Maintenance method and equipment for brake calipers

Abstract

The invention discloses a brake caliper maintenance method which comprises the following steps: S1, placing a brake caliper to be maintained in an operation area, disassembling and decomposing the brake caliper by using a tool assembly, and shooting the disassembling and decomposing process of the brake caliper through an image acquisition module; s2, the decomposed brake caliper parts are put into an ultrasonic cleaning machine to be cleaned; s3, the cleaned brake caliper parts are transferred into a drying device to be dried; s4, the dried brake calipers are assembled in an operation area, the assembling process is shot through an image acquisition module, and the assembled brake calipers are installed on a hydraulic sealing detection tool; s5, a corresponding brake caliper type is selected through a software interface of the control system, and sealing performance test parameters are set; s6, starting the hydraulic sealing detection tool, carrying out a pressurization test on the brake caliper, and shooting the test process through an image acquisition module; s7, the control system collects and displays test data in real time, and automatically generates a test result report after the test is completed; and S8, judging whether the sealing performance of the brake calipers is qualified or not according to the test result report.

Description

Technical Field

[0001] This invention relates to the field of automotive repair and maintenance technology, specifically to methods and equipment for repairing and maintaining automotive brake calipers. Background Technology

[0002] As a crucial component of the disc brake system, the performance of the brake caliper directly affects the braking safety and reliability of a vehicle. During vehicle maintenance and repair, brake calipers require regular disassembly, cleaning, seal replacement, and sealing tests to eliminate potential problems such as jamming and oil leaks.

[0003] Currently, the maintenance and repair of brake calipers in the industry generally relies on traditional manual operations and a combination of scattered equipment. The typical process involves disassembly using general-purpose tools on a standard workbench, cleaning the parts in a separate ultrasonic cleaner, air-drying or drying them with other heat sources, reassembling them on the workbench, and finally connecting them to a separate hydraulic test bench for a rough pressure test. This model has significant drawbacks: First, the process is cumbersome, requiring repeated handling of parts between different workstations, resulting in low efficiency and a high risk of part loss or contamination. Second, critical testing (especially functional testing of integrated electronic parking brake (EPB) calipers) often relies on the experience and judgment of repair personnel, lacking accurate and objective data support, making it difficult to standardize testing and guarantee quality. Third, the entire repair process lacks systematic data recording and traceability methods, making it impossible to create electronic repair records, which is detrimental to quality management and accountability. Summary of the Invention

[0004] To address the above-mentioned shortcomings, this invention provides a method and equipment for the maintenance and repair of automotive brake calipers.

[0005] The technical solution of this invention is implemented as follows:

[0006] This invention discloses a method for repairing and maintaining brake calipers, comprising the following steps:

[0007] S1. Place the brake caliper to be repaired in the operating area, disassemble it using the tool assembly, and simultaneously capture the disassembly process using the image acquisition module.

[0008] S2. Place the disassembled brake caliper components into an ultrasonic cleaner for cleaning;

[0009] S3. Transfer the cleaned brake caliper components to a drying device for drying;

[0010] S4. Assemble the dried brake calipers in the operating area, and simultaneously capture the assembly process using an image acquisition module. Then, install the assembled brake calipers on the hydraulic seal testing fixture.

[0011] S5. Select the corresponding brake caliper type and set the sealing test parameters through the control system's software interface;

[0012] S6. Start the hydraulic seal testing fixture to perform a pressure test on the brake caliper, and at the same time, capture the test process through the image acquisition module;

[0013] S7. The control system collects and displays test data in real time, and automatically generates a test result report after the test is completed;

[0014] S8. Based on the test result report, determine whether the brake caliper sealing performance is qualified, and complete the subsequent maintenance or repair operations.

[0015] Preferably, after step S7 and before step S8, step S7a is further included:

[0016] The control system drives the printer to print the test result report, and uploads the test data and test result report to the cloud server when a network connection is available.

[0017] Preferably, in step S7, the test data includes at least:

[0018] a) Hydraulic sealing test data: collected during hydraulic sealing tests, specifically including real-time pressure values, leakage values, and pressure-time change curves during the test process;

[0019] b) Electronic Parking Brake (EPB) Function Test Data: When the brake caliper is a caliper with integrated EPB function, the data is collected during the functional test of the electronic parking brake, specifically including motor operating current, motor action time, clamping force, and current-time change curve.

[0020] Preferably, in step S6, when the leakage value in the test data exceeds a preset threshold, the control system automatically performs the following operations:

[0021] Generate and issue an alarm signal;

[0022] The image acquisition module is controlled to capture and store images of abnormal moments;

[0023] The test data corresponding to the abnormal moments are marked and stored in association.

[0024] This invention also discloses a brake caliper maintenance and repair device, comprising:

[0025] The integrated enclosure has an internal space comprising an upper operation and maintenance layer and a lower equipment storage layer.

[0026] A workbench is located on the left side of the operation and maintenance layer, and its surface forms a working plane for disassembling and assembling brake calipers; a vertical bracket is provided on one side of the workbench for suspending disassembly and assembly tools.

[0027] An ultrasonic cleaner is located on the right side of the equipment housing layer and is used to clean disassembled brake caliper components.

[0028] A drying device is located in the left side region of the equipment housing layer and is used to dry the cleaned brake caliper components;

[0029] A hydraulic seal testing fixture is set on a testing platform in the right-side area of ​​the operation and maintenance layer, and is used to perform a sealing pressure test on the assembled brake caliper.

[0030] The system includes a main control unit located within the equipment housing layer, and an interactive interface of the control system positioned above the work surface and facing the operator.

[0031] Preferably, it also includes an EPB hydraulic pressurization module, which is located above the testing platform in the right area of ​​the operation and maintenance layer, and is used to perform functional tests on brake calipers with electronic parking brake function.

[0032] Preferably, it also includes an image acquisition module, which includes at least two cameras;

[0033] The first camera is positioned above or to the side of the workbench to capture images of the disassembly and assembly process of the brake caliper on the working plane.

[0034] The second camera is positioned above or to the side of the testing platform to capture images of the brake caliper being tested on the hydraulic seal testing fixture.

[0035] Preferably, the control panel is located above the drying device and faces the operator.

[0036] Preferably, in the equipment housing layer, above the operation button panel, there are multiple drawer boxes for storing maintenance parts.

[0037] Preferably, the operation and maintenance layer is provided with opening and closing doors at opposite positions on both the front and back sides to facilitate operation by the operator.

[0038] The brake caliper maintenance method and apparatus of the present invention have the following beneficial technical effects:

[0039] 1. By integrating functional modules such as disassembly, cleaning, drying, and testing onto the same platform, a streamlined operation of the entire maintenance process is realized, avoiding repeated handling of parts between different devices and significantly improving work efficiency and space utilization.

[0040] 2. Based on the control system and hydraulic seal testing fixture, the automatic control of the testing process, real-time data acquisition and automatic result judgment are realized, effectively eliminating human interference and ensuring the uniformity of testing standards and the objectivity and accuracy of test results.

[0041] 3. By using the control system to record images of key steps in the maintenance process, and automatically storing and uploading test data and result reports to the cloud, electronic record management of the maintenance process is realized, which facilitates quality traceability, analysis and optimization.

[0042] 4. The equipment integrates interactive interface, automatic alarm, parameter preset and other functions, and provides an integrated testing solution for traditional hydraulic calipers and EPB calipers, which greatly reduces the dependence on operator experience, simplifies operation and improves the convenience and universality of use.

[0043] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0044] Figure 1 This is one of the structural schematic diagrams of the brake caliper maintenance equipment in Embodiment 1 of the present invention;

[0045] Figure 2 This is the second schematic diagram of the brake caliper maintenance equipment according to Embodiment 1 of the present invention;

[0046] Figure 3 This is a schematic diagram of the external structure of the brake caliper maintenance equipment according to Embodiment 1 of the present invention;

[0047] Figure 4 This is a schematic diagram of the external structure of the brake caliper maintenance equipment according to Embodiment 1 of the present invention from another perspective;

[0048] Figure 5 This is an electrical control block diagram of the brake caliper maintenance equipment according to Embodiment 1 of the present invention.

[0049] The attached diagram is labeled as follows:

[0050] Integrated enclosure 100, operation and maintenance layer 110, door 111, equipment storage layer 120, horizontal partition 130, workbench 200, working plane 210, vertical support 220, testing platform 300, hydraulic seal testing fixture 310, EPB function testing module 320, drying device 400, ultrasonic cleaner 500, control system 600, main control unit 610, interactive interface 620, operation button panel 630, drawer box 700, image acquisition module 800, first camera 810, second camera 820, air source assembly 900. Detailed Implementation

[0051] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0052] Example 1

[0053] This embodiment provides a brake caliper repair and maintenance device, which is an integrated, multi-functional all-in-one repair workstation.

[0054] Please see Figure 1 , Figure 2 , Figure 3 and Figure 4 The main body of the brake caliper maintenance equipment is an integrated housing 100. The internal space of the housing 100 is divided into two layers by a horizontal partition 130: an upper operation and maintenance layer 110 and a lower equipment storage layer 120. This layout achieves functional zoning; the upper layer is used for manual operation and testing, facilitating operation, while the lower layer is used to accommodate power and auxiliary equipment. The structure is compact and occupies a small area.

[0055] like Figure 1 As shown, a workbench 200 is fixedly installed on the left side of the operation and maintenance layer 110. The surface of the workbench 200 forms a flat and sturdy working surface 210, specifically for performing disassembly and assembly operations of brake calipers. On one side of the workbench 200 (e.g., the rear or side), a vertical support 220 is installed, which is equipped with hooks or tool racks for hanging disassembly and assembly tools such as screwdrivers, snap ring pliers, and piston-specific tools, making them easily accessible and keeping the working surface clean.

[0056] like Figure 1 and Figure 2As shown, a testing platform 300 is provided on the right side of the operation and maintenance layer 110. A hydraulic seal testing fixture 310 is mounted on the testing platform 300. This hydraulic seal testing fixture 310 is equipped with a special clamp and a quick-connect interface for fixing the assembled brake caliper and applying hydraulic pressure to perform a seal test. The operation and maintenance layer 110 has openable doors 111 on both the front facing the operator and the opposite back side, facilitating operator access to the workpiece from different angles and aiding in equipment maintenance.

[0057] like Figure 1 and Figure 2 As shown, the left side of the equipment housing 120 houses a drying unit 400 (such as a drying chamber), with its door facing the operator. This drying unit 400 is used to quickly dry damp brake caliper components after cleaning. The right side of the equipment housing 120 houses an ultrasonic cleaner 500, with its cleaning tank also easily accessible. This ultrasonic cleaner 500 is used for efficient and thorough cleaning of disassembled metal parts.

[0058] like Figure 2 As shown, an operation button panel 630 (such as an emergency stop button, power switch, etc.) for the control system is installed on the front panel of the equipment housing layer 120 above the drying device 400. The panel faces the operator for easy operation of the basic equipment. Above the operation button panel 630, there is a row of multiple drawer boxes 700 for storing commonly used maintenance parts and small tools such as piston seals, dust covers, and guide pin sleeves.

[0059] like Figure 1 , Figure 2 and Figure 3 As shown, an EPB function test module 320 (or EPB hydraulic pressurization module) is also provided above the testing platform 300. This EPB function test module 320 integrates a circuit drive interface and is specifically used for functional verification of brake calipers with electronic parking brake (EPB) function, such as motor drive and clamping force testing.

[0060] like Figure 4 and Figure 5 As shown, the image acquisition module 800 includes at least two high-definition industrial cameras: the first camera 810 is mounted above or to the side of the workbench 200, with its lens aimed at the working plane 210, for capturing and recording images or videos of the entire disassembly and assembly process of the brake caliper; the second camera 820 is mounted above the testing platform 300 or the hydraulic seal testing fixture 310, with its lens aimed at the caliper under test, for specifically capturing status images during the sealing test process, especially possible leakage points.

[0061] like Figure 1 and Figure 2 As shown, the air supply assembly 900 includes an air pump located in the central region of the equipment housing layer 120 for supplying compressed air to the equipment.

[0062] like Figure 1 and Figure 5 As shown, the main control unit 610 (such as an industrial computer or PLC) of the control system 600 is installed inside the equipment housing layer 120. The interactive interface 620 (such as a touch screen) of the control system 600 is located above the working plane 210 and slightly tilted towards the operator, used to display the software operation interface, test parameters, real-time data, and curves. The control system 600 is connected to all electrical components such as the hydraulic seal testing fixture 310, the EPB function testing module 320, the image acquisition module 800, the ultrasonic cleaner 500, and the drying device 400 via cables or wirelessly, realizing centralized control, data acquisition, and process management.

[0063] During operation, maintenance personnel disassemble the calipers on the left workbench 200. The components are then cleaned by the ultrasonic cleaner 500 on the right and dried by the drying device 400 on the left before being returned to the workbench 200 for reassembly. Finally, the caliper assembly is moved to the right testing platform 300 for sealing and EPB function testing. The entire process can be controlled and monitored through the interactive interface 620. The image acquisition module 800 records key steps, and all data is processed and archived by the control system 600 to form a complete digital maintenance record.

[0064] Example 2: Brake caliper maintenance method based on the device described in Example 1.

[0065] This embodiment provides a maintenance method based on the brake caliper maintenance equipment described in Embodiment 1. This method integrates the equipment's control system, connecting discrete maintenance procedures into a standardized, automated, and traceable complete process.

[0066] Step S1: Disassembly and process video recording.

[0067] The brake caliper to be repaired is fixed on the working surface of the workbench described in Example 1. The operator uses a special tool assembly suspended on a vertical support to disassemble the caliper according to the standardized procedure, including removing the guide pin, piston, and seals. During this process, a first camera (part of the image acquisition module) located above the workbench is automatically or controlled to record the entire disassembly operation, and the video data is transmitted in real time to the control system for storage, establishing a traceable disassembly image archive.

[0068] Step S2: Ultrasonic cleaning.

[0069] Place all disassembled metal parts into the ultrasonic cleaner of Example 1. Add a special water-based cleaning agent and set the cleaning parameters (such as temperature and time) through the control system's interactive interface or operation panel. Start the cleaning program, and use ultrasonic waves to thoroughly remove oil, rust, and brake dust.

[0070] Step S3: Hot air drying.

[0071] After cleaning, the parts are transferred to the drying device described in Example 1. A suitable drying temperature and time are set, and the equipment is started. The drying device generates circulating hot air, quickly drying the surface of the parts and removing any moisture residue, thus preparing them for subsequent assembly.

[0072] Step S4: Assembly, recording, and installation.

[0073] On a clean work surface, the dried components are reassembled using new seals and other accessories (available from the drawer). The assembly process is also recorded by the first camera. After assembly, the brake caliper assembly is mounted and fixed on the special fixture of the hydraulic seal testing tooling described in Example 1, and the hydraulic lines are connected.

[0074] Step S5: Test preparation and parameter setting.

[0075] Operators operate the control system via its interactive interface (touchscreen) or computer terminal. In the software interface, they select or input the model of the caliper currently being serviced (e.g., vehicle brand, front / rear wheel, whether it has EPB functionality). The control system automatically loads the corresponding standard test parameters (including test pressure, holding time, leakage threshold, etc.) from its built-in database, which the operator can then confirm or fine-tune.

[0076] Step S6: Automated pressure testing and process monitoring.

[0077] After confirming the parameters, the test program is started through the interactive interface. The control system automatically pressurizes the electric high-pressure pump of the hydraulic seal testing fixture to the set value and enters the pressure holding stage. At the same time, the second camera set above the testing fixture automatically starts to monitor and record images of the calipers (especially the piston area and interface) during the test in real time.

[0078] This step also includes intelligent anomaly response: During the pressure holding test, the control system calculates the pressure leakage rate in real time. If the leakage value exceeds a preset threshold, the system immediately and automatically performs the following actions:

[0079] 1. Trigger the audible and visual alarm to generate and emit an alarm signal;

[0080] 2. Send a command to the image acquisition module to control the second camera to immediately capture the current high-definition image and save it separately as an "abnormal snapshot";

[0081] 3. In the data stream, all test data (stress value, timestamp) corresponding to this abnormal moment are specially marked, and an associated index is established with the above "abnormal snapshot" to facilitate subsequent accurate analysis.

[0082] Step S7: Data collection, analysis, and report generation.

[0083] Throughout the test, the control system collects and displays data in real time through sensors.

[0084] For routine hydraulic sealing tests, hydraulic sealing test data including real-time pressure values, leakage rates, and complete pressure-time curves are collected and generated.

[0085] If the brake caliper under test is a caliper with electronic parking brake (EPB) function, the control system will also call the EPB function test module to perform a telescopic cycle test on the caliper's EPB motor. During this process, parameters such as motor operating current, motor action response time, and clamping force are collected simultaneously, and a current-time variation curve is generated to form EPB function test data. After the test, the control system automatically integrates all test data, graphs, and image recording indexes of key steps (S1, S4, S6) to generate a structured electronic test result report with a clear "pass / fail" judgment, which is displayed on the interactive interface.

[0086] Step S7a (Report Output and Data Upload):

[0087] As an enhancement to this method, the control system can automatically execute the following after the report is generated:

[0088] 1. The driver connects to a small printer to print out a paper version of the test results report for on-site archiving.

[0089] 2. When the equipment detects a valid network connection, it automatically encrypts and uploads the complete electronic test result report and related test data to the designated cloud server, realizing remote backup and centralized management of maintenance data, which facilitates quality traceability and analysis.

[0090] Step S8: Result determination and subsequent operations.

[0091] The operator will process the test report based on the overall conclusion: if it is deemed "qualified", the brake caliper is repaired and can be packaged or installed directly on the vehicle; if it is deemed "unqualified", the operator will perform targeted repairs on the fault point according to the report prompts (especially the abnormal information and related screens recorded in step S6), and repeat the test procedure if necessary.

[0092] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for brake caliper maintenance, comprising the following steps: S1. placing a brake caliper to be maintained in an operation area, disassembling the brake caliper by using a tool assembly, and photographing the disassembling process by using an image acquisition module; S2. placing the disassembled brake caliper components in an ultrasonic cleaner for cleaning; S3. transferring the cleaned brake caliper components to a drying device for drying; S4. assembling the dried brake caliper in the operation area, photographing the assembling process by using the image acquisition module, and mounting the assembled brake caliper on a hydraulic sealing detection tool; S5. selecting a corresponding brake caliper type by using a software interface of a control system, and setting sealing test parameters; S6. starting the hydraulic sealing detection tool to test the brake caliper under pressure, and photographing the testing process by using the image acquisition module; S7. collecting and displaying testing data in real time by using the control system, and automatically generating a testing result report after the testing is completed; S8. judging whether the sealing performance of the brake caliper is qualified according to the testing result report, and completing subsequent maintenance or repair operations. 2.The method according to claim 1, further comprising a step S7a after the step S7 and before the step S8: the control system drives a printer to print the testing result report, and uploads the testing data and the testing result report to a cloud server when a network connection is available. 3.The method according to claim 2, wherein the testing data in the step S7 at least includes: a) hydraulic sealing test data: collected during the hydraulic sealing test, and specifically including real-time pressure values, leakage values, and pressure-time change curves during the test; b) electronic parking brake (EPB) function test data: collected during the function test of the electronic parking brake when the brake caliper is an integrated EPB caliper, and specifically including motor working current, motor action time, clamping force, and current-time change curves. 4.The method according to claim 1, wherein when the leakage value in the testing data exceeds a preset threshold in the step S6, the control system automatically performs the following operations: generating and sending an alarm signal; controlling the image acquisition module to capture and store a picture at an abnormal moment; labeling and associating the testing data corresponding to the abnormal moment. The device comprises an integrated box body, an operation and maintenance layer on an upper layer of the box body, and a device containing layer on a lower layer of the box body; a workbench is arranged on a left side area of the operation and maintenance layer, a tabletop of the workbench constitutes a work plane for performing brake caliper disassembly and assembly, and a vertical support is arranged on one side of the workbench for suspending disassembly tools; an ultrasonic cleaner is arranged on a right side area of the device containing layer for cleaning disassembled brake caliper components; and a drying device is arranged on a left side area of the device containing layer for drying cleaned brake caliper components. ​ ​ 5. A service apparatus for a brake caliper, characterized in that ​ ​ ​ ​ ​ The hydraulic sealing detection tool is arranged on the detection platform of the right area of the operation and maintenance layer, and is used for sealing pressure test of the assembled brake caliper. The control system has a main control unit arranged in the equipment containing layer, and an interactive interface of the control system is arranged above the operation plane and faces the operator.

6. The maintenance equipment according to claim 5, further comprising: An EPB hydraulic pressure module is arranged above the detection platform of the right area of the operation and maintenance layer, and is used for function test of the brake caliper with electronic parking brake function.

7. The maintenance equipment according to claim 6, further comprising: An image acquisition module comprises at least two cameras. The first camera is arranged above or beside the workbench, and is used for acquiring images of the disassembly and assembly process of the brake caliper on the operation plane. The second camera is arranged above or beside the detection platform, and is used for acquiring images of the test process of the brake caliper on the hydraulic sealing detection tool.

8. The maintenance equipment according to claim 7, wherein: The operation button plate of the control system is arranged above the drying device and faces the operator.

9. The maintenance equipment according to claim 8, wherein: A plurality of drawer boxes for storing maintenance accessories are arranged above the operation button plate in the equipment containing layer.

10. The maintenance equipment according to claim 9, wherein: The front and rear positions of the operation and maintenance layer are both provided with opening and closing doors for the convenience of the operator.

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