Device and method for testing mechanical efficiency of EMB system

Abstract

The invention discloses an EMB system mechanical efficiency testing device and method, and the device part comprises a simulation caliper and a torque applying assembly. The simulation calipers are provided with a group of test cavities for accommodating the ball screw module; the test cavity is provided with a head end and a tail end which are opposite, and the outer wall of the simulation caliper in the direction of the head end of the test cavity is also provided with a mounting position for mounting the gear motor assembly; the ball screw module and the gear motor assembly can be in driving connection along a through hole in the wall surface of the test cavity; a restraining surface for restraining the freedom degree of a nut of the ball screw module is arranged in the testing cavity, so that the nut moves in the head and tail end directions of the testing cavity; the wall surface of the tail end of the testing cavity is positioned in the moving stroke of the nut, so that the nut can be propped against the wall surface of the tail end of the testing cavity; the torque applying assembly acts on the driving shaft of the gear motor assembly and generates parameter-readable manual torque, the mechanical efficiency of the EMB system is accurately measured through the device, and timely troubleshooting and improvement in the development process of the EMB system are facilitated.

Description

Technical Field

[0001] This invention relates to the field of vehicle braking technology, and more specifically, to an EMB system mechanical efficiency testing device and method. Background Technology

[0002] The EMB (Electromechanical Braking) system consists of a motor, a reduction gear assembly, a ball screw module, and a caliper. Its braking principle is as follows: the force generated by the motor is amplified by the reduction gear assembly and transmitted to the ball screw module; the ball screw module converts the rotation of the screw into the movement of the nut along the screw axis, and the nut pushes the friction plate in the caliper against the brake disc to achieve braking. Compared with the EHB (Electrohydraulic Braking System), EMB has the advantages of simple structure, good NVH performance, sensitive control, and convenient maintenance.

[0003] Generally, EMB systems developed in the industry are equipped with force sensors to measure and provide feedback on the braking force output by the EMB system at any time.

[0004] Currently, the industry generally requires the design and development of dedicated test benches for different EMB systems, a process that is time-consuming, typically requiring more than six months. In addition, installing the EMB assembly and setting up the test environment during testing is also an extremely time-consuming and labor-intensive process. Although using dedicated test benches to test various functional indicators of the EMB system is more complete and comprehensive, the design and setup cycle of dedicated test benches is long, and many problems during development only become apparent after testing on dedicated test benches, which is not conducive to improving the efficiency of EMB system development and design. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide an EMB system testing device and method with simple structural design and short development cycle. By testing the important indicator of mechanical efficiency of the EMB system, many testing problems can be identified and discovered in a timely manner during the development of the EMB system, which facilitates timely optimization and improvement and greatly reduces the development and testing cycle of the EMB system.

[0006] The above-mentioned objective of the present invention is achieved through the following technical solution: On one hand, the present invention provides a mechanical efficiency testing device for an EMB system, including a simulated caliper and a torque application component; The simulated caliper has a set of test chambers for accommodating the ball screw module; the test chambers have opposing head and tail ends, and the outer wall of the simulated caliper in the direction of the head end of the test chamber is also provided with a mounting position for mounting the geared motor assembly; the test chambers and the mounting position are connected by a through hole, so that the ball screw module and the geared motor assembly can be driven and connected along the through hole. The test chamber has a constraint surface to limit the degree of freedom of the nut in the ball screw module, so that the nut can only move along the first and last ends of the test chamber; the end wall of the test chamber is located within the movement stroke of the nut, so that the nut can abut against the end wall of the test chamber. The torque application component acts on the drive shaft of the geared motor assembly to apply a manually operated torque with readable parameters.

[0007] The EMB system mechanical efficiency testing device of the present invention has at least the following beneficial effects: The EMB system mechanical efficiency testing device of the present invention has a simple structure. It applies a manually operated torque with readable parameters to the EMB system through a torque application component, replacing the output torque of the motor in the EMB system. The ball screw module is installed in the test chamber of the simulated caliper. After being processed and amplified by the geared motor assembly, the manually operated torque drives the nut in the ball screw module to move towards the end wall of the test chamber and generate a force. This actual force is obtained by the force sensor built into the EMB system. In addition, the theoretical force of the nut can be calculated from the applied manually operated torque value. By comparing the actual force with the theoretical force, the mechanical efficiency of the EMB system can be obtained.

[0008] By testing the mechanical efficiency of the EMB system, a crucial indicator, many problems can be identified and addressed promptly during the EMB system development process, facilitating timely optimization and improvement, and significantly reducing the development and testing cycle of the EMB system.

[0009] Furthermore, in existing EMB dedicated test benches, the EMB system is driven by a motor, and the motor's driving parameters are pre-calibrated. However, the calibration parameters themselves have errors, which affect the accuracy of the motor drive and the accuracy of the EMB system's mechanical efficiency measurement. In contrast to the dedicated EMB test bench, this invention manually applies torque to the EMB system through a torque application component, without any additional intermediate parameters, resulting in extremely high measurement accuracy.

[0010] Furthermore, the simulated caliper includes a base and a caliper body, which are detachably connected by several bolts; the test chamber is located inside the caliper body, and one end of the test chamber is closed by the base.

[0011] The above settings allow the ball screw module to be easily placed into and removed from the test chamber.

[0012] Furthermore, the simulated caliper is also equipped with a constraint structure, which is used to limit the simulated caliper from moving and rotating due to external forces.

[0013] Furthermore, the constraint structure includes at least two sets of handles disposed on the simulated caliper; And / or a clamping part provided on a simulated caliper.

[0014] With the above settings, during the mechanical efficiency test of the EMB system, the simulated caliper can be held manually or by a mechanical clamp to prevent the simulated caliper from rotating during the application of manual torque.

[0015] Furthermore, the handle is detachably mounted on the analog caliper and can be removed or installed as needed.

[0016] Furthermore, the handle is plugged into and connected to the caliper body.

[0017] Furthermore, an observation hole communicating with the test chamber is provided on the upper part of the base or caliper body.

[0018] With the above settings, the working status of the simulated caliper can be observed through the observation hole, and it can be checked whether there is obvious misalignment or other abnormal phenomena between the caliper body and the base, thereby avoiding distortion of the force.

[0019] Furthermore, the observation hole is a through groove formed on the surface of the base.

[0020] Furthermore, the torque application assembly includes a torque wrench and a torque adapter; The torque adapter has a first connection part that can be connected to a torque wrench drive, and a second connection part that can be detachably connected to a drive shaft.

[0021] The above settings enable quick-release and replacement of torque adapters within the EMB system, allowing for the installation of torque wrenches adapted to different operating parameters.

[0022] Furthermore, the torque adapter has multiple expansion holes arranged in parallel, and the second connection part includes multiple pins inserted into at least some of the expansion holes.

[0023] On the other hand, the present invention also provides a method for testing the mechanical efficiency of an EMB system, comprising the following steps: S1. Apply manual torque to the drive shaft of the geared motor assembly, and obtain the actual force exerted by the nut in the ball screw module on the end wall of the test chamber through the force sensor in the EMB system. S2. The mechanical efficiency of the EMB system is calculated by the ratio of the actual force of the nut to the theoretical force, and the theoretical force of the nut is calculated by the manual torque value. Attached Figure Description

[0024] Figure 1 A cross-sectional view of the EMB system mechanical efficiency testing device provided in an embodiment of the present invention; Figure 2 An exploded view of the EMB system mechanical efficiency testing device provided in an embodiment of the present invention; Figure 3A perspective view of a torque adapter provided in an embodiment of the present invention; The attached diagram lists the components represented by each number as follows: 1. Torque application assembly; 10. Torque adapter; 100. First connecting part; 101. Second connecting part; 102. Expansion hole; 2. Simulated caliper; 20. Caliper body; 21. Base; 22. Test chamber; 23. Bolt; 24. Handle; 25. Through hole; 26. Mounting position; 27. Observation hole; 30. Gear motor assembly; 300. Drive shaft; 31. Ball screw module; 310. Screw; 311. Nut; 312. Force sensor. Detailed Implementation

[0025] The principles and features of the present invention are described below. The examples given are only for explaining the present invention and are not intended to limit the scope of the present invention.

[0026] In the prior art, the EMB system includes components such as a motor, a reduction gear assembly, and a ball screw module 31. For ease of description, the motor and reduction gear assembly will be referred to as a geared motor assembly 30 in the following text. This is to make it easy to distinguish from the installation position of the ball screw module 31 in the EMB system, and does not mean that the motor and reduction gear assembly must be installed in an integrated structure. That is, the motor and reduction gear assembly in the geared motor assembly 30 of the present invention can be designed as an integrated structure and installed in the EMB system, or the motor and reduction gear can be designed as independent structures and installed in the EMB system. However, regardless of whether an integrated or separate installation structure is adopted, there must be a drive connection between the motor spindle and the reduction gear assembly in the geared motor assembly 30, which will not be elaborated here.

[0027] Furthermore, it should be emphasized that the EMB system mechanical efficiency testing device and method of the present invention are not intended to replace the dedicated EMB system test bench, but rather to provide a simpler and shorter-cycle EMB system mechanical efficiency testing device compared to the dedicated EMB system test bench. Before testing the developed EMB system prototype on the dedicated test bench, the mechanical efficiency of the designed EMB system can be quickly and conveniently detected using the EMB system mechanical efficiency testing device and method provided by the present invention. This allows for timely identification and detection of problems and defects during the EMB system prototype development process, enabling timely optimization and improvement, and shortening the EMB system development and testing cycle. Finally, the EMB system prototype tested by the mechanical efficiency testing device of the present invention must undergo testing on the dedicated test bench before delivery.

[0028] Example 1: Reference Figures 1 to 3 This embodiment provides an EMB system mechanical efficiency testing device, including a torque application component 1 and a simulated caliper 2.

[0029] The torque application component 1 acts on the drive shaft 300 of the geared motor assembly 30 to apply a manually operated torque with readable parameters; the drive shaft 300 refers to the input shaft of the geared gear assembly.

[0030] Reference Figure 1 The simulated caliper 2 has a set of test chambers 22 for accommodating the ball screw module 31; Figure 1 In the vertical direction of the test cavity 22 shown, the test cavity 22 has a front end and a rear end, wherein the front end is located on the upper side of the test cavity 22 and the rear end is located on the lower side of the test cavity 22.

[0031] On the outer wall of the simulated caliper 2 at the head end of the test chamber 22, there is also a mounting position 26 for mounting the geared motor assembly 30. The geared motor assembly 30 is connected to the upper outer wall of the simulated caliper 2 during the test.

[0032] Reference Figure 1 and Figure 2 The test chamber 22 is connected to the mounting position 26 through the through hole 25, so that the ball screw module 31 and the geared motor assembly 30 can be driven and connected along the through hole 25.

[0033] The contact surface between the lead screw 310 of the ball screw module 31 and the drive shaft 300 of the geared motor assembly 30 can be located inside the through hole 25; or, the lead screw 310 extends through the through hole 25 to the outside of the simulated caliper 2 and connects with the drive shaft 300; or, the drive shaft 300 extends through the through hole 25 to the test chamber 22 and connects with the lead screw 310.

[0034] Reference Figure 1 The test cavity 22 has a constraint surface for limiting the degree of freedom of the nut 311 in the ball screw module 31, so that the nut 311 can only move along the head and tail directions of the test cavity 22. The constraint surface serves two functions: preventing the nut 311 from rotating and providing guidance for the nut 311 to move axially along the screw 310. The constraint surface can be the inner wall surface of the test cavity 22; or, the constraint surface can also be the wall surface of the guide structure (such as guide shaft, pin, etc.) in the test cavity 22 that provides guidance for the movement of the nut 311.

[0035] Reference Figure 1 The end wall of the test cavity 22 is located within the travel of the nut 311, so that the nut 311 can abut against the end wall of the test cavity 22, thereby generating a force on the end wall of the test cavity 22.

[0036] In the mechanical efficiency testing device of the EMB system of the present invention, a manual torque with readable parameters is applied to the drive shaft 300 in the EMB system by the torque application component 1, replacing the output torque of the motor in the EMB system; the ball screw module 31 is installed in the test chamber 22 of the simulated caliper 2, and the manual torque is processed and amplified by the reduction motor assembly 30, which drives the nut 311 in the ball screw module 31 to move towards the tail end wall of the test chamber 22 and generate a force. The actual force can be obtained by the force sensor 312 built into the EMB system.

[0037] Furthermore, the theoretical force of the nut 311 can be calculated by combining the applied manual torque value with the existing formula. By comparing the actual force with the theoretical force, the mechanical efficiency of the EMB system can be obtained.

[0038] The EMB system mechanical efficiency testing device of the present invention has a simple structure. It manually applies torque to the EMB system through the torque application component 1 without any additional intermediate quantities, and the measurement accuracy is extremely high. In addition, by testing the important indicator of the mechanical efficiency of the EMB system, many problems can be identified in a timely manner during the development of the EMB system, which facilitates timely optimization and improvement and greatly reduces the development and testing cycle of the EMB system.

[0039] In one embodiment, the simulated caliper 2 can be an integral structure, with a set of channels communicating with the test cavity 22 opened on its side wall, serving as a means for disassembling and installing the rolling resistance screw module 31 within the test cavity 22.

[0040] Reference Figure 1 and Figure 2 In this embodiment, the simulated caliper 2 adopts a split structure, including a base 21 and a caliper body 20. The base 21 and the caliper body 20 are detachably connected by several bolts 23. The test chamber 22 is located inside the caliper body 20, and the tail end of the test chamber 22 is closed by the base 21. The split structure of the simulated caliper 2 allows the ball screw module 31 to be easily placed into and removed from the test chamber 22.

[0041] In addition, refer to Figure 1 and Figure 2 The simulated caliper 2 is also equipped with a constraint structure, which is used to limit the simulated caliper 2 by external forces to prevent it from moving or rotating.

[0042] For example, refer to Figure 1 The constraint structure includes at least two sets of handles 24 on the simulated caliper 2, which can prevent the simulated caliper 2 from rotating during the application of manual torque by gripping the handles 24.

[0043] In addition, the constraint structure may also include a clamping part provided on the simulated caliper 2, and the simulated caliper 2 can be fixed by clamping the clamping part with a tooling fixture.

[0044] Depending on actual needs, the simulated caliper 2 may be equipped with both a handle 24 and a clamping part, or only one of the handle 24 and the clamping part may be provided; no limitation is made here.

[0045] In addition, when the simulated caliper 2 is equipped with multiple handles 24, the handles 24 can be fixed to the simulated caliper 2, or the handles 24 can be installed on the simulated caliper 2 in a pluggable manner.

[0046] The mounting positions 26 of the handle 24 and the clamping part on the simulated caliper 2 are not limited. For example, they can be mounted on either the caliper body 20 or the base 21.

[0047] Reference Figure 2 In this embodiment, the handle 24 is plugged into the caliper body 20.

[0048] In addition, an observation hole 27 communicating with the test chamber 22 can be opened in the base 21 or the caliper body 20. The working state of the simulated caliper 2 can be observed through the observation hole 27, and it can be checked whether there is obvious deviation or other abnormal phenomena between the caliper body 20 and the base 21, thereby avoiding distortion of the force.

[0049] Reference Figure 2 In this embodiment, the observation hole 27 is a through groove formed on the surface of the base 21.

[0050] In the above embodiments, the caliper body 20, base 21 and bolt 23 in the simulated caliper 2 are all high-rigidity structures. When selecting materials and designing, it is necessary to ensure that the test cavity 22 has undergone CAE strength calculation or highly redundant manual calculation. At this time, the force of the nut 311 of the EMB system acts in the test cavity 22, and it can be considered that there is no force loss.

[0051] The torque application assembly 1 includes a torque wrench (not shown) and a torque adapter 10, wherein the torque wrench has the function of displaying the torque magnitude and is commercially available.

[0052] Reference Figure 3 The torque adapter 10 has a first connecting part 100 that can be connected to the torque wrench drive, and a second connecting part 101 that can be detachably connected to the drive shaft 300.

[0053] For example, in order to adapt to the profile of the output part of a certain type of torque wrench, the end face of the first connecting part 100 is a regular hexagonal structure; while the second connecting part 101 can be a coupling structure adapted to the profile of the drive shaft 300.

[0054] Reference Figure 2 In one embodiment, the upper end of the drive shaft 300 has a ratchet portion with multiple insertion holes, so that the torque adapter 10 can be driven by inserting a pin into the aforementioned multiple insertion holes.

[0055] Specifically, refer to Figure 3 The torque adapter 10 has a plurality of expansion holes 102 arranged in parallel. The second connection part 101 includes a plurality of pins inserted into at least some of the expansion holes 102. The number of expansion holes 102 and pins can be flexibly set according to the structure type of the drive shaft 300 in the EMB system and the magnitude of the manual torque, and is not limited here.

[0056] Example 2: This embodiment also provides a method for testing the mechanical efficiency of an EMB system, including the following steps: S1. Apply manual torque to the drive shaft 300 of the geared motor assembly 30, and obtain the actual force exerted by the nut 311 in the ball screw module 31 on the end wall of the test chamber 22 through the force sensor 312 in the EMB system. S2. The mechanical efficiency of the EMB system is obtained by calculating the ratio of the actual force of the nut 311 to the theoretical force. The theoretical force of the nut 311 is obtained by calculating the manual torque value.

[0057] In step S1, the simulated caliper 2 is first fixed, and then the torque wrench is manually and slowly rotated to ensure that the reading of the torque wrench gradually and continuously increases. When the torque wrench reaches the predetermined torque value, the torque wrench is held for 3 seconds, and the value of the force sensor 312 is read.

[0058] In step S2, the theoretical force of the nut 311 is calculated using the following formula: F = (Tin×i×2π) / P; In the formula, F is the theoretical force of the nut 311, Tin represents the manual torque value, i is the reduction ratio of the reduction gear assembly in the geared motor assembly 30, and P is the lead of the ball screw module 31.

[0059] The mechanical efficiency of the EMB system is obtained by dividing the actual force of the nut 311 by the theoretical force of the nut 311.

[0060] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0061] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0062] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0063] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0064] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0065] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. An EMB system mechanical efficiency test device, characterized in that, The simulation caliper and the torque applying assembly are included. The simulation caliper has a group of test cavities for accommodating ball screw modules; the test cavities have opposite head ends and tail ends; a mounting position for mounting a reduction motor assembly is arranged on the outer wall of the simulation caliper in the direction of the head end of the test cavities; the test cavities and the mounting position are communicated through a through hole, so that the ball screw modules and the reduction motor assembly can be drivingly connected along the through hole; The test cavities have a restriction surface for limiting the freedom of a nut in the ball screw modules, so that the nut can only move in the direction of the head and tail ends of the test cavities; the tail end wall of the test cavities is located in the moving stroke of the nut, so that the nut can abut against the tail end wall of the test cavities; The torque applying assembly acts on the driving shaft of the reduction motor assembly to apply a parameter-readable manual torque.

2. The EMB system mechanical efficiency test device of claim 1, wherein, The simulation caliper includes a base and a caliper body, the base and the caliper body are detachably connected through a plurality of bolts; the test cavities are arranged in the caliper body, and one end of the test cavities is closed through the base.

3. The EMB system mechanical efficiency test device of claim 2, wherein, The simulation caliper is further provided with a restriction structure for being limited by external force to prevent the simulation caliper from moving and rotating.

4. The EMB system mechanical efficiency test device of claim 3, wherein, The restriction structure includes at least two groups of handles arranged on the simulation caliper; And / or a clamped part arranged on the simulation caliper.

5. The EMB system mechanical efficiency test device of claim 4, wherein, The handles are detachably mounted on the caliper body.

6. The EMB system mechanical efficiency test device of claim 2, wherein, An observation hole communicating with the test cavities is arranged on the base or the caliper body.

7. The EMB system mechanical efficiency test device of claim 6, wherein, The observation hole is a through groove arranged on the surface of the base.

8. The EMB system mechanical efficiency test device of claim 1, wherein, The torque applying assembly includes a torque wrench and a torque adapter; The torque adapter has a first connecting part capable of being drivingly connected with the torque wrench, and a second connecting part capable of being detachably connected with the driving shaft.

9. The EMB system mechanical efficiency test device of claim 8, wherein, A plurality of expansion holes are arranged in parallel on the torque adapter, and the second connecting part includes a plurality of pins inserted into at least part of the expansion holes.

10. A method of testing the mechanical efficiency of an EMB system, characterised in that, The method includes the following steps by using the EMB system mechanical efficiency test device according to any one of claims 1 to 9: S1, a manual torque is applied to the driving shaft of the reduction motor assembly, and an actual force of the nut in the ball screw module acting on the tail end wall of the test cavities is obtained through a force sensor in the EMB system; S2, the mechanical efficiency of the EMB system is calculated by the ratio of the actual force of the nut to the theoretical force of the nut, and the theoretical force of the nut is calculated by the value of the manual torque.

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