Intelligent brake chamber and assembly method thereof

Abstract

The application provides an intelligent brake chamber and an assembling method thereof, and relates to the technical field of commercial vehicle braking systems. The intelligent brake chamber comprises a driving cavity module and a parking cavity module, and further comprises: a breathing protection device arranged on the front shell and configured to communicate a cavity above the driving diaphragm with the outside atmosphere and filter the gas entering the cavity; a stroke monitoring device comprising a monitoring module and an alarm module, which is used to monitor the stroke of the push rod assembly in real time and generate an alarm signal when the stroke exceeds a preset range; wherein the driving cavity module and the parking cavity module are connected through a press riveting structure. Based on this, the application solves the problems of complex structure, low assembly efficiency, single function and potential safety hazards in the prior art.

Description

Technical Field

[0001] This invention relates to the field of commercial vehicle braking system technology, and in particular to an intelligent brake chamber and its assembly method. Background Technology

[0002] The diaphragm spring brake chamber is a key actuator in the air braking system of commercial vehicles, typically consisting of a driving chamber module that provides service braking force and a parking chamber module that provides parking / emergency braking force. Existing diaphragm spring brake chambers have several structural and functional shortcomings, specifically: Structurally, the connection between the driving chamber module and the parking chamber module typically employs a multi-part method. Specifically, the middle body assembly and cylinder block assembly within the parking chamber are secured by multiple sets (usually eight sets) of bolts, nuts, and washers, often totaling up to 24 parts. The front shell assembly of the driving chamber, however, is connected to the middle body assembly via a separate set of clamps, bolts, and nuts. This connection method leads to the following problems: First, the large number of parts increases material management and procurement costs; second, the assembly process is cumbersome, reliant on manual operation, resulting in low efficiency and inconsistent quality; improper assembly can easily cause air leaks, affecting braking safety; third, the overall weight is significant, contradicting the trend towards lightweight commercial vehicles.

[0003] Functionally, existing brake chambers also have significant shortcomings: First, for wedge or disc brakes with exposed pushrods, the cavity above the diaphragm is usually directly or indirectly connected to the atmosphere. During the braking and release cycle, external contaminants such as dust and mud are easily drawn into the cavity, accelerating the wear of the pushrod seals and potentially even entering the brake itself, leading to decreased brake sealing and reliability. Second, existing brake chambers are purely mechanical actuators and cannot actively provide feedback on their operating status. Therefore, when the automatic brake clearance adjustment function fails, the brake clearance gradually increases, resulting in excessive pushrod travel. This not only delays braking response but, more seriously, can lead to insufficient braking force, creating a significant safety hazard. Drivers often fail to notice such progressive malfunctions until braking performance significantly deteriorates.

[0004] Therefore, how to simplify the structure of the brake chamber, improve assembly efficiency and reliability, and enable it to have environmental adaptability and state self-sensing capability are technical problems that urgently need to be solved in this field. Summary of the Invention

[0005] The purpose of this invention is to provide a brake chamber that is structurally simplified, highly reliable, lightweight, and equipped with intelligent monitoring and environmental protection functions, in order to solve the problems of complex structure, low assembly efficiency, single function, and safety hazards in the prior art.

[0006] This invention is achieved using the following technical solution: An intelligent brake chamber includes a driving chamber module and a parking chamber module. The driving chamber module includes a front shell, a driving diaphragm, and a push rod assembly linked to the driving diaphragm. The parking chamber module includes a cylinder, a middle body, a piston, and a parking spring. The middle body is disposed within the cylinder, and the piston is configured to reciprocate within the cylinder to compress or release the parking spring. The chamber also includes: a breathing protection device disposed on the front shell, configured to connect the chamber above the driving diaphragm to the outside atmosphere and filter the gas entering the chamber; and a stroke monitoring device including a monitoring module and an alarm module, used to monitor the stroke of the push rod assembly in real time and generate an alarm signal when the stroke exceeds a preset range. The driving chamber module and the parking chamber module are connected by a press-fit structure.

[0007] The intelligent brake chamber provided by this invention integrates three major structural improvements: First, the integrated riveting structure fundamentally changes the product's assembly and connection methods, solving the defects of numerous parts, cumbersome assembly, and easy air leakage in the prior art. Second, the addition of a breathing protection device solves the problem of contaminant intrusion leading to seal wear and brake failure, improving the product's environmental adaptability and reliability. Third, the integrated stroke monitoring device endows traditional mechanical components with intelligent attributes of self-sensing and self-diagnosis, solving the safety hazards caused by excessively long braking strokes.

[0008] Furthermore, the press-fit structure is an integrated, non-removable type, disposed between the front shell and the cylinder body; the outer edge of the front shell is provided with a first flange edge, and the open end of the cylinder body is provided with a malleable second flange edge, the second flange edge covering and pressing against the first flange edge.

[0009] In the above structure, the first flange edge at the front shell and the second flange edge at the cylinder are precisely designed to fit together. This covering and pressing structure makes the contact area at the connection point much larger than that of traditional bolt connections, resulting in extremely high mechanical locking force and sealing performance, and uniform stress distribution, avoiding local stress concentration. This structural design is the basis for achieving high-efficiency and high-quality automated assembly, and effectively avoids the risk of bolt loosening or clamp failure.

[0010] Furthermore, the breathing protection device includes a respirator and a filter integrated on the respirator, the filter being made of a polymer material; the respirator is configured in a self-cleaning mode: during braking, the gas in the cavity above the diaphragm is discharged through the respirator, and the discharged airflow backwashes the filter.

[0011] In the aforementioned structure, the breathing protection device is not merely a simple filter. Its innovation lies in utilizing the self-cleaning function of the brake chamber's own working cycle. Specifically, when the service brake is released, the upper chamber of the diaphragm (atmospheric chamber) draws in air due to negative pressure, and the polymer filter effectively blocks external dust. During the next braking, the air in this chamber is rapidly compressed and expelled, forming a strong reverse airflow that blows away dust adhering to the filter's outer surface, thus regenerating the filter. This design requires no additional power, achieving maintenance-free operation and a long lifespan for the filter, ensuring a consistently unobstructed breathing passage.

[0012] Furthermore, the stroke monitoring device includes a stroke sensor, which is fixed on the front housing; the sensing probe of the stroke sensor cooperates with the sensing structure provided on the push rod assembly, and can automatically sense the stroke of the push rod when the brake chamber is working, so as to convert the linear displacement of the push rod assembly into an electrical signal; the push rod assembly is provided with a rack, and the stroke sensor is an angular displacement stroke sensor, which is provided with a gear that meshes with the rack.

[0013] In the above structure, linear motion can be converted into rotational motion for measurement. Specifically, the rack is directly integrated into the pushrod assembly, and the angular displacement sensor and its gear are fixed to the front housing. This built-in design provides excellent protection for the sensing mechanism from external impacts and contamination by the air chamber shell. Compared to external wire-type or contact sensors, the durability and measurement stability of this structure are greatly improved, ensuring the continuous effectiveness of intelligent monitoring functions throughout the vehicle's entire lifecycle.

[0014] Furthermore, the alarm module is connected to the vehicle's electronic control unit (ECU).

[0015] In the above structure, by setting an alarm module, this product can be upgraded from an independent intelligent component to a node in the vehicle's intelligent network. Specifically, abnormal signals detected by the travel sensor (e.g., the travel value exceeds a preset threshold multiple times consecutively) can be transmitted to the vehicle ECU via CAN bus or hardwire, instead of simply illuminating a local warning light. This allows the alarm to be triggered using the standard instrument panel or central control screen in the driver's cab, making the prompts more standardized and easier for the driver to understand. Moreover, the ECU can record detailed fault codes, facilitating rapid diagnosis by maintenance personnel.

[0016] Furthermore, the middle body and piston are injection molded from a high-strength composite material in one step; the high-strength composite material is polyamide reinforced with long glass fibers or carbon fibers, with a fiber content of 30% to 45% by weight. The surface of the middle body and piston made of the high-strength composite material is provided with grid-like or radial reinforcing ribs.

[0017] In the above structure, considering that the middle body and piston of the traditional gas chamber are usually made of cast aluminum or steel, which has the disadvantages of being bulky and complicated to process, this solution innovatively uses polyamide 66 (PA66) material reinforced with long glass fiber or carbon fiber for injection molding. The selection of this material (fiber content of 30%~45%) is a balance between cost, strength and weight. Through mold design, grid-like or radial reinforcing ribs can be directly injection molded on the surface of the piston and middle body. These reinforcing ribs can not only greatly improve the rigidity and compressive strength of the components, but their smooth and precise surface can also play a guiding role, thereby eliminating the piston guide ring that must be assembled separately in the traditional design. Based on this, this structure simultaneously achieves the three major goals of weight reduction, cost reduction and simplified assembly.

[0018] Furthermore, depending on the type of brake it is adapted to, the push rod assembly can be a push disc for a wedge brake, a push rod with a connecting fork for a cam brake, or a push rod with a ball-shaped push rod for a disc brake. When adapted to a disc brake, the breathing protection device includes a vent on the front housing and a dust cover is provided outside the ball-shaped push rod of the push rod assembly.

[0019] In the aforementioned structure, for disc brake chambers where the pushrod is not exposed, the main risk of wear and contamination shifts to the spherical pushrod connecting the pushrod to the brake drive arm. Therefore, the breathing requirements of the brake chamber are reduced, and a simple vent is sufficient. The focus of protection is on the ball joint, so a flexible dust cover is added to effectively prevent mud and sand intrusion. This targeted structure avoids over-design and provides a cost-effective solution for different application scenarios while ensuring reliability.

[0020] An assembly method for an intelligent brake chamber, used for assembling the aforementioned intelligent brake chamber, includes the following steps: Step 1: Complete the pre-assembly of the driving cavity module and the parking cavity module respectively; Step 2: Align and overlap the driving cavity module and the parking cavity module, and clamp the edge of the driving diaphragm; Step 3: Apply axial pressure to press the driving cavity module and the parking cavity module together; Step 4: Apply radial pressure to the open end of the cylinder block to cause it to undergo plastic deformation and wrap around the outer edge of the front shell, thereby forming an integrated press-fit structure and completing the assembly.

[0021] In the above assembly method, by applying an axial pressure no less than the maximum service braking thrust before riveting, the edge of the service diaphragm can be firmly pressed onto the sealing surface. Furthermore, it simulates the state of the air chamber under extreme operating conditions, eliminating assembly gaps in all internal parts. Performing the final radial riveting under this pre-tightened state ensures optimal internal stress state of the assembled product, resulting in excellent airtightness. This method transforms traditional multi-station, multi-process manual assembly into single-station automated pressing, effectively improving assembly efficiency and quality.

[0022] The beneficial effects achieved by this invention are: Intelligent and highly safe: By integrating a stroke sensor, the brake chamber has the ability to sense its working status; when the brake clearance self-adjustment function fails and causes abnormal stroke, it can automatically alarm in time to remind the driver to check and repair, thereby eliminating major safety hazards and improving driving safety.

[0023] High reliability and long service life: The added breathing protection device can effectively prevent water and dust from entering the engine compartment, protect the push rod seals, and prevent contaminants from entering the brake. This significantly improves the sealing performance and operational reliability of the brake chamber and the entire brake, and extends its service life.

[0024] Simplified structure and high integration: The integrated press-fit connection eliminates the need for multiple sets of bolts, nuts, washers and clamps, greatly simplifying the structure and increasing integration. This effectively solves the problem of air leakage caused by loose connections or improper assembly.

[0025] Lightweight and low cost: By using high-strength composite materials to manufacture the body and piston, and optimizing the structure to eliminate the guide ring, combined with the elimination of connecting parts, the total weight of the product is significantly reduced; at the same time, the reduction in material, machining and assembly costs leads to a significant decrease in overall cost.

[0026] High-efficiency production: By using a one-time riveting assembly method and combining multiple assembly processes into one, the assembly efficiency of the assembly is effectively improved, thereby reducing manufacturing costs and ensuring the consistency of assembly quality. Attached Figure Description

[0027] Figure 1 This is a structural cross-sectional view of an embodiment of the present invention applied to a wedge brake; Figure 2 This is a structural cross-sectional view of an embodiment of the present invention applied to a cam-type (drum) brake; Figure 3 This is a structural cross-sectional view of an embodiment of the present invention applied to a disc brake; Figure 4 This is a structural cross-sectional view of the parking cavity module described in an embodiment of the present invention; Figure 5 This is a structural cross-sectional view of the wedge-shaped traveling cavity module described in an embodiment of the present invention; Figure 6 This is a structural cross-sectional view of the cam-type traveling chamber module described in an embodiment of the present invention; Figure 7 This is a structural cross-sectional view of the disc-type traveling cavity module described in an embodiment of the present invention; Figure 8 This is a cross-sectional view of the diaphragm spring brake chamber structure in the prior art; Figure 9 This is a cross-sectional view of the traveling chamber module structure in the diaphragm spring brake chamber of existing technology; In the diagram: 1. Cylinder block; 2. Parking spring; 3. Tie rod; 4. Piston; 5. Seal ring one; 6. Seal ring two; 7. Middle body; 8. Internal breather valve; 9. Seal ring three; 10. Wedge-type travel chamber travel diaphragm; 11. Wedge-type travel chamber push plate; 12. Wedge-type travel chamber front shell; 13. Breathing filter valve; 14. Filter screen; 15. Oil seal; 16. Wedge-type travel chamber angular displacement travel sensor; 17. Cam-type travel chamber front shell; 18. Connecting bolt; 19. Disc-type travel chamber return spring; 20. Connecting fork; 21. 1. Cam-type travel chamber angular displacement travel sensor; 22. Cam-type travel chamber travel diaphragm; 23. Cam-type travel chamber push plate; 24. Disc-type travel chamber front shell; 25. Disc-type travel chamber travel diaphragm; 26. Disc-type travel chamber return spring; 27. Disc-type travel chamber angular displacement travel sensor; 28. Spherical push rod; 29. ​​Dust cover; 30. Piston guide ring; 31. Middle body guide ring; 32. Breathing hole; 33. M8 bolt; 34. M8 nut; 35. Elastic washer; 36. Clamp bolt; 37. Clamp. Detailed Implementation

[0028] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0029] Example 1

[0030] Please refer to Figures 1 to 7 This embodiment provides an intelligent brake chamber with a modular design, consisting of a universal parking chamber module and a travel chamber module customized according to different brake types. It also includes a breathing protection device and a travel monitoring device. The travel chamber module and the parking chamber module are connected by a press-fit structure. Specifically: The parking chamber module mainly includes cylinder 1, parking spring 2, tie rod 3, piston 4, seal ring 1 5, seal ring 2 6, middle body 7, and seal ring 3 9, wherein: The cylinder body 1 is formed by stamping and stretching steel plate. Its shape is a cup-shaped structure with three cylindrical steps of different diameters. This structural design can not only accommodate the internal parts, but also provide a structural basis for subsequent press-fit connection with the traveling cavity module.

[0031] A piston 4 is slidably mounted in the lower inner cavity of cylinder 1. Piston 4 forms a dynamic seal with the inner wall of cylinder 1 through a sealing ring 5 on its outer edge, isolating the interior of cylinder 1 into an upper parking inflation chamber and a lower spring chamber. A parking spring 2 is located within the spring chamber, with one end abutting the bottom of cylinder 1 and the other end abutting the piston 4. During driving, the parking spring 2 is in a compressed state. When parking, because the air pressure in the parking chamber is zero, the parking spring 2 releases its mechanical force, driving the brake to keep the vehicle stationary. The spring chamber is connected to the outside atmosphere through an internal breather valve 8 to balance the air pressure within the spring chamber.

[0032] The middle body 7 is installed in the second cylindrical step of the cylinder 1, and forms a static seal with the inner wall of the cylinder 1 through the sealing ring 2 6 on the outer edge; the inner hole of the middle body 7 is engaged with the upper rod of the piston 4, and forms a dynamic seal through the sealing ring 3 9. This seal is used to isolate the air pressure in the driving chamber; two air ports are opened on the middle body 7, namely the air inlet of the driving chamber and the air inlet of the parking chamber.

[0033] The tie rod 3 is used to compress the parking spring 2 in the factory-shipped state of the air chamber to ensure safety; after the vehicle is assembled, the compression of the spring can be released by screwing in the tie rod 3.

[0034] The vehicle cavity module varies depending on the type of brake it is designed for: like Figure 5 The wedge-shaped travel chamber module shown includes a wedge-shaped travel chamber diaphragm 10, a wedge-shaped travel chamber push plate 11, a wedge-shaped travel chamber front shell 12, a breathing filter valve 13 (as a breathing protection device), an oil seal 15, and a wedge-shaped travel chamber angular displacement stroke sensor 16 (as a stroke monitoring device). The breathing filter valve 13 is fixed on the wedge-shaped travel chamber front shell 12, and a filter screen 14 made of polymer material is provided inside it. The wedge-shaped travel chamber push plate 11 is part of the push rod assembly, and its rod passes through the central hole of the front shell and achieves sliding sealing through the oil seal 15. A rack is machined on the rod of the wedge-shaped travel chamber push plate 11, which meshes with the gear of the wedge-shaped travel chamber angular displacement stroke sensor 16 fixed on the front shell.

[0035] like Figure 6 The cam-type travel chamber module shown includes a cam-type travel chamber front housing 17, a cam-type travel chamber travel diaphragm 22, a cam-type travel chamber push plate 23, a disc-type travel chamber return spring 26, a connecting bolt 18, a connecting rod fork 20, etc.; its push rod assembly includes a push rod connected to the connecting rod fork 20, and the push rod is also provided with a rack, which meshes with the cam-type travel chamber angular displacement stroke sensor 21 fixed on the front housing.

[0036] like Figure 7The disc-type travel chamber module shown includes a disc-type travel chamber front shell 24, a disc-type travel chamber travel diaphragm 25, a spherical push rod 28, a dust cover 29, and a disc-type travel chamber return spring 26; the main body of its push rod assembly is the spherical push rod 28; the disc-type travel chamber front shell 24 has a vent 38 as a breathing protection device, and the dust cover 29 prevents contaminants from entering the brake; the spherical push rod 28 is also equipped with a rack, which meshes with the disc-type travel chamber angular displacement travel sensor 27 fixed on the front shell.

[0037] The assembly method for the above-mentioned brake chamber is as follows: Step 1: Complete the pre-assembly of the driving cavity module and the parking cavity module respectively.

[0038] Step 2: Align and overlap the pre-assembled driving cavity module and parking cavity module, and clamp the edge of the driving diaphragm, wherein: The outer edge of the front shell of the driving cavity module (wedge-type driving cavity front shell 12, cam-type driving cavity front shell 17 or disc-type driving cavity front shell 24) forms a first flange edge, and the upper opening of the cylinder 1 of the parking cavity module forms a cylindrical second flange edge with a thin wall and strong plasticity; the first flange edge is placed inside the second flange edge, and the edge of the driving diaphragm is sandwiched between the two.

[0039] Step 3: Using specialized tooling equipment, apply a strong axial pressure (not less than the maximum service braking thrust of the air chamber) to ensure that the middle body 7, cylinder 1, front shell and service diaphragm fit together tightly without gaps.

[0040] Step 4: Apply radial pressure from the outside to the second flange edge of cylinder body 1 using a special pressure head, causing it to curl and deform inward, ultimately tightly covering and locking the first flange edge of the front housing, forming a shape like... Figure 1 , 2 The press-fit connection structure shown in Figure 3; this structure achieves complete sealing and a robust mechanical connection without the need for any bolts or clamps 37.

[0041] The working principle of the intelligent brake chamber provided in this embodiment is as follows: Parking brake release: Before the vehicle starts, compressed air enters the parking air chamber (above piston 4) through the parking chamber air inlet. The air pressure pushes piston 4 downward, compressing parking spring 2 and releasing the braking force on the brake.

[0042] Service Braking: When the driver presses the brake pedal, compressed air enters the area below the service diaphragm through the air inlet of the service chamber, pushing the service diaphragm and push rod assembly (push disc, connecting rod fork 20 or ball push rod 28) to output thrust and achieve service braking.

[0043] Parking brake: When parking, the compressed air in the parking air chamber is released, and the parking spring 2 rebounds under its own elastic force, pushing the piston 4 upward, which in turn generates braking force through the push rod assembly to keep the vehicle stationary.

[0044] This brake chamber features intelligent and protective functions: The breathing protection function, taking a wedge brake as an example: When the service brake is released, the wedge-type service chamber pusher 11 and the wedge-type service chamber diaphragm return to their original positions, and the upper chamber volume of the wedge-type service chamber diaphragm 10 increases, drawing in air from the outside through the breathing filter valve 13. At this time, the filter screen 14 intercepts moisture and dust in the air. When the service brake is applied again, the wedge-type service chamber pusher 11 and the wedge-type service chamber diaphragm 10 quickly move upward, reducing the upper chamber volume. The gas inside the chamber is discharged at high speed from the breathing filter valve 13. This reverse airflow blows off and carries away contaminants attached to the outside of the filter screen 14, achieving regeneration or self-cleaning of the filter screen 14 and ensuring long-term effective filtration performance.

[0045] Travel monitoring and alarm function: During braking, each displacement of the pushrod assembly drives the gear of the travel sensor to rotate via its rack, causing the sensor to convert the travel magnitude into an electrical signal in real time and send it to the vehicle ECU. The ECU has a normal travel threshold set internally; under normal conditions (e.g., normal wear of the friction pads and normal compensation of the brake self-adjustment mechanism), the pushrod travel will not exceed this threshold; once the self-adjustment mechanism fails, the brake clearance will increase abnormally, causing the pushrod travel to exceed the threshold; at this time, the ECU will immediately determine that the braking system is abnormal and illuminate the malfunction indicator light on the instrument panel or issue an audible alarm to prompt the driver to check.

[0046] In addition, this brake chamber also achieves lightweight and low cost: In the parking cavity module, the middle body 7 and piston 4 are preferably made of PA66 high-strength composite material reinforced with 40%~45% long glass fiber or carbon fiber, and manufactured by one-time injection molding process; and through reasonable structural design, such as adding grid or radial reinforcing ribs, it can be ensured that its strength fully meets the usage requirements. Compared to traditional die-cast aluminum alloy ADC12, these composite materials are essentially equivalent in tensile strength and flexural strength, and even superior in toughness and impact resistance, while their density is significantly reduced. For example, 45% glass fiber reinforced PA66 has a tensile strength of 210~235MPa, a flexural strength of 340~360MPa, and a density of 1.47~1.49; 40% carbon fiber reinforced PA66 has a tensile strength of 240~270MPa, a flexural strength of 320~350MPa, and a density of 1.32~1.35; and the commonly used die-cast aluminum alloy ADC12 has a tensile strength of 230~330MPa, a flexural strength of 300~350MPa, and a density of 2.7. From the perspective of comprehensive mechanical properties, the three are basically similar, and the high-strength composite material has better toughness and impact resistance.

[0047] By using injection molding, the surface finish of the parts is high, allowing them to directly mate with the sealing rings without the need for multiple machining processes required for aluminum alloy parts (such as turning the outer diameter, inner hole, grooving, etc.). Figure 8 The additional guide rings shown are the piston guide ring 30 and the middle body guide ring 31.

[0048] In a specific embodiment, it can be calculated that: with Figure 8 and Figure 9 Compared to the existing diaphragm spring brake chamber structure shown, the brake chamber proposed in this invention eliminates 31 connecting parts (M8 bolts 33, M8 nuts 34, elastic washers 35, a total of 8 sets of 24 pieces, clamp bolts 36, clamps 37, nuts, a total of 3 pieces), as well as piston guide rings 30, middle body guide rings 31, etc., and adopts composite materials and simplified processes, which can achieve a weight reduction of 1.5Kg~2.5Kg (weight reduction of more than 20%), saving more than 12 yuan in material costs, more than 3 yuan in assembly costs, and a comprehensive cost reduction of more than 15 yuan.

[0049] Specifically: To improve the reliability of the riveting process and reduce the impact of material thermal expansion and contraction, the height of the largest cylinder on cylinder block 1 used for connecting the parking chamber module and the driving chamber module is controlled to a minimum. For wedge-type, cam-type, and disc-type diaphragm spring brake chambers, the rated stroke of the angular displacement stroke sensor is set according to different operating conditions.

[0050] It should be noted that the parts of the above solutions that are not described in detail or in an elaborate manner are all prior art, and are not improvements made by this invention to the prior art, nor are they within the protection scope of the technical solutions of this invention. Therefore, they will not be elaborated on in this article.

[0051] Of course, the above description is only a preferred embodiment of the present invention and should not be considered as limiting the scope of the embodiments of the present invention. The present invention is also not limited to the above examples, and all equivalent changes and improvements made by those skilled in the art within the scope of the present invention should fall within the patent coverage of the present invention.

Claims

1. An intelligent brake chamber, comprising a driving chamber module and a parking chamber module, wherein the driving chamber module comprises a front shell, a driving diaphragm and a push rod assembly linked with the driving diaphragm, and the parking chamber module comprises a cylinder (1), a middle body (7), a piston (4) and a parking spring (2), wherein the middle body (7) is disposed within the cylinder (1), and the piston (4) is configured to reciprocate within the cylinder (1) to compress or release the parking spring (2); Its features are, Also includes: A respiratory protection device, disposed on the front shell, is configured to connect the cavity above the diaphragm to the outside atmosphere; The trip monitoring device includes a monitoring module and an alarm module; The driving cavity module and the parking cavity module are connected by a press-fit structure.

2. The intelligent brake chamber according to claim 1, characterized in that: The press-fit structure is an integrated, non-detachable type, and is located between the front shell and the cylinder (1); The outer edge of the front shell is provided with a first flange edge, and the open end of the cylinder body (1) is provided with a malleable second flange edge, which covers and presses against the first flange edge.

3. The intelligent brake chamber according to claim 1, characterized in that: The respiratory protection device includes a respirator and a filter (14) integrated on the respirator, the filter (14) being made of a polymer material; The respirator is configured in a self-cleaning mode: during braking, the gas in the cavity above the diaphragm is discharged through the respirator, and the discharged airflow backwashes the filter (14).

4. The intelligent brake chamber according to claim 1, characterized in that: The stroke monitoring device includes a stroke sensor, which is fixed to the front housing; The push rod assembly is equipped with a rack, and the stroke sensor is an angular displacement stroke sensor, which is equipped with a gear that meshes with the rack.

5. The intelligent brake chamber according to claim 1, characterized in that: The alarm module is connected to the vehicle's electronic control unit (ECU).

6. The intelligent brake chamber according to claim 1, characterized in that: The middle body (7) and piston (4) are injection molded from high-strength composite materials in one step; The high-strength composite material is polyamide reinforced with long glass fibers or carbon fibers, with a fiber content of 30% to 45% by weight.

7. The intelligent brake chamber according to claim 6, characterized in that: The surfaces of the middle body (7) and piston (4) made of the high-strength composite material are provided with grid-like or radial reinforcing ribs.

8. The intelligent brake chamber according to claim 1, characterized in that: The push rod assembly, depending on the type of brake it is adapted to, can be a push disc for a wedge brake, a push rod with a connecting fork (20) for a cam brake, or a push rod with a ball-shaped push rod (28) for a disc brake.

9. The intelligent brake chamber according to claim 8, characterized in that: When adapted to a disc brake, the breathing protection device includes a breathing hole (38) provided on the front housing, and a dust cover (29) provided outside the spherical push rod (28) of the push rod assembly.

10. A method for assembling an intelligent brake chamber, used for assembling the intelligent brake chamber according to any one of claims 1-9, characterized in that, Includes the following steps: Step 1: Complete the pre-assembly of the driving cavity module and the parking cavity module respectively; Step 2: Align and overlap the driving cavity module and the parking cavity module, and clamp the edge of the driving diaphragm; Step 3: Apply axial pressure to press the driving cavity module and the parking cavity module together; Step 4: Apply radial pressure to the open end of the cylinder block (1) to cause it to undergo plastic deformation and wrap around the outer edge of the front shell, thereby forming an integrated press-fit structure and completing the assembly.

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