Brake caliper hydraulic rigidity testing device

Abstract

The utility model belongs to the field of automobile brake testing, and relates to a brake caliper hydraulic rigidity testing device, which comprises an installation platform, a hydraulic rigidity testing platform and a hydraulic rigidity testing platform, and two aligning structures and a clamping structure. The two alignment structures have the function of enabling the to-be-tested position of the caliper to be in a vertical central plane, so that the plurality of displacement detection structures slide along the Y direction, and the side surfaces are locked after alignment for detecting the displacement of the to-be-tested position; the clamping structure has an X-direction adjusting function and a Y-direction adjusting function and can be adjusted in the X direction through an adjustable cushion block; a bolt hole in the adjustable clamp is matched with a test piece mounting hole in a sliding mode in the Y direction; the simulation disc adapts to test pieces with different disc diameters and disc thicknesses, and the X direction is perpendicular to the Y direction. The system is pressurized, and the displacement sensor transmits data to the test analyzer through multiple channels. Establishing a relational graph between the caliper displacement and the fluid pressure; the utility model relates to a relational graph between brake pad back plate deformation and fluid pressure. According to the hydraulic rigidity testing device, the testing precision can be improved.

Description

Technical Field

[0001] This utility model belongs to the field of automotive braking testing and relates to a brake caliper hydraulic stiffness testing device. Background Technology

[0002] Stiffness and deformation, specifically hydraulic stiffness, literally refers to the ability of a hydraulic (braking) system to resist deformation under pressure, manifested as the relationship between pressure changes and displacement changes (volume changes). Hydraulic stiffness directly impacts traditional braking performance and safety aspects such as braking response speed, pedal feel and controllability (requiring fluid volume changes), and resistance to heat fade. Recent research indicates that hydraulic stiffness has an increasingly intuitive and positive impact on analyzing vibration and low-frequency noise. For example, poor stiffness can induce vibration, tremors, and low-frequency moaning and groaning noises. Furthermore, traditional stiffness testing largely focuses on the rigidity of the brake pads themselves. New failure modes such as vibration and low-frequency noise are directly related to the deformation and stability of the brake pads, but traditional deformation testing does not test the rigidity of brake pad deformation, making it impossible to accurately analyze these non-traditional braking problems. Therefore, establishing a hydraulic stiffness testing system, increasing the accuracy of brake pad deformation testing, and establishing a corresponding stiffness evaluation system are crucial and targeted.

[0003] Currently, most industry testing methods for brake caliper stiffness use a general technical solution that only measures the axial deformation at a single point on both ends of the caliper. This lacks a lattice test of the caliper's central plane and cannot test the deformation of the brake pads themselves. Specifically, this manifests in the following technical limitations:

[0004] (1) The hydraulic stiffness testing method is limited: the current test is limited to single-point test of the cylinder head and claw along the axis of the clamp body. The influence of the irregular shape of the clamp body and the rough surface of the casting is not eliminated, and the deformation of the brake block is not measured. It is impossible to meet the requirements of high-precision calibration and accurate alignment analysis of braking performance such as vibration.

[0005] (2) Incomplete evaluation leads to evaluation error: Traditional test evaluation uses simulated single-point axis deformation, resulting in large error in test results and serious distortion of prediction results.

[0006] (3) Insufficient clamping adaptability: Due to vehicle model adaptation requirements, brake calipers have various specifications for mounting hole spacing, such as 140mm, 160mm, and 170mm. Most existing fixtures have a fixed hole spacing structure, which requires frequent fixture changes when testing different models of calipers. Furthermore, it is difficult to ensure clamping coaxiality (when the deviation is >0.5mm, the risk of axis deviation increases by 40%), which greatly affects testing efficiency and data reliability.

[0007] The aforementioned technical deficiencies have led to the heavy reliance on later-stage bench testing and real-vehicle road testing for the research and development of brake calipers. The problems are as follows:

[0008] The design iteration cycle is extended: due to the deviation between laboratory test data and actual vehicle conditions, designers need to repeatedly adjust the caliper bridge parameters, optimize the topology, and make multiple prototype molds, with the design optimization cycle lasting 3-4 months; multiple mold openings lead to a sharp increase in costs.

[0009] Therefore, developing a dedicated "hydraulic stiffness" performance testing device for brake caliper assemblies to achieve high-precision, multi-condition, and fully adaptable standardized testing has become an urgent need to break through industry technical bottlenecks and improve the reliability and comfort of braking systems. Utility Model Content

[0010] In view of this, the purpose of this utility model is to provide a brake caliper hydraulic stiffness testing device to test the hydraulic stiffness of the brake caliper, which is of great significance for performance improvement such as reducing drag, matching fluid demand, analyzing brake vibration, analyzing low-frequency noise, and topology optimization and lightweight design.

[0011] To achieve the above objectives, this utility model provides the following technical solution: a brake caliper hydraulic stiffness testing device, comprising an installation platform, adjustable alignment structures symmetrically arranged at both ends of the installation platform, and a clamping system and a simulation disc located between the two alignment structures;

[0012] Two alignment structures are adjustablely arranged at both ends of the mounting platform along the X direction by connecting bolts. Each alignment structure is provided with a sensor positioning hole and a displacement detection positioning rod that can slide along the Y direction. The displacement detection positioning rod is fixed by side fastening bolts.

[0013] The clamping structure includes an adjustable pad and an adjustable clamp. The adjustable pad adjusts the distance between the test piece mounting surface and the braking surface in the X direction through the mother-daughter pad structure. The adjustable clamp is provided with bolt holes that slide in the Y direction to accommodate test pieces with different mounting hole spacings.

[0014] In this configuration, the sensor positioning hole of the alignment structure is aligned with the center of the clamping structure to form a vertical central plane, and the X direction is orthogonal to the Y direction.

[0015] Optionally, the simulation disk can be installed on the mounting platform via a quick-change method to accommodate test pieces with different disk diameters and thicknesses.

[0016] Optionally, the testing apparatus also includes a pressure regulation system and a displacement sensor multi-channel data transmission and analysis system; the pressure regulation system includes a liquid storage tank, a pressure regulator and a flow meter, which are connected to the test piece through hydraulic lines; the multi-channel data acquisition and analysis system includes a displacement sensor, a multi-channel data acquisition and analysis instrument and a computer.

[0017] Optionally, the displacement sensors are mounted on the displacement detection and positioning rod; the multi-channel data acquisition and analysis instrument is connected to all displacement sensors via signal lines; and the computer communicates with the multi-channel data acquisition and analysis instrument to process the data.

[0018] Optionally, after the displacement detection positioning rod of the alignment structure is locked by the fastening bolt, the displacement sensor connected to its end is arranged at the following test points: outer circumference A of the outer caliper of the clamp body cylinder head, outer circumference B of the outer back plate, outer circumference D of the inner caliper, and outer circumference C of the inner back plate; inner circumference E of the outer caliper of the clamp body claw, inner circumference F of the outer back plate, inner circumference G of the inner back plate, and inner circumference H of the inner caliper.

[0019] Optionally, the adjustable fixture has a Y-axis adjustment range of 140mm, 160mm, and 170mm, and is locked after being aligned with the test piece mounting hole by sliding bolt holes.

[0020] The beneficial effects of this utility model are as follows:

[0021] 1) This utility model discloses a brake caliper hydraulic stiffness testing device, enabling accurate and realistic testing of hydraulic stiffness. Through this innovative testing method, we can deeply analyze and evaluate the design rationality of key performance parameters such as drag torque and fluid requirement. This not only helps optimize the overall design of the brake caliper and improve its performance under different operating conditions, but also provides strong analytical basis and solutions for potential fault modes and problems such as vibration and low-frequency noise that may occur during the use of end products. This further enhances user safety and driving experience.

[0022] 2) This utility model discloses a brake caliper hydraulic stiffness testing device, detailing the testing principle, the components of the testing device, and the testing guarantee conditions. The testing device consists of multiple modules, including a pressure adjustment system, a clamping and alignment unit, and a test data analysis system. Each module is meticulously designed to ensure the accuracy and reliability of the testing process. By clearly defining the testing principle and the functions and coordination of each component, this utility model provides strong support for the complete and accurate implementation of the testing method. Furthermore, the use of this testing device helps improve the first-pass yield of brake caliper assembly development, significantly shortening the development cycle and reducing the development time and costs for bench and road tests. In addition, due to its simple structure, convenient operation, and high degree of automation, the testing device is easily promoted and applied within the industry, contributing new strength to the development of automotive brake testing technology.

[0023] Other advantages, objectives, and features of this invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination and study, or may be learned from practice of this invention. The objectives and other advantages of this invention can be realized and obtained through the following description. Attached Figure Description

[0024] To make the objectives, technical solutions, and advantages of this utility model clearer, the preferred embodiments of this utility model will be described in detail below with reference to the accompanying drawings, wherein:

[0025] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0026] Figure 2 This is a flowchart of the testing process for this utility model;

[0027] Figure 3 This is a schematic diagram of the dot matrix of the caliper testing area of ​​this utility model;

[0028] Figure 4 This is a schematic diagram of the adjustable hole spacing structure of this utility model;

[0029] Figure 5 This is a schematic diagram of the data processing result curve of the test structure of this utility model.

[0030] Reference numerals in the attached drawings: 1. Installation platform; 2. Simulation disk; 3. Adjustable pad; 4. Adjustable clamp; 5. Alignment structure; 6. Brake backplate extension support; 7, 8. Test piece; 9. Fastening bolt; 10. Connecting bolt; 11. Adjusting bolt; 12. Displacement detection positioning rod; 13. Displacement sensor; 14. Multi-channel data acquisition and analysis instrument; 15. Sensor positioning hole; 16. Detailed Implementation

[0031] The following specific examples illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification. This utility model can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this utility model. It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of this utility model. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0032] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual pictures. They should not be construed as limiting the present invention. To better illustrate the embodiments of the present invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual product dimensions. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0033] In the accompanying drawings of this utility model, the same or similar reference numerals correspond to the same or similar components. In the description of this utility model, it should be understood that if terms such as "upper," "lower," "left," "right," "front," and "rear" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing this utility model 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, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting this utility model. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0034] Please see Figures 1-5 This is a brake caliper hydraulic stiffness testing device, comprising a mounting platform 1, adjustable alignment structures 5 and 6 symmetrically arranged at both ends of the mounting platform 1, and a clamping system and a simulation disk 2 located between the two alignment structures; the two alignment structures are adjustablely arranged at both ends of the mounting platform along the X direction by connecting bolts 11, each alignment structure is provided with a sensor positioning hole 16 and a displacement detection positioning rod 13 that can slide along the Y direction, the displacement detection positioning rod 13 is fixed by side fastening bolts 10; the clamping system includes adjustable pads 3 and adjustable clamps 4, the adjustable pads 3 adjust the distance between the test piece mounting surface and the brake surface along the X direction through a mother-daughter pad structure; the adjustable clamps 4 are provided with bolt holes that slide along the Y direction, and are used to adapt to test pieces with different mounting hole spacings by adjusting bolts 12; wherein, the sensor positioning hole 16 of the alignment structure is aligned with the center of the clamping system to form a vertical center plane, and the X direction is orthogonal to the Y direction.

[0035] The simulation disc 2 is installed on the mounting platform via a quick-change mechanism, adapting to test pieces with different disc diameters and thicknesses. The testing device also includes a pressure regulation system and a multi-channel data transmission and analysis system for displacement sensors. The pressure regulation system includes a liquid storage tank, a pressure regulator, and a flow meter, connected to the test piece via hydraulic lines. The multi-channel data acquisition and analysis system includes displacement sensors 14, a multi-channel data acquisition and analysis instrument 15, and a computer. The displacement sensors are mounted on displacement detection and positioning rods 13. The multi-channel data acquisition and analysis instrument 15 is connected to all displacement sensors via signal lines. The computer communicates with the multi-channel data acquisition and analysis instrument 15 to process data.

[0036] After the displacement detection positioning rod 13 of the alignment structure of this utility model is locked by the fastening bolt 10, the displacement sensor 14 connected to its end is arranged at the following test points: outer circumference A of the outer caliper of the clamp body cylinder head, outer circumference B of the outer back plate, outer circumference D of the inner caliper, outer circumference C of the inner back plate; inner circumference E of the outer caliper of the clamp body claw, inner circumference F of the outer back plate, inner circumference G of the inner back plate, and inner circumference H of the inner caliper.

[0037] The adjustable clamp 4 of this utility model has a Y-axis adjustment range of 140mm, 160mm, and 170mm, and is locked after being aligned with the test piece mounting hole by sliding bolt holes.

[0038] A method for testing the hydraulic stiffness of a brake caliper, using the brake caliper hydraulic stiffness testing device described above, wherein the test piece 9 is a brake caliper, includes the following steps:

[0039] S1, clamping and adjustment steps: Adjust the Y-axis mounting hole distance of the test piece using the adjustable clamp 4, adjust the X-axis mounting surface distance of the test piece to the brake disc using the adjustable pad 3, and clamp the test piece using the simulated disc 2 to adapt to different disc diameters and disc thicknesses.

[0040] S2, Sensor positioning steps: Adjust the position of displacement sensor 14 through the displacement sensor positioning hole on the alignment structure; and adjust the displacement detection positioning rod 13 in the X direction so that the test position is in the vertical center plane.

[0041] S3, Pressure test procedure: Apply fluid pressure of 0.5MPa and 1-12MPa to each test point of AH of the test piece respectively, and collect displacement data of each test point in real time through multi-channel data acquisition and analysis instrument 15.

[0042] S4, Data processing steps: Based on the deformation corresponding to each pressure, establish the relationship diagram between caliper displacement and fluid pressure and the relationship diagram between brake block backplate deformation and fluid pressure.

[0043] The testing and evaluation system consists of a comprehensive evaluation based on single-point hydraulic and deformation, vertical plane deformation at the center of the clamp body, and vertical deformation at the center of the inner and outer brake backplates, resulting in hydraulic and deformation curves.

[0044] The evaluation system first uses single-point hydraulic and deformation evaluation, forming hydraulic and deformation curves for each point A, B, C, D...H. Then, it comprehensively evaluates the deformation in the vertical plane at the center of the clamp body, where the clamp body deformation is calculated as (|displacement E - displacement H|) - (|displacement A - displacement D|). The system also evaluates the deformation in the vertical plane at the center of the brake backplate, where the deformation of the inner and outer backplates is calculated as (|displacement F - displacement G|) - (|displacement B - displacement C|).

[0045] Specific Implementation Example 1,

[0046] Tested brake caliper assembly with mounting hole spacing of 140, center distance from mounting surface to brake surface of 30, disc diameter of 350, and disc thickness of 32:

[0047] 1. Clamping and automatic alignment: Based on the mounting hole distance of the test part, use the adjustable clamp 4 to adjust the mating mounting hole distance to 140;

[0048] 2. Based on the distance of 30 from the mounting surface of the caliper to the braking surface, use the adjustable shim 3 to adjust the distance to 30 to match the center distance;

[0049] 3. Based on the different large arc of the caliper body and the different opening of the claw, adapt the 350×32 simulated brake disc 2 to complete the installation of the brake caliper assembly;

[0050] 4. Adjust the pressurization system: Apply a pre-pressure of 7MPa to the pressurization system 5 times to maintain the initial gap;

[0051] 5. Install and adjust displacement sensor 14: According to the displacement sensor positioning holes on the alignment structure 5 and 6, adjust the fixed displacement detection positioning rod 13, and as shown in Figure 3, make the test position in the vertical center plane, such as the test dot matrix position AH, and install the sensor.

[0052] The specific requirement is to test at 8 points simultaneously, with the test points located on the cylinder head and tail claw of the caliper, perpendicular to the center plane of the caliper.

[0053] The clamp body, cylinder head, and tail claws include the outer circumference of the outer caliper, the inner circumference of the outer caliper, the outer circumference of the inner caliper, and the inner circumference of the inner caliper.

[0054] Specifically, the inner and outer brake block backplate sensors are installed and fixed on the brake backplate extension supports 7 and 8.

[0055] 6. Each displacement sensor 14 is connected to a multi-channel data acquisition and analysis instrument 15 (8 channels or more). After adjusting and installing the displacement sensor to the zero position, use the fastening bolts 10 to fix the displacement detection positioning rod 13.

[0056] 7. Pressurization and Testing: As shown in the figure, apply the following fluid pressures at each position AH and measure the displacement in the piston sliding direction. Pressure: 0.5, 1 - 12 MPa (per 1 MPa);

[0057] 8. Collect and transmit data from each test location;

[0058] 9. Data Processing: Using a multi-channel data acquisition instrument, establish a graph showing the relationship between caliper displacement and fluid pressure; and a graph showing the relationship between brake block backplate deformation and fluid pressure.

[0059] Output single-point hydraulic pressure and deformation; optionally, the evaluation first adopts single-point hydraulic pressure and deformation evaluation, and hydraulic pressure and deformation curves are generated point by point for A, B, C, D...H respectively.

[0060] The vertical plane deformation at the center of the output clamp body and the vertical deformation at the center of the inner and outer brake backplates are comprehensively evaluated to form a hydraulic & deformation curve. The vertical plane deformation at the center of the clamp body is calculated as follows: clamp body deformation = (|displacement E - displacement H|) - (|displacement A - displacement D|); the vertical plane deformation at the center of the brake backplate is calculated as follows: inner and outer backplate deformation = (|displacement F - displacement G|) - (|displacement B - displacement C|).

[0061] Specific embodiment 2,

[0062] Tested brake caliper assembly with mounting hole spacing of 160, center distance from mounting surface to brake surface of 35, disc diameter of 380, and disc thickness of 28:

[0063] 1. Clamping and automatic alignment: Based on the mounting hole distance of the test part, use adjustable fixture 4 to adjust the mating mounting hole distance to 160;

[0064] 2. Based on the distance of 35 from the mounting surface of the caliper to the braking surface, use the adjustable shim 3 to adjust the distance to 35 to match the center distance;

[0065] 3. Based on the different large arc of the caliper body and the different opening of the claw, adapt the 380×28 simulated brake disc 2 to complete the installation of the brake caliper assembly;

[0066] 4. Perform steps 4-9 of specific embodiment 1 to complete the test.

[0067] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of this utility model and are not intended to limit it. Although this utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solution of this utility model without departing from the spirit and scope of this technical solution, and all such modifications or substitutions should be covered within the scope of the claims of this utility model.

Claims

1. A brake caliper hydraulic stiffness testing device, characterized in that: It includes an installation platform, adjustable alignment structures symmetrically arranged at both ends of the installation platform, and a clamping structure and simulation disk located between the two alignment structures; Two alignment structures are adjustablely arranged at both ends of the mounting platform along the X direction by connecting bolts. Each alignment structure is provided with a sensor positioning hole and a displacement detection positioning rod that can slide along the Y direction. The displacement detection positioning rod is fixed by side fastening bolts. The clamping structure includes an adjustable pad and an adjustable clamp. The adjustable pad adjusts the distance between the test piece mounting surface and the braking surface in the X direction through the mother-daughter pad structure. The adjustable clamp is provided with bolt holes that slide in the Y direction to accommodate test pieces with different mounting hole spacings. In this configuration, the sensor positioning hole of the alignment structure is aligned with the center of the clamping structure to form a vertical central plane, and the X direction is orthogonal to the Y direction.

2. The brake caliper hydraulic stiffness testing device according to claim 1, characterized in that: The simulation disk is installed on the mounting platform via a quick-change method, adapting to test pieces with different disk diameters and thicknesses.

3. The brake caliper hydraulic stiffness testing device according to claim 1, characterized in that: The testing apparatus also includes a pressure regulation system and a multi-channel data transmission and analysis system for displacement sensors.

4. The brake caliper hydraulic stiffness testing device according to claim 3, characterized in that: The pressure regulation system includes a liquid storage tank, a pressure regulator, and a flow meter, which are connected to the test piece via hydraulic lines.

5. The brake caliper hydraulic stiffness testing device according to claim 3, characterized in that: The multi-channel data acquisition and analysis system includes displacement sensors, a multi-channel data acquisition and analysis instrument, and a computer; the displacement sensors are mounted on displacement detection and positioning rods; the multi-channel data acquisition and analysis instrument is connected to all displacement sensors via signal lines; the computer communicates with the multi-channel data acquisition and analysis instrument to process the data.

6. The brake caliper hydraulic stiffness testing device according to claim 1, characterized in that: After the displacement detection positioning rod of the alignment structure is tightened by the fastening bolts, the displacement sensor connected to its end is arranged at the following test points: A. Outer circumference of the outer caliper of the clamp body cylinder head; B. Outer circumference of the outer back plate; D. Outer circumference of the inner caliper; C. Outer circumference of the inner back plate. The inner circumference of the outer caliper of the jaws is E, the inner circumference of the outer backplate is F, the inner circumference of the inner backplate is G, and the inner circumference of the inner caliper is H.

7. The brake caliper hydraulic stiffness testing device according to claim 1, characterized in that: The adjustable fixture has a Y-axis adjustment range of 140mm, 160mm, and 170mm, and is locked after being aligned with the test piece mounting hole by sliding bolt holes.

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