Brake disc wear early warning sensor device

Abstract

The utility model discloses a kind of brake disc wear early warning sensing devices, belong to brake disc technical field, its technical scheme main points include brake disc body, the surface of brake disc body right side is equipped with connecting mechanism, the front side and rear side of inside of connecting mechanism are all welded with early warning sensing mechanism, contact sensor in early warning sensing mechanism and microcontroller constitute electronic early warning structure, with the continuous wear of brake disc body, its thickness gradually reduces, mobile pipe slides under the elastic thrust of reset spring to brake disc direction, when brake disc wear reaches critical value, contact sensor is separated from brake disc, and trigger sensor will send signal to microcontroller, and early warning is sent by controller through vehicle instrument panel or siren.The whole process does not need artificial inspection, can capture wear critical state in real time, avoid brake efficiency decline, brake failure and other safety risks due to excessive wear.

Description

Technical Field

[0001] This utility model relates to the field of brake disc technology, and in particular to a brake disc wear early warning sensing device. Background Technology

[0002] The brake disc is the friction pair of a disc brake. In addition to having the strength and rigidity required as a component, it should also have the highest possible and most stable coefficient of friction, as well as appropriate wear resistance, heat resistance, heat dissipation and heat capacity.

[0003] To address the aforementioned problems, existing patents offer solutions. However, current brake discs lack a structure to warn of wear, making it difficult for drivers to detect the actual wear condition of the brake discs in a timely manner. During daily driving, the brake discs are subjected to frequent friction, and wear occurs silently without any visual indication to the driver. When the brake discs wear down to a certain extent, the braking effect will be significantly weakened because wear makes the surface of the brake discs rough or uneven, reducing the contact area with the brake pads and decreasing friction. This significantly increases the braking distance of the vehicle, making it unable to stop in time during emergency braking, thereby increasing the safety risks during driving.

[0004] Therefore, a brake disc wear early warning sensing device is proposed. Utility Model Content

[0005] The purpose of this invention is to provide a brake disc wear warning sensor, which solves the problem that existing brake discs lack a structure to warn of wear, making it difficult for drivers to detect the actual wear condition of the brake discs in a timely manner. In daily driving, the brake discs are constantly subjected to frequent friction, and wear occurs silently without the driver having any intuitive indication of the degree of wear. When the brake discs wear to a certain extent, the braking effect will be significantly weakened because wear makes the surface of the brake discs rough or uneven, reducing the contact area with the brake pads and decreasing the friction. The braking distance of the vehicle becomes significantly longer, making it impossible to stop in time during emergency braking, thereby increasing the safety risks during driving.

[0006] To achieve the above objectives, this utility model provides the following technical solution: a brake disc wear warning sensing device, comprising a brake disc body, a connecting mechanism mounted on the right side surface of the brake disc body, and warning sensing mechanisms welded to the front and rear sides of the inner side of the connecting mechanism. The warning sensing mechanism includes a limiting shell, a return spring, a moving tube, a mounting hole, a contact sensor, and a microcontroller. The limiting shell is welded to the front and rear sides of the inner side of the connecting mechanism, the return spring is mounted on the inner side of the limiting shell, the moving tube is slidably connected to the inner side of the limiting shell, the side of the return spring away from the limiting shell is fixedly connected to the surface of the moving tube, the mounting hole is opened on the side of the limiting shell away from the connecting mechanism, the contact sensor is mounted on the inner side of the mounting hole, and the microcontroller is mounted on the right side of the connecting mechanism.

[0007] Preferably, the connecting mechanism includes a connecting beam, a connecting block, a connecting screw hole, a connecting rod, an outer sleeve, a pressure spring, and a contact ring, with the connecting beam mounted on the right side surface of the brake disc body.

[0008] Preferably, the limiting shell is welded to the front and rear sides of the inner side of the connecting beam, the mounting hole is opened on the side of the limiting shell away from the connecting beam, the microcontroller is installed on the right side of the connecting beam, the connecting block is welded to the right side of the top of the connecting beam, and the connecting screw hole is opened on the inner side of the top of the connecting block.

[0009] Preferably, the connecting rods are welded to the left front side and the left rear side of the connecting beam, respectively; the outer sleeve is welded to the top and bottom of the connecting rod, respectively; the pressure spring is installed inside the outer sleeve; the contact ring is welded to the side of the pressure spring away from the outer sleeve; and the side of the contact ring away from the pressure spring is attached to the surface of the brake disc body.

[0010] Preferably, contact plates are welded to both the front and rear sides of the inner side of the connecting beam, and the surface of the contact plates is coated with an anti-wear coating.

[0011] Preferably, a mounting shell is welded to the right side of the connecting beam, and the microcontroller is installed inside the mounting shell.

[0012] Preferably, the contact ring is fitted with an anti-wear pad on the side near the brake disc body, and the anti-wear pad is made of stainless steel 304.

[0013] Preferably, a wear-resistant plate is installed on the side of the contact sensor near the brake disc body, and the wear-resistant plate is made of stainless steel 304.

[0014] Compared with the prior art, the beneficial effects of this utility model are:

[0015] 1. The connecting screw holes in the connecting mechanism of this application can be connected to the peripheral fixing structure of the braking system, such as the brake caliper bracket, through bolts to ensure that the connecting beam is stably attached to the right side surface of the brake disc body, and to prevent the device from loosening or shifting during high-speed rotation or high-frequency friction of the brake disc, thus ensuring the accuracy of subsequent wear monitoring. The pressure spring provides elastic support on the inner side of the outer sleeve, and the contact ring is attached to the surface of the brake disc body through the pressure spring, which can offset the slight vibration and thermal expansion displacement of the brake disc during operation, avoid the wear aggravated by direct hard contact between the device and the brake disc, extend the service life of the connecting mechanism, and reduce scratch damage to the surface of the brake disc body.

[0016] 2. The contact sensor and microcontroller in the warning sensing mechanism of this application form an electronic warning structure. As the brake disc body continues to wear, its thickness gradually decreases. The moving tube slides towards the brake disc under the elastic thrust of the return spring. When the wear of the brake disc reaches the critical value, the contact sensor separates from the brake disc. The trigger sensor will send a signal to the microcontroller, and the controller will issue a warning through the vehicle's instrument panel or alarm. The whole process does not require manual inspection and can capture the critical wear state in real time, avoiding safety risks such as reduced braking performance and brake failure due to excessive wear. Attached Figure Description

[0017] Figure 1 This is an overall structural diagram of the brake disc wear early warning sensing device of this utility model;

[0018] Figure 2 This is a schematic diagram of the structure of the reset spring of this utility model;

[0019] Figure 3 This is a schematic diagram of the structure of the contact sensor of this utility model;

[0020] Figure 4 This is a schematic diagram of the structure of the microcontroller of this utility model;

[0021] Figure 5 This is a schematic diagram of the outer sleeve of this utility model;

[0022] Figure 6 This is a schematic diagram of the structure of the anti-wear pad of this utility model.

[0023] In the diagram, 1. Brake disc body; 2. Connecting mechanism; 21. Connecting beam; 22. Connecting block; 23. Connecting screw hole; 24. Connecting rod; 25. Outer sleeve; 26. Pressure spring; 27. Contact ring; 3. Warning sensing mechanism; 31. Limiting shell; 32. Return spring; 33. Moving tube; 34. Mounting hole; 35. Contact sensor; 36. Microcontroller; 4. Contact plate; 5. Mounting shell; 6. Anti-wear pad; 7. Wear-resistant plate. Detailed Implementation

[0024] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0025] Please see Figure 1-6 The present invention provides the following technical solution:

[0026] A brake disc wear warning sensing device includes a brake disc body 1. A connecting mechanism 2 is installed on the right side surface of the brake disc body 1. Warning sensing mechanisms 3 are welded to the front and rear sides of the inner side of the connecting mechanism 2. The warning sensing mechanism 3 includes a limiting shell 31, a return spring 32, a moving tube 33, a mounting hole 34, a contact sensor 35, and a microcontroller 36. The limiting shell 31 is welded to the front and rear sides of the inner side of the connecting mechanism 2, respectively. The return spring 32 is installed inside the limiting shell 31. The moving tube 33 is slidably connected to the inner side of the limiting shell 31. The side of the return spring 32 away from the limiting shell 31 is fixedly connected to the surface of the moving tube 33. The mounting hole 34 is opened on the side of the limiting shell 31 away from the connecting mechanism 2. The contact sensor 35 is installed inside the mounting hole 34. The microcontroller 36 is installed on the right side of the connecting mechanism 2.

[0027] In this embodiment: By setting the brake disc body 1 as the core friction component of the vehicle braking system, it provides an installation base for the connecting mechanism 2 and the warning sensing mechanism 3. Braking force is generated through friction with the brake pads, enabling vehicle deceleration or stopping. The limiting shell 31 provides installation space and motion guidance for components such as the return spring 32 and the moving tube 33, limiting the range of motion of each component. The return spring 32 provides a continuous elastic force to the moving tube 33, ensuring that the moving tube 33 always tends to move towards the brake disc body 1. When the brake disc body 1 wears and its thickness decreases, the moving tube 33 can follow up promptly under the action of the return spring 32, ensuring a sensitive response to changes in brake disc wear. The moving tube 33 can slide within the limiting shell 31, and its position change directly reflects the degree of wear of the brake disc body 1. When the brake disc is not worn or has minimal wear, the moving tube... The moving tube 33 is blocked by the brake disc body 1 and is in a specific position. When the brake disc wears to a certain extent, the moving tube 33 moves under the action of the return spring 32, thereby triggering the subsequent warning action. The mounting hole 34 provides a precise installation position for the contact sensor 35, ensuring that the contact sensor 35 can maintain a preset relative position relationship with the moving tube 33. When the moving tube 33 moves to a position where it can no longer make contact due to brake disc wear, the contact sensor 35 can quickly sense and generate an electrical signal, converting the wear state of the brake disc into a transmittable electrical signal. The microcontroller 36 receives the electrical signal from the contact sensor 35, processes it, and can issue a warning command, such as controlling the warning light on the vehicle's instrument panel to light up or emitting an alarm sound, so as to inform the driver of the wear state of the brake disc in a timely manner, so that the driver can know in time and take corresponding measures to avoid safety accidents caused by excessive wear of the brake disc.

[0028] Specifically, such as Figure 5 , Figure 6 As shown, the connecting mechanism 2 includes a connecting beam 21, a connecting block 22, a connecting screw hole 23, a connecting rod 24, an outer sleeve 25, a pressure spring 26, and a contact ring 27. The connecting beam 21 is installed on the surface of the right side of the brake disc body 1.

[0029] Specifically, such as Figure 5 , Figure 6 As shown, the limiting shell 31 is welded to the front and rear sides of the inner side of the connecting beam 21, respectively. The mounting hole 34 is opened on the side of the limiting shell 31 away from the connecting beam 21. The microcontroller 36 is installed on the right side of the connecting beam 21. The connecting block 22 is welded to the right side of the top of the connecting beam 21. The connecting screw hole 23 is opened on the inner side of the top of the connecting block 22.

[0030] Specifically, such as Figure 5 , Figure 6As shown, the connecting rod 24 is welded to the left front side and the left rear side of the connecting beam 21, respectively. The outer sleeve 25 is welded to the top and bottom of the connecting rod 24, respectively. The pressure spring 26 is installed inside the outer sleeve 25. The contact ring 27 is welded to the side of the pressure spring 26 away from the outer sleeve 25. The side of the contact ring 27 away from the pressure spring 26 is attached to the surface of the brake disc body 1.

[0031] In this embodiment: by setting the connecting beam 21 to be directly installed on the right side surface of the brake disc body 1, it can provide support and limit the warning sensing mechanism 3, the connecting block 22, and the connecting rod 24. The connecting block 22 can be docked with external structures such as brackets or housings of the vehicle braking system. The connecting screw hole 23 can be used to detachably fix the connecting block 22 to the external structure with bolts. The connecting rod 24 can support and limit the outer sleeve 25 and the pressure spring 26. The outer sleeve 25 provides a closed installation space for the pressure spring 26. At the same time, the inner wall of the outer sleeve 25 can guide the extension and retraction movement of the pressure spring 26. The spring 26 ensures that the spring only extends and retracts axially without lateral displacement, thus ensuring that the contact ring 27 maintains a stable contact direction with the brake disc body 1. The pressure spring 26 provides continuous contact pressure to the contact ring 27 through its own elasticity, ensuring that the contact ring 27 always fits tightly against the surface of the brake disc body 1. When the brake disc thickness decreases due to wear, the spring can contract synchronously, causing the contact ring 27 to move synchronously with the surface of the brake disc, achieving adaptive contact. The contact ring 27 directly fits against the surface of the brake disc body 1, and its annular structure can increase the contact area with the brake disc, disperse the contact pressure, and avoid excessive local pressure that could cause scratches on the surface of the brake disc.

[0032] Specifically, such as Figure 1 As shown, contact plates 4 are welded to both the front and rear sides of the inner side of the connecting beam 21, and the surface of the contact plates 4 is coated with anti-wear paint.

[0033] Specifically, such as Figure 4 As shown, a mounting shell 5 is welded to the right side of the connecting beam 21, and the microcontroller 36 is installed inside the mounting shell 5.

[0034] In this embodiment: by setting the contact plate 4, the connecting beam 21 can be prevented from directly contacting the brake disc body 1. By setting the anti-wear coating, the coefficient of friction can be significantly reduced, and the scratching and wear of dust and debris on the surface of the contact plate 4 can be reduced, thus preventing the contact plate 4 from becoming thin or falling off due to long-term wear. By setting the mounting shell 5, the microcontroller 36 can be protected.

[0035] Specifically, such as Figure 6 As shown, the contact ring 27 is fitted with an anti-wear pad 6 on the side near the brake disc body 1. The anti-wear pad 6 is made of stainless steel 304.

[0036] Specifically, such as Figure 2As shown, a wear-resistant plate 7 is installed on the side of the contact sensor 35 near the brake disc body 1. The wear-resistant plate 7 is made of stainless steel 304.

[0037] In this embodiment: By setting the anti-wear pad 6, wear can be prevented from occurring after the contact ring 27 directly contacts the surface of the brake disc body 1. The anti-wear pad 6 is made of stainless steel 304. Stainless steel 304 anti-wear pad 6 has moderate hardness and is more rust-resistant and wear-resistant than ordinary carbon steel. It can serve as an intermediate buffer layer to withstand the friction between the contact ring 27 and the brake disc, avoiding direct wear between the two and extending the service life of the contact ring 27 and the brake disc body 1. By setting the wear-resistant plate 7, wear can be prevented from occurring after the contact sensor 35 directly contacts the surface of the brake disc body 1. The wear-resistant plate 7 is made of stainless steel 304. Stainless steel 304 wear-resistant plate 7 has high hardness and strong impact resistance. It can directly withstand the contact pressure and friction of the moving tube 33, avoiding direct force on the sensor probe, protecting the core components of the sensor and extending its service life.

[0038] Working principle: First, the operator fixes the connecting beam 21 to the relevant brackets of the vehicle braking system via the connecting block 22 and the connecting screw hole 23, using external bolts. Simultaneously, the connecting rods 24 on the left front and left rear sides of the connecting beam 21 drive the outer sleeve 25, pressure spring 26, and contact ring 27. Under the elastic force of the pressure spring 26, the contact ring 27 adheres to the surface of the brake disc body 1, forming an initial contact state. At this time, the anti-wear pad 6 also adheres to the surface of the brake disc body 1. Then, the normal operation and wear monitoring of the brake disc are activated. During vehicle operation, the brake disc... The brake disc body 1 rotates synchronously with the wheel, decelerating or stopping the vehicle through friction with the brake pads. During this process, the brake disc body 1 gradually wears down due to continuous friction, and its thickness slowly decreases. At this time, the pressure spring 26 extends synchronously, causing the contact ring 27 to move synchronously with the surface of the brake disc body 1, always maintaining a tight fit. Simultaneously, under the continuous elastic thrust of the return spring 32, the moving tube 33 slowly follows the brake disc as its thickness decreases, providing real-time feedback on the wear changes of the brake disc. Then, when the brake disc body 1 wears down to a preset critical thickness, the moving tube... Under the push of the return spring 32, tube 33 moves to its limit position. When the wear-resistant pad 7 separates from the brake disc body 1, the contact sensor 35 loses contact pressure and quickly converts the signal into a transmittable electrical signal. The signal is transmitted to the microcontroller 36 installed in the mounting housing 5 through a preset circuit. After receiving the electrical signal from the contact sensor 35, the microcontroller 36 verifies and processes the signal through its internal preset program algorithm. It confirms that the brake disc wear has reached the critical state requiring replacement. Subsequently, the microcontroller 36 generates a corresponding warning control command according to the adaptation requirements of the vehicle's electrical system. This command can be transmitted through the circuit to terminal devices such as the warning light, buzzer, or central control display screen on the vehicle's instrument panel. Finally, after receiving the warning command from the microcontroller 36, the vehicle terminal device will visually inform the driver that the brake disc is excessively worn by illuminating the warning light (such as a red fault light), emitting an alarm sound through the buzzer, or displaying a text prompt on the screen. After seeing or hearing the warning signal, the driver can arrange for vehicle maintenance in a timely manner and replace the worn brake disc to avoid safety accidents such as brake failure caused by excessive brake disc wear.

[0039] The above are merely preferred embodiments of the present utility model and are not intended to limit the present utility model. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A brake disc wear early warning sensor device comprising a brake disc body (1), characterized in that: A connecting mechanism (2) is installed on the right side surface of the brake disc body (1). A warning sensing mechanism (3) is welded to the front and rear sides of the inner side of the connecting mechanism (2). The warning sensing mechanism (3) includes a limiting shell (31), a return spring (32), a moving tube (33), a mounting hole (34), a contact sensor (35), and a microcontroller (36). The limiting shell (31) is welded to the front and rear sides of the inner side of the connecting mechanism (2). The return spring (32) is installed on the inner side of the limiting shell (31). The moving tube (33) is slidably connected to the inner side of the limiting shell (31). The side of the return spring (32) away from the limiting shell (31) is fixedly connected to the surface of the moving tube (33). The mounting hole (34) is opened on the side of the limiting shell (31) away from the connecting mechanism (2). The contact sensor (35) is installed on the inner side of the mounting hole (34). The microcontroller (36) is installed on the right side of the connecting mechanism (2).

2. A brake disc wear warning sensor device according to claim 1, characterised in that: The connecting mechanism (2) includes a connecting beam (21), a connecting block (22), a connecting screw hole (23), a connecting rod (24), an outer sleeve (25), a pressure spring (26), and a contact ring (27). The connecting beam (21) is installed on the surface of the right side of the brake disc body (1).

3. A brake disc wear alerting sensor device according to claim 2, characterised in that: The limiting shell (31) is welded to the front and rear sides of the inner side of the connecting beam (21), the mounting hole (34) is opened on the side of the limiting shell (31) away from the connecting beam (21), the micro controller (36) is installed on the right side of the connecting beam (21), the connecting block (22) is welded to the right side of the top of the connecting beam (21), and the connecting screw hole (23) is opened on the inner side of the top of the connecting block (22).

4. A brake disc wear alerting sensor device according to claim 2, characterised in that: The connecting rod (24) is welded to the left front side and the left rear side of the connecting beam (21) respectively. The outer sleeve (25) is welded to the top and bottom of the connecting rod (24) respectively. The pressure spring (26) is installed inside the outer sleeve (25). The contact ring (27) is welded to the side of the pressure spring (26) away from the outer sleeve (25). The side of the contact ring (27) away from the pressure spring (26) is attached to the surface of the brake disc body (1).

5. A brake disc wear warning sensor device according to claim 2, characterised in that: Contact plates (4) are welded to the front and rear sides of the inner side of the connecting beam (21), and the surface of the contact plates (4) is coated with anti-wear paint.

6. A brake disc wear warning sensor device according to claim 2, characterised in that: A mounting shell (5) is welded to the right side of the connecting beam (21), and the microcontroller (36) is installed inside the mounting shell (5).

7. A brake disc wear alert sensing device as claimed in claim 2, wherein: The contact ring (27) is fitted with an anti-wear pad (6) on the side near the brake disc body (1), and the anti-wear pad (6) is made of stainless steel 304 material.

8. A brake disc wear alert sensing device as claimed in claim 1, wherein: The contact sensor (35) has a wear-resistant plate (7) installed on the side near the brake disc body (1), and the wear-resistant plate (7) is made of stainless steel 304.

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