A multi-dimensional real-time detection and early warning device for brake pad wear

Abstract

The application relates to the technical field of brake pad detection and early warning, in particular to a multi-dimensional real-time detection and early warning device for brake pad wear, which comprises a caliper cover, an oil inlet pipe arranged on one side of the caliper cover, an exhaust pipe arranged on the other side of the caliper cover and an oil inlet pipe in communication with an external automobile brake oil pipe; brake limiting grooves are symmetrically arranged on the inner side of the caliper cover, two piston columns are arranged in the two brake limiting grooves, brake pads are arranged in the two brake limiting grooves through locking screws, the brake pads are respectively in abutment with the two sides of a brake disc, two mounting grooves are arranged on the caliper cover, alignment grooves are arranged at one end of the two mounting grooves, and Hall wear detection assemblies are arranged in the two mounting grooves; the Hall wear detection and infrared temperature measurement double-mode sensing are combined to realize independent, real-time and multi-dimensional monitoring of different brake pads; the device has the advantages of high precision, high reliability, self-cleaning, quick maintenance and mechanical redundancy alarm and the like in combination with temperature compensation and uneven wear early warning.

Description

Technical Field

[0001] This invention relates to the field of brake pad detection and early warning technology, and in particular to a multi-dimensional real-time detection and early warning device for brake pad wear. Background Technology

[0002] A brake pad detection and warning device is a device used to monitor the status of a car's braking system. Its main function is to detect the wear and working condition of the brake pads in a timely manner to ensure the safety and performance of the vehicle. It typically monitors the thickness and temperature of the brake pads through sensors. When the brake pads wear to a certain extent, the sensors will send a signal to trigger a warning. By equipping the vehicle with a brake pad detection and warning device, car owners can better understand the vehicle's braking status, thereby improving driving safety and reliability.

[0003] Traditional brake pad detection and warning devices are mostly single-point mechanical or resistive sensing devices, which cannot reflect the wear differences between different brake pads. In real life, brake pad wear is usually inconsistent, making it impossible to accurately reflect the wear status of different brake pads. This limitation not only affects the safety of the braking system, but also makes it difficult for car owners to make accurate judgments when maintaining and replacing brake pads. In order to improve the reliability of the braking system, there is an urgent need in the market to develop more advanced multi-point monitoring technology that can provide more accurate and comprehensive data by monitoring the wear of each brake pad in real time. Summary of the Invention

[0004] The purpose of this invention is to provide a multi-dimensional real-time detection and early warning device for brake pad wear, in order to solve the problem that the current brake pad detection and early warning devices mentioned in the background art cannot reflect the wear differences of different brake pads, while in real life the wear of brake pads is usually inconsistent and cannot truly reflect the wear state of different brake pads.

[0005] A multi-dimensional real-time detection and early warning device for brake pad wear includes a caliper cover, an oil inlet pipe installed on one side of the caliper cover, and an exhaust pipe located on the other side of the caliper cover. The oil inlet pipe is connected to an external automotive brake fluid line. It also includes symmetrically positioned brake limiting grooves inside the caliper cover. Two piston rods are installed inside each of the two brake limiting grooves, and brake pads are installed inside each of the two brake limiting grooves via locking screws. The brake pads abut against both sides of the brake disc. Two mounting grooves are provided on the caliper cover, and each of the two mounting grooves has an alignment groove at one end. Hall effect wear detection components are snapped into each of the two mounting grooves. Both Hall effect wear detection components are connected to the brake pads via positioning snap-fit ​​components. Each of the two Hall effect wear detection components is equipped with a cleaning and sealing component. Infrared temperature measuring components are fixedly installed in the two alignment grooves via screws. The infrared temperature measuring components monitor the temperature of the brake pads. The Hall effect wear detection components and the infrared temperature measuring components are connected to a connector via wires. A connector socket is snapped into the connector, and the connector socket is electrically connected to the automotive ECU.

[0006] As a preferred option, physical warning discs are installed on both brake pads.

[0007] Preferably, the Hall wear detection assembly includes a first mounting block, a Hall sensor, a positioning plate, a first spring, a movable positioning cylinder, a fixed base, a central column, and a permanent magnet; the first mounting block is snapped into each of the two mounting slots, the Hall sensor is installed inside the first mounting block, two positioning plates are symmetrically installed inside the first mounting block, the first spring is connected inside the first mounting block, the movable positioning cylinder is slidably connected inside the first mounting block, the inner side of the movable positioning cylinder is slidably connected to the positioning plate, and a central column is fixedly set in the middle of the movable positioning cylinder, with a permanent magnet installed on the central column.

[0008] As a preferred option, a limiting groove is provided on the positioning plate, and guide strips are provided on the inner side of the movable positioning cylinder at positions corresponding to the limiting groove.

[0009] The infrared temperature measurement assembly includes a second mounting block and an infrared temperature sensor; the second mounting block is fixedly installed in each of the two alignment slots by screws, and the infrared temperature sensor is set on the second mounting block.

[0010] Preferably, the infrared temperature measurement component also includes a wedge-shaped positioning block; the second mounting block is provided with a wedge-shaped positioning block on the side near the first mounting block, and the first mounting block is provided with an angle at the end near the second mounting block, with the wedge-shaped positioning block and the angle cooperating with each other.

[0011] Preferably, the outer shells of both the first and second mounting blocks are made of silicon carbide ceramic composite material.

[0012] As a preferred option, the connector plug and connector socket are AMP automotive-grade waterproof connectors.

[0013] Preferably, the positioning and locking assembly includes a guide positioning frame, locking holes, a plug plate, mounting holes, a second spring, positioning protrusions, and anti-detachment plates. The guide positioning frame is installed on the brake pad, and two locking holes are provided on the guide positioning frame. A plug plate is fixedly connected to one side of the fixing seat, and two symmetrical mounting holes are provided on the plug plate. The second spring and the positioning protrusion are installed in the mounting holes from the inside to the outside in sequence. Two anti-detachment plates are symmetrically inserted into the plug plate, and the ends of the positioning protrusions pass through the anti-detachment plates, which are engaged with the locking holes.

[0014] Preferably, the cleaning and sealing assembly includes a fixed cylinder, a cleaning scraper, an elastic sealing plate, and a rubber sealing ring; the fixed cylinder is installed on the first mounting block, and multiple cleaning scrapers and elastic sealing plates are arranged sequentially from the inside to the outside of the fixed cylinder. Each cleaning scraper is covered with a rubber sealing ring, and the rubber sealing ring, the cleaning scraper, and the movable positioning cylinder are slidably connected.

[0015] The beneficial effects of this invention are:

[0016] 1. Each caliper has a pair of brake pads with an individual Hall wear detection component, which can not only independently detect the wear state of different brake pads, but also read the real-time thickness of different sides of the same brake disc and send it to the car ECU to calculate the difference. If the difference exceeds the standard, it will trigger an "imbalance warning" to improve safety.

[0017] 2. The infrared temperature measurement component synchronously collects the brake pad temperature, and the vehicle ECU calculates and eliminates temperature interference to achieve accurate detection;

[0018] 3. The positioning and snap-fit ​​components facilitate alignment and connection with the brake pads, ensuring sensing accuracy;

[0019] 4. Both the Hall wear detection component and the infrared temperature measurement component can be replaced separately, improving the convenience and economy of maintenance;

[0020] 5. The cleaning and sealing components on the Hall wear detection assembly prevent dirt from entering, ensuring the accuracy of the sensing data and avoiding mechanical jamming. Attached Figure Description

[0021] Figure 1 The diagram shown is a schematic representation of the overall structure of the present invention. Figure 1 ;

[0022] Figure 2 The diagram shown is a schematic representation of the disassembled structure of the present invention;

[0023] Figure 3 The diagram shown is a schematic representation of the internal structure of the caliper cover of the present invention.

[0024] Figure 4 The diagram shown is a schematic representation of the mounting groove and alignment groove structure of the present invention.

[0025] Figure 5 The diagram shown is a cross-sectional view of the Hall wear detection component of the present invention.

[0026] Figure 6 The diagram shown is a schematic representation of the movable positioning cylinder structure of the present invention.

[0027] Figure 7 The diagram shown is a schematic of the split structure of the Hall wear detection component of the present invention;

[0028] Figure 8 This invention is shown. Figure 7 A detailed structural diagram of point A;

[0029] Figure 9 The diagram shown is a schematic representation of the infrared temperature measurement component structure of the present invention.

[0030] Figure 10 The diagram shown is a schematic of the installation structure of the positioning clip assembly of the present invention.

[0031] Figure 11 This invention is shown. Figure 10 A detailed structural diagram of point B;

[0032] Figure 12 The diagram shown is a schematic representation of the electrical connection structure of the present invention.

[0033] Explanation of reference numerals in the attached diagram: 1. Caliper cover; 2. Oil inlet pipe; 3. Exhaust pipe; 4. Brake limit groove; 5. Piston rod; 6. Locking screw; 7. Brake pad; 8. Physical alarm plate; 9. Mounting groove; 10. Alignment groove; 15. Connecting plug; 16. Connecting socket; 1101. First mounting block; 1102. Hall sensor; 1103. Positioning plate; 1104. First spring; 1105. Movable positioning cylinder; 1106. Fixed base; 1107. 1108. Central column; 1201. Permanent magnet; 1202. Second mounting block; 1203. Infrared temperature sensor; 1204. Wedge positioning block; 1305. Guide positioning frame; 1306. Locking hole; 1307. Insertion plate; 1308. Mounting hole; 1309. Second spring; 13000. Positioning protrusion; 1301. Anti-detachment plate; 1401. Fixing cylinder; 1402. Cleaning scraper; 1403. Elastic sealing plate; 1404. Rubber sealing ring. Detailed Implementation

[0034] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0035] Please see Figures 1 to 12This invention provides an embodiment of a multi-dimensional real-time detection and early warning device for brake pad wear, comprising a caliper cover 1, an oil inlet pipe 2 installed on one side of the caliper cover 1, and an exhaust pipe 3 located on the other side of the caliper cover 1. The oil inlet pipe 2 is connected to an external automotive brake oil pipe. It also includes brake limiting grooves 4 symmetrically mounted inside the caliper cover 1. Two piston pins 5 are installed inside each of the two brake limiting grooves 4, and brake pads 7 are mounted inside each of the two brake limiting grooves 4 via locking screws 6. The brake pads 7 abut against both sides of the brake disc. Two mounting grooves 9 are provided on the caliper cover 1, and each of the two mounting grooves 9 has an alignment groove 10 at one end. Hall effect sensors are engaged in both mounting grooves 9. The wear detection components include two Hall effect wear detection components, both connected to the brake pads 7 via positioning clip components. Each of the two Hall effect wear detection components is equipped with a cleaning and sealing component. Infrared temperature measuring components are fixedly installed in the two alignment slots 10 by screws, and the temperature of the brake pads 7 is monitored by the infrared temperature measuring components. The Hall effect wear detection components and the infrared temperature measuring components are connected to the docking plug 15 via wires. The docking plug 15 is clipped with a docking socket 16, which is electrically connected to the vehicle ECU. Each of the two brake pads 7 is equipped with a physical alarm pad 8. When the brake pad wears to the limit thickness, the physical alarm pad 8 rubs against the brake disc to generate abnormal noise, serving as a mechanical redundancy alarm method. The Hall wear detection assembly includes a first mounting block 1101, a Hall sensor 1102, a positioning plate 1103, a first spring 1104, a movable positioning cylinder 1105, a fixed base 1106, a central column 1107, and a permanent magnet 1108. The first mounting block 1101 is engaged in both mounting slots 9. The Hall sensor 1102 is installed inside the first mounting block 1101. Two positioning plates 1103 are symmetrically installed inside the first mounting block 1101. The first spring 1104 is connected inside the first mounting block 1101, allowing for sliding within the first mounting block 1101. A movable positioning cylinder 1105 is connected, and the inner side of the movable positioning cylinder 1105 is slidably connected to the positioning plate 1103. A central column 1107 is fixedly set in the middle of the movable positioning cylinder 1105, and a permanent magnet 1108 is installed on the central column 1107. As the brake pad 7 wears and becomes thinner, the movable positioning cylinder 1105 moves towards the brake pad under the thrust of the first spring 1104, causing the permanent magnet 1108 to move closer to or away from the Hall sensor 1102. The Hall sensor 1102 outputs an electrical signal corresponding to the amount of wear, thereby realizing non-contact high-precision thickness detection.

[0036] Please see Figures 1 to 12In this embodiment, a limiting groove is formed on the positioning plate 1103, and guide strips are provided on the inner side of the movable positioning cylinder 1105 at positions corresponding to the limiting grooves to ensure that the movable positioning cylinder 1105 slides smoothly only along the axial direction and avoids deflection affecting the detection accuracy. The infrared temperature measurement component includes a second mounting block 1201 and an infrared temperature sensor 1202; the second mounting block 1201 is fixedly installed in each of the two alignment grooves 10 by screws, and the infrared temperature sensor 1202 is provided on the second mounting block 1201 for real-time acquisition of the surface temperature of the brake pad 7. The infrared temperature measurement component also includes a wedge-shaped positioning block 1203; the second mounting block 1201 has a wedge-shaped positioning block 1203 on the side near the first mounting block 1101, and the first mounting block 1101 has an angled end near the second mounting block 1201. The wedge-shaped positioning block 1203 and the angled end cooperate to achieve quick alignment and stable fit during installation of the two components. The outer shells of both the first mounting block 1101 and the second mounting block 1201 are made of silicon carbide ceramic composite material, which has excellent high temperature resistance, thermal shock resistance and insulation performance, and is suitable for high temperature and high dust conditions in braking systems. The docking plug 15 and docking socket 16 adopt AMP automotive-grade waterproof connectors to ensure stable and reliable signal transmission in humid and vibrating environments.

[0037] Please see Figures 1 to 12In this embodiment, the positioning and locking assembly includes a guide positioning frame 1301, locking holes 1302, a plug-in plate 1303, mounting holes 1304, a second spring 1305, a positioning protrusion 1306, and an anti-detachment plate 1307. The guide positioning frame 1301 is mounted on the brake pad 7. Two locking holes 1302 are provided on the guide positioning frame 1301. A plug-in plate 1303 is fixedly connected to one side of the fixing base 1106. Two symmetrical mounting holes 1304 are provided on the plug-in plate 1303. The second spring 1305 and the positioning protrusion 1306 are sequentially installed in the mounting holes 1304 from the inside out. Two anti-detachment plates 1307 are symmetrically inserted into the plug-in plate 1303. The ends of the positioning protrusions 1306 pass through the anti-detachment plates 1307. The anti-detachment plates 1307 engage with the locking holes 1302, achieving a quick and reliable connection between the Hall wear detection assembly and the brake pad 7, and ensuring... To ensure sensor synchronization, the cleaning and sealing assembly includes a fixed cylinder 1401, a cleaning scraper 1402, an elastic sealing plate 1403, and a rubber sealing ring 1404. The fixed cylinder 1401 is mounted on the first mounting block 1101. Multiple cleaning scrapers 1402 and elastic sealing plates 1403 are arranged sequentially from the inside to the outside of the fixed cylinder 1401. Each cleaning scraper 1402 is covered with a rubber sealing ring 1404. The rubber sealing ring 1404 and the cleaning scraper 1402 are slidably connected to the movable positioning cylinder 1105. During the reciprocating motion of the movable positioning cylinder 1105, the cleaning scraper 1402 can scrape off the dust and oil adhering to its surface. The rubber sealing ring 1404 and the elastic sealing plate 1403 together form a multi-level seal, effectively preventing external dirt from entering the interior of the first mounting block 1101, ensuring the long-term stable operation of the Hall sensor 1102, and avoiding mechanical jamming.

[0038] Working principle: When the vehicle is in normal driving or braking state, this device simultaneously activates the multi-dimensional real-time monitoring function. During braking, the brake pad 7 rubs against the high-speed rotating brake disc, generating heat and causing the material to wear down gradually. As the thickness of the brake pad 7 decreases, the distance between its back and the Hall sensor 1102 increases. The first spring 1104 pushes the movable positioning cylinder 1105 to slide axially toward the brake pad, causing the central column 1107 and the permanent magnet 1108 to move synchronously. Since the Hall sensor 1102 is fixed inside the first mounting block 1101, the relative distance between the permanent magnet 1108 and the Hall sensor 1102 changes accordingly. The Hall sensor 1102 outputs a continuously changing analog voltage signal based on the magnetic field strength. After being processed by the built-in signal conditioning circuit, the signal is transmitted to the docking plug 15 through the wire. At the same time, the infrared temperature sensor 1202 continuously targets the area near the friction surface of the brake pad 7, collects surface temperature data in a non-contact manner, and sends the temperature signal synchronously into the same signal path.

[0039] The two signals mentioned above are connected to the vehicle ECU via connector 16. The ECU has a pre-set wear-magnetic field mapping model and temperature compensation algorithm: First, the remaining thickness of the brake pads is calculated based on the Hall voltage value; second, the Hall signal is dynamically corrected by combining the real-time temperature feedback from the infrared temperature sensor 1202. Because high temperature will cause slight decay of the magnetic properties of the permanent magnet 1108, if not compensated, it will cause misjudgment of the thickness. This system eliminates temperature interference by using a lookup table method or polynomial fitting to ensure that the detection accuracy is within ±0.1mm. More importantly, the ECU receives independent wear data from the brake pads on both sides of the brake disc and calculates the thickness difference between the two in real time. When the difference exceeds the safety threshold, such as 1.5mm, it can be set by the vehicle model calibration, which is to determine "uneven wear". The "uneven brake pad wear" warning is immediately triggered through the instrument panel or vehicle information system to remind the driver to check in time and avoid vehicle deviation or brake failure due to insufficient braking force on one side.

[0040] In addition, the physical alarm piece 8 serves as a mechanical backup. The physical alarm piece 8 is an L-shaped metal spring piece riveted to the brake pad 7 near the outer edge. This structure is a common brake pad accessory structure. One end is fixed to the back plate (steel base plate) of the brake pad 7, and the other end extends freely towards the brake disc. This ensures that when the brake pad wears to its limit thickness, the free end of the alarm piece just contacts the surface of the brake disc. When the brake pad 7 wears to its limit thickness, which is usually 2-3mm, its metal piece directly scrapes the brake disc, emitting a high-frequency sharp abnormal noise. Even if the electronic system fails, it can still provide an effective warning. The cleaning and sealing assembly automatically completes self-cleaning during each reciprocating motion of the movable positioning cylinder 1105: the rubber sealing ring 1404 prevents external mud, water, and metal dust from entering the inner cavity of the first mounting block 1101, while the multi-stage cleaning scraper 1402 scrapes off the attachments on the outer wall of the movable positioning cylinder 1105, preventing dirt accumulation from causing jamming and ensuring long-term operational reliability.

[0041] In terms of maintenance, the Hall wear detection component and the infrared temperature measurement component adopt a modular quick-release design: when a sensor on one side is damaged or needs calibration, only the corresponding screw needs to be loosened, and the entire sensor can be pulled out and replaced using the wedge-shaped positioning block 1203 and the oblique guide, without disassembling the entire caliper assembly; the anti-disengagement plate 1307 and the locking hole 1302 in the positioning and locking component achieve "one-plug-and-lock", and the second spring 1305 drives the positioning protrusion 1306 to automatically embed, ensuring that the sensing end and the brake pad 7 are always closely linked. The entire system is connected to the ECU through AMP automotive-grade waterproof connectors 15 and 16, and has an IP67 or higher protection level, adapting to harsh working conditions such as wading, salt spray, and high vibration. In summary, this invention achieves dual-sided independent, thickness + temperature fusion, real-time accurate, and redundant reliable multi-dimensional monitoring of the brake pad wear state, significantly improving driving active safety and intelligent maintenance level.

Claims

1. A multi-dimensional real-time detection and early warning device for brake pad wear, comprising a caliper cover (1), an oil inlet pipe (2) installed on one side of the caliper cover (1), and an exhaust pipe (3) disposed on the other side of the caliper cover (1), wherein the oil inlet pipe (2) is connected to an external automotive brake oil pipe; characterized in that: It also includes brake limiting grooves (4) symmetrically mounted inside the caliper cover (1). Two piston pins (5) are installed inside each of the two brake limiting grooves (4). Brake pads (7) are installed inside each of the two brake limiting grooves (4) via locking screws (6). The brake pads (7) abut against both sides of the brake disc. Two mounting grooves (9) are provided on the caliper cover (1). One end of each mounting groove (9) is provided with an alignment groove (10). Hall wear detection components are snapped into each of the two mounting grooves (9). Both Hall wear detection components are connected to the brake pads (7) via positioning snap-fit ​​components. Both Hall wear detection components are provided with cleaning The clean sealing assembly has an infrared temperature measuring component fixedly installed in the two alignment grooves (10) by screws. The infrared temperature measuring component monitors the temperature of the brake pads (7). The Hall wear detection assembly and the infrared temperature measuring component are connected to the docking plug (15) by wires. The docking plug (15) has a docking socket (16) snapped on it. The docking socket (16) is electrically connected to the vehicle ECU. The Hall wear detection assembly includes a first mounting block (1101), a Hall sensor (1102), a positioning plate (1103), a first spring (1104), a movable positioning cylinder (1105), a fixed base (1106), and a center column (1107).

1. Permanent magnet (1108); 2. First mounting block (1101) is snapped into each of the two mounting slots (9). Hall sensor (1102) is installed inside the first mounting block (1101). Two positioning plates (1103) are symmetrically installed inside the first mounting block (1101). First spring (1104) is connected inside the first mounting block (1101). Movable positioning cylinder (1105) is slidably connected inside the first mounting block (1101). The inner side of the movable positioning cylinder (1105) is slidably connected to the positioning plate (1103). A central column (1107) is fixedly set in the middle of the movable positioning cylinder (1105). A permanent magnet (1108) is installed on the first mounting block (1107). The cleaning and sealing assembly includes a fixed cylinder (1401), a cleaning scraper (1402), an elastic sealing plate (1403), and a rubber sealing ring (1404). A fixed cylinder (1401) is installed on the first mounting block (1101). Multiple cleaning scrapers (1402) and elastic sealing plates (1403) are arranged sequentially from the inside to the outside of the fixed cylinder (1401). Each cleaning scraper (1402) is covered with a rubber sealing ring (1404). The rubber sealing ring (1404) and the cleaning scraper (1402) are slidably connected to the movable positioning cylinder (1105).

2. The multi-dimensional real-time detection and early warning device for brake pad wear according to claim 1, characterized in that: Physical alarm pads (8) are installed on both brake pads (7).

3. The multi-dimensional real-time detection and early warning device for brake pad wear according to claim 2, characterized in that: A limiting groove is provided on the positioning plate (1103), and guide strips are provided on the inner side of the movable positioning cylinder (1105) at the corresponding positions of the limiting groove.

4. The multi-dimensional real-time detection and early warning device for brake pad wear according to claim 3, characterized in that: The infrared temperature measurement component includes a second mounting block (1201) and an infrared temperature sensor (1202); the second mounting block (1201) is fixedly installed in both alignment slots (10) by screws, and the infrared temperature sensor (1202) is provided on the second mounting block (1201).

5. The multi-dimensional real-time detection and early warning device for brake pad wear according to claim 4, characterized in that: The infrared temperature measurement component also includes a wedge-shaped positioning block (1203); the second mounting block (1201) is provided with a wedge-shaped positioning block (1203) on the side near the first mounting block (1101), and the first mounting block (1101) is provided with an angle at the end near the second mounting block (1201), and the wedge-shaped positioning block (1203) and the angle cooperate with each other.

6. The multi-dimensional real-time detection and early warning device for brake pad wear according to claim 5, characterized in that: The outer shells of the first mounting block (1101) and the second mounting block (1201) are both made of silicon carbide ceramic composite material.

7. The multi-dimensional real-time detection and early warning device for brake pad wear according to claim 6, characterized in that: The connector plug (15) and connector socket (16) are AMP automotive-grade waterproof connectors.

8. The multi-dimensional real-time detection and early warning device for brake pad wear according to claim 7, characterized in that: The positioning and locking assembly includes a guide positioning frame (1301), a locking hole (1302), a plug plate (1303), a mounting hole (1304), a second spring (1305), a positioning protrusion (1306), and an anti-detachment plate (1307). The guide positioning frame (1301) is installed on the brake pad (7). The guide positioning frame (1301) has two locking holes (1302). The plug plate (1303) is fixedly connected to one side of the fixing seat (1106). The plug plate (1303) has two symmetrical mounting holes (1304). The second spring (1305) and the positioning protrusion (1306) are installed in the mounting holes (1304) from the inside to the outside. Two anti-detachment plates (1307) are symmetrically inserted into the plug plate (1303). The end of the positioning protrusion (1306) passes through the anti-detachment plate (1307). The anti-detachment plate (1307) is locked with the locking hole (1302).

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