reducing brake caliper drag.

[0043] like Figure 6As shown, the present invention provides a technical solution: a reset spring 14 is installed between the inner friction plate assembly 7 and the outer friction plate assembly 8 on both sides and the caliper body bracket 3. A retaining ring 1401 is provided opposite to the upper and lower ends of the reset spring 14. The reset spring 14 is used to apply an outward force through the retaining ring 1401 to move the inner friction plate assembly 7 and the outer friction plate assembly 8 away from the brake disc.

[0044] Through the above technical solution, the setting of the reset spring 14 makes the outward force of the inner friction plate assembly 7 and the outer friction plate assembly 8 stronger, and the response speed of the inner friction plate assembly 7 and the outer friction plate assembly 8 separating from the brake disc after braking is faster.

[0045] The present invention provides a technical solution: an inner friction plate assembly 7 is embedded in the upper end of the caliper body bracket 3, an outer friction plate assembly 8 is embedded in the lower end of the caliper body bracket 3, and a second grating displacement sensor 12 is provided on the side of the caliper body bracket 3 near the outer friction plate assembly 8. The second grating displacement sensor 12 is used to monitor the distance between the outer friction plate assembly 8 and the brake disc after braking and send the distance between the outer friction plate assembly 8 and the brake disc to the vehicle control system.

[0046] The vehicle control system calculates the speed at which the external friction pad assembly 8 separates from the brake disc based on the distance between the external friction pad assembly 8 and the brake disc received at different times.

[0047] The reset performance of the second reset spring 801, the third reset spring 802, and the reset spring 14 is determined based on the separation speed.

[0048] Through the above technical solution, a threshold is set according to the reset performance of the second reset spring 801, the third reset spring 802 and the reset spring 14. When the speed at which the outer friction pad assembly 8 separates from the brake disc is lower than the threshold, the vehicle control system issues a prompt and suggests replacing the reset components.

[0049] The present invention provides a technical solution: the first reset spring 701, the second reset spring 801, the third reset spring 802 and the reset spring 14 are made of ceramic-aluminum shape memory alloy;

[0050] Ceramic-aluminum shape memory alloy does not soften at high temperatures and does not become brittle at low temperatures, making it suitable for high / low temperature working conditions in different regions of the north and south.

[0051] Working principle of the invention:

[0052] First, the required amount of fluid in the braking system and brake caliper needs to be collected. Then, the displacement distance of the self-adjusting nut 10 is monitored by the first grating displacement sensor 11 and sent to the vehicle control system. The vehicle control system calculates the required amount of fluid for braking according to the formula V (volume) = S (cross-sectional area of ​​piston cylinder 6) · H (displacement). The cross-sectional area S is set to a uniform specification, such as φ20mm. The required amount of fluid in the braking system and brake caliper is added to the calculated required amount of fluid to generate a control signal. The control signal is used to control the speed of the motor assembly 1. The motor assembly 1 is used to rotate the drive shaft 9. The drive shaft 9 and the self-adjusting nut 10 drive the self-adjusting nut 10 to move through the threaded transmission. The movement of the self-adjusting nut 10 drives the piston cylinder 6 to move, so that the friction pads and brake discs can be put into contact to complete the braking.

[0053] After braking, the inner friction pad assembly 7 pulls the friction pads away from the brake disc through the upward elastic force of the first reset springs 701 on both sides. The outer friction pad assembly 8 provides a downward return force through the second reset springs 801 on both sides. The bottom third reset spring 802 (three pieces combined) enhances the downward pressure. At the same time, the reset springs 14 installed between the inner and outer friction pad assemblies 7 and the caliper body bracket 3 on both sides work together, and the retaining springs 1401 apply a thrust to both sides, accelerating the separation of the inner and outer friction pads from the brake disc. The triple reset mechanism, combined with the synergistic thrust of the reset springs 14, eliminates residual braking force, reducing energy consumption and wear.

[0054] After braking, the second grating displacement sensor 12 monitors the distance between the outer friction pad assembly 8 and the brake disc, and sends the distance to the vehicle control system. The vehicle control system calculates the speed at which the outer friction pad assembly 8 separates from the brake disc based on the distance received at different times. Based on the speed at which the outer friction pad assembly 8 separates from the brake disc, the system judges the reset performance of the second reset spring 801, the third reset spring 802, and the reset spring 14, and sets a threshold based on the reset performance. When the speed at which the outer friction pad assembly 8 separates from the brake disc is lower than the threshold, the vehicle control system issues a warning and suggests replacing the reset components.

[0055] The various embodiments of this disclosure have been described above. These descriptions are exemplary and not exhaustive, nor are they limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is chosen to best explain the principles, practical application, or technical improvements to the embodiments in the market, or to enable others skilled in the art to understand the embodiments disclosed herein.

Claims

1. A low-drag brake caliper assembly based on grating displacement sensor measurement, characterized in that: It includes a motor assembly (1), a caliper body (2) and a caliper body bracket (3). The caliper body (2) is located below the motor assembly (1). The caliper body (2) and the caliper body bracket (3) are connected by a first flange bolt (4) and a second flange bolt (5). An inner friction plate assembly (7) is embedded in the upper end of the caliper body bracket (3), and an outer friction plate assembly (8) is embedded in the lower end of the caliper body bracket (3). The caliper body (2) is equipped with a piston cylinder (6), and the piston cylinder (6) is equipped with a self-adjusting nut (10). The self-adjusting nut (10) is fitted with a drive shaft (9). The lower outer periphery of the self-adjusting nut (10) is equipped with a guide platform (13). The guide platform (13) is equipped with a first grating displacement sensor (11). The first grating displacement sensor (11) is used to monitor the displacement distance of the self-adjusting nut (10) and send the displacement distance of the self-adjusting nut (10) to the vehicle control system. The vehicle control system generates a control signal based on the displacement distance of the self-adjusting nut (10). The control signal is used to control the speed of the motor assembly (1). The motor assembly (1) is used to control the rotation of the drive shaft (9). The rotation of the drive shaft (9) drives the self-adjusting nut (10) to move. The movement of the self-adjusting nut (10) drives the piston cylinder (6) to move, so as to achieve the friction pad and the brake disc to fit together and complete the braking. The vehicle control system generates a control signal based on the displacement distance of the self-adjusting nut (10), including: The required brake fluid volume V is calculated using equation (1): (1) Where V represents volume, S represents the cross-sectional area of ​​piston cylinder (6), and H represents the displacement distance of self-adjusting nut (10); A control signal is generated based on the liquid volume V; The outer friction pad assembly (8) is provided with a second reset spring (801) on both sides. One end of the second reset spring (801) is connected to both sides of the outer friction pad assembly (8), and the other end is engaged with the lower end of the caliper body bracket (3). The second reset spring (801) is used to make the outer friction pad assembly (8) automatically return to its original position away from the brake disc by its own elastic force after the vehicle braking ends. The bottom of the outer friction pad assembly (8) is provided with a third reset spring (802). The third reset spring (802) is composed of three reset springs. One end of the third reset spring (802) is connected to the bottom of the outer friction pad assembly (8), and the other end is snapped into the bottom of the caliper body (2). The third reset spring (802) is used to make the outer friction pad assembly (8) automatically return to its original position away from the brake disc by its own elasticity after the vehicle braking ends.

2. The low-drag brake caliper assembly based on grating displacement sensor measurement according to claim 1, characterized in that: The inner friction pad assembly (7) is provided with a first reset spring (701) on both sides. One end of the first reset spring (701) is connected to both sides of the inner friction pad assembly (7), and the other end is engaged with the upper end of the caliper body bracket (3). The first reset spring (701) is used to automatically return the inner friction pad assembly (7) away from the brake disc by its own elastic force after the vehicle braking ends.

3. The low-drag brake caliper assembly based on grating displacement sensor measurement according to claim 2, characterized in that: Both sides of the inner friction plate assembly (7) and the outer friction plate assembly (8) are equipped with reset springs (14) between the caliper body bracket (3). The upper and lower ends of the reset springs (14) are provided with retaining rings (1401). The reset springs (14) are used to apply an outward force through the retaining rings (1401) to move the inner friction plate assembly (7) and the outer friction plate assembly (8) away from the brake disc.

4. The low-drag brake caliper assembly based on grating displacement sensor measurement according to claim 3, characterized in that: A second grating displacement sensor (12) is provided on the side of the caliper body bracket (3) near the outer friction pad assembly (8). The second grating displacement sensor (12) is used to monitor the distance between the outer friction pad assembly (8) and the brake disc after braking ends and send the distance between the outer friction pad assembly (8) and the brake disc to the vehicle control system. The vehicle control system calculates the speed at which the external friction pad assembly (8) separates from the brake disc based on the distance between the external friction pad assembly (8) and the brake disc received at different times; The reset performance of the second reset spring (801), the third reset spring (802), and the reset spring (14) is determined based on the separation speed.

5. A low-drag brake caliper assembly based on grating displacement sensor measurement according to claim 1, characterized in that: The caliper body (2) is provided with a first circular through hole (201) and a second circular through hole (202) on the left and right sides respectively. The caliper body bracket (3) is provided with a third circular through hole (301) and a fourth circular through hole (302) on the left and right sides respectively. The first flange bolt (4) passes through and connects the first circular through hole (201) and the third circular through hole (301), and the second flange bolt (5) passes through and connects the second circular through hole (202) and the fourth circular through hole (302). The caliper body (2) and the caliper body bracket (3) are connected by the first flange bolt (4) and the second flange bolt (5).

6. The low-drag brake caliper assembly based on grating displacement sensor measurement according to claim 3, characterized in that: The first reset spring (701), the second reset spring (801), the third reset spring (802) and the reset spring (14) are made of ceramic aluminum memory alloy.

Images