Disc brake system maintenance teaching aid

Abstract

The utility model discloses a disc brake system maintenance teaching aid belongs to the technical field of automobile teaching equipment. It includes frame main part, demonstration platform and sets up brake calliper, sub -pump push rod motor, parking push rod motor, total pump push rod motor, brake master cylinder, ABS pump, water curtain lamp area, control button etc. The teaching aid replaces hydraulic power through push rod motor, and water curtain lamp area simulates oil flow, solves the problem that the core component of brake system is shielded in traditional teaching equipment, hydraulic process is invisible, dynamic demonstration is missing. Control module assembly realizes independent control of each working condition, and cooperates with remote control module to improve operation convenience. Brake disc sample display area helps fault identification teaching. Therefore, the utility model can directly show the structure of brake system, working principle and working state under different working conditions, which helps to improve teaching efficiency and practical training effect, and is suitable for teaching and practical training of vocational colleges, technician colleges and automobile maintenance training institutions.

Description

Technical Field

[0001] This utility model belongs to the field of automotive teaching equipment technology, specifically relating to a disc brake system maintenance teaching aid. Background Technology

[0002] In the field of automotive repair education, disc brake systems, as a key component of vehicles, have always been a focus of vocational education, with instruction on their structural principles and maintenance techniques being a primary emphasis. The Beijing BJ80, as a typical rugged off-road vehicle, exhibits unique characteristics in its disc brake system due to its heavy load and complex operating conditions. These characteristics manifest in its brake caliper structure, hydraulic pipeline layout, and braking performance control, demanding a high degree of relevance and simulation in teaching equipment. Currently, most teaching equipment uses a general-purpose design, making it difficult to precisely match the braking system characteristics of this vehicle model. This hinders students' ability to establish a correspondence between the vehicle model and technical principles during practical training, impacting their proficiency in actual repair operations. A significant shortcoming exists, particularly in the fault diagnosis and maintenance aspects under complex operating conditions.

[0003] Traditional teaching equipment for disc brake systems suffers from the following technical shortcomings: First, visual obstructions exist in structural demonstrations: existing teaching aids often retain the complete wheel hub and tire, obscuring core components such as the brake caliper and brake disc. Students cannot directly observe key structural details such as the fit between the brake pads and disc, and the piston movement trajectory. Even when simplified models are used, the lack of anatomical representation of actual vehicle components makes it difficult to accurately reproduce the unique structure of the Beijing BJ80 braking system, leading to a vague understanding among students of how the precision of the brake caliper and disc's fit affects braking performance. Second, the dynamic processes of the hydraulic system are not visible: information such as the flow path, pressure changes, and fluid state of the brake fluid cannot be visually presented using traditional teaching aids. Students can only infer the hydraulic transmission process from static diagrams, lacking a concrete understanding of the working principles of the master cylinder, ABS pump, and wheel cylinders, significantly impacting their understanding of brake failure, uneven braking, and other malfunction mechanisms.

[0004] Furthermore, the limited functionality and operational complexity of existing teaching equipment further reduce teaching efficiency. On the one hand, dynamic demonstration capabilities are lacking; most teaching aids can only display static structures and cannot simulate dynamic processes such as brake pad clamping and parking brake linkage, making it difficult for students to observe the synchronous relationship between mechanical actions and hydraulic changes during braking. On the other hand, switching between teaching scenarios is cumbersome; traditional teaching aids lack a centralized control system, requiring manual adjustment of multiple components when demonstrating different teaching content such as normal braking, oil change procedures, and fault simulations, which is time-consuming and prone to coordination errors. Simultaneously, there is insufficient demonstration of fault cases, lacking physical comparisons of typical faults such as brake disc wear, cracks, and deformation, making it difficult for students to quickly identify fault types during actual repairs. Therefore, developing a teaching device for the Beijing BJ80 disc brake system that enables structural visualization, dynamic demonstration of hydraulic processes, and supports centralized control has become a key requirement for addressing current teaching pain points. Utility Model Content

[0005] In view of the many problems existing in the teaching equipment in the background art, this utility model provides a disc brake system maintenance teaching tool.

[0006] To achieve the above objectives, this utility model adopts the following technical solution: a disc brake system maintenance teaching aid, comprising a frame body and a demonstration platform mounted thereon. The frame body is equipped with lockable casters. Four brake calipers are mounted on the demonstration platform, corresponding to the left and right sides of the front wheels and the left and right sides of the rear wheels, respectively. The demonstration platform is equipped with four slave cylinder push rod motors, a parking push rod motor, and a master cylinder push rod motor, used to replace the original hydraulic oil power and simulate handbrake power. The piston components of the four brake calipers are connected to the push rods of the four slave cylinder push rod motors. The two brake calipers on the right side are arranged vertically on the plane of the demonstration platform, and the two on the left side are arranged parallel to the plane of the demonstration platform, and all are equipped with... It features a brake disc, with the left rear brake caliper having a semi-split structure. The brake drum's pull cable is connected to the push rod of the parking actuator motor. The demonstration platform also includes a master cylinder and an ABS pump. The master cylinder's brake push rod is connected to the push rod of the master cylinder's push rod motor. The supply and return oil lines between the two, as well as the connections between the four brake caliper filler ports and the ABS pump outlet, are all replaced by sequential LED strips. The demonstration platform is equipped with brake buttons, an oil change button, a fault button, and a parking button. The four buttons are connected to the respective push rod motors and sequential LED strips via a control module assembly, used to simulate the working status of the brake calipers and the oil flow under braking, oil change, fault, and parking conditions.

[0007] As a further explanation and limitation of the above technical solution, the control module assembly is installed on the back of the demonstration stand, including an isolated power conversion module, a power transformer module, an interlock module, two relay modules, and a light strip controller; an external 220V AC power supply sequentially provides 12V DC power to the interlock module and the two relay modules through a leakage current protector and the isolated power conversion module. The light strip controller is connected to the power conversion module through the power transformer module and obtains 5V low-voltage power; four buttons are connected in series in the four-way control circuit between the power conversion module and the interlock module. The three output terminals of the interlock module for braking, oil change, and fault are connected to the flowing light strip through the light strip controller. The braking output terminal is electrically connected to the master cylinder push rod motor through a relay module. The four slave cylinder push rod motors are connected in parallel with the master cylinder push rod motor. The parking output terminal is electrically connected to the parking push rod motor through another relay module.

[0008] As a further supplement to the above technical solution, the demonstration stand is equipped with a brake disc sample display area, including new brake discs, brake discs with extreme wear, deformed brake discs, and brake discs with cracks.

[0009] As a further explanation of the above technical solution, the front of the demonstration stand is equipped with a panel ambient light and a title backlight, both of which are powered by a power conversion module. The panel ambient light is located at the edge of the front, and the title backlight is located in the title area.

[0010] As a further explanation of the above technical solution, a remote control module is installed on the back of the demonstration stand. This module is powered by a power conversion module, connected in parallel to the control circuit of the four buttons, and wirelessly connected to a handheld remote control.

[0011] As a further explanation of the above technical solution, the front of the demonstration stand features a two-dimensional planar schematic diagram of the brake master cylinder structure.

[0012] As a further explanation and limitation of the above technical solution, the running light strip is threaded through a transparent flexible tube and fixed to the front of the demonstration stand by a buckle.

[0013] Compared with the prior art, the present invention has the following advantages: 1. This utility model utilizes a sub-pump push rod motor, a parking push rod motor, and a master pump push rod motor to replace the original hydraulic oil power and simulate handbrake power, avoiding the complexity and danger of actual hydraulic oil operation. Trainees can clearly observe the power transmission process of the braking system. Simultaneously, a flowing light strip replaces the supply and return oil lines to simulate oil flow, making the previously difficult-to-display oil circuit conditions readily apparent, effectively solving the problem of poor visualization of oil flow in existing technologies. Furthermore, the frame body and locking casters enable convenient movement and fixation of the teaching aid, flexibly adapting to different teaching locations.

[0014] 2. This utility model features a brake disc sample display area on the demonstration stand, showcasing brake discs in various states. This helps trainees comprehensively understand the characteristics of brake discs at different stages of use, improving their fault identification and diagnosis abilities. Furthermore, the panel ambient lighting, title backlighting, and a two-dimensional diagram of the brake master cylinder structure provide more auxiliary means for teaching from both visual and knowledge explanation perspectives, enhancing the teaching effect.

[0015] 3. In terms of the control module component design, this utility model improves the system's safety and reliability by enabling independent operation of each analog circuit under different conditions through interlocking modules, thus avoiding the risk of misoperation. Simultaneously, the added remote control module overcomes the limitations of physical button operation distance, greatly facilitating operation during the teaching process and meeting the needs of different teaching scenarios. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the maintenance teaching aid for the disc brake system of this utility model; Figure 2 This is a circuit diagram of the control module component in this utility model.

[0017] In the diagram: 1. Main frame; 2. Demonstration stand; 3. Locking caster wheel; 4. Brake caliper; 5. Segment cylinder push rod motor; 6. Parking push rod motor; 7. Master cylinder push rod motor; 8. Brake disc; 9. Master cylinder; 10. ABS pump; 11. Flowing light strip; 12. Brake button; 13. Oil change button; 14. Fault button; 15. Parking button; 16. New brake disc; 17. Brake disc with extreme wear; 18. Deformed brake disc; 19. Cracked brake disc; 20. Panel ambient light; 21. Title backlight; 22. Master cylinder structural schematic diagram. Detailed Implementation

[0018] To further illustrate the technical solution of this utility model, the following description is in conjunction with the appendix. Figure 1-2 Taking the braking system of the BJ80 as an example, we will further illustrate this utility model through four embodiments. It should be noted that the brake master cylinder, ABS pump, brake caliper, and brake disc in the following embodiments are all derived from actual parts of this vehicle model. Those skilled in the art can obtain these components based on publicly available technologies related to this vehicle model; therefore, the specific structures of the aforementioned actual parts will not be described in detail. Example 1

[0019] As attached Figure 1 and 2As shown, a disc brake system maintenance teaching aid includes a frame body 1 and a demonstration platform 2 mounted on it. The bottom of the frame body 1 is equipped with lockable casters 3 for movement and fixation. Four brake calipers 4 are mounted on the demonstration platform 2, corresponding to the left and right sides of the front wheels and the left and right sides of the rear wheels, respectively. The two right-side brake calipers 4 are vertically arranged on the plane of the demonstration platform 2, while the two left-side brake calipers 4 are parallel to the plane of the demonstration platform 2. Each of the four brake calipers 4 is equipped with a brake disc 8. The demonstration platform 2 also includes four slave cylinder push rod motors 5, a parking push rod motor 6, and a master cylinder push rod motor 7. The piston components of the four brake calipers 4 are connected to the push rods of the four slave cylinder push rod motors 5. The left rear brake caliper 4 has a semi-split structure, and its brake drum cable is connected to the push rod of the parking push rod motor 6. The push rod of the master cylinder push rod motor 7 is connected to the brake push rod of the master cylinder 9. The demonstration stand 2 is equipped with an ABS pump 10. The oil supply and return lines between the brake master cylinder 9 and the ABS pump 10, as well as the connections between the four brake caliper 4 filler ports and the ABS pump 10 outlet ports, are all replaced by a sequential light strip 11. The sequential light strip 11 is threaded through a transparent flexible tube and fixed to the front of the demonstration stand 2 with clips. The demonstration stand 2 is equipped with a brake button 12, an oil change button 13, a fault button 14, and a parking button 15. Ambient lights 20 are arranged on the front edge, and a title backlight 21 is arranged in the title area. The front also features a two-dimensional schematic diagram 22 of the brake master cylinder structure. The back of the demonstration stand 2 is equipped with a control module assembly and a remote control module. The control module assembly includes an isolated power conversion module, a power transformer module, an interlock module, two relay modules, and a light strip controller for the sequential light strip 11.

[0020] As attached Figure 2 As shown, the circuit connection and design principle are as follows: The external 220V AC power supply is converted to 12V DC power through a leakage current protector and an isolated power conversion module, which powers the panel ambient light 20, the title backlight 21, the interlock module, and two relay modules respectively; the power transformer module converts the 12V DC power output from the isolated power conversion module to 5V low-voltage power to power the light strip controller. The brake button 12, oil change button 13, fault button 14, and parking button 15 are connected in series in the four-way control circuit between the isolated power conversion module and the interlock module. The brake, oil change, and fault output terminals of the interlock module are electrically connected to the flowing light strip 11 through the light strip controller. One output terminal of the brake is electrically connected to the master cylinder push rod motor 7 through one of the relay modules. At the same time, the four slave cylinder push rod motors 5 are connected in parallel with the master cylinder push rod motor 7. One output terminal of the parking is electrically connected to the parking push rod motor 6 through another relay module. This circuit design uses an interlock module to achieve independent control of each working condition, avoiding simultaneous operation; a relay module to drive each push rod motor; and a light strip controller to realize the dynamic display logic of the flowing light strip 11. Example 2

[0021] Traditional teaching equipment only displays a single brake disc structure, making it impossible for trainees to intuitively grasp different damage states such as wear limits, cracks, and deformation, resulting in insufficient fault identification capabilities during actual maintenance. This embodiment demonstrates maintenance standards and fault diagnosis criteria through multi-state samples and dynamic demonstrations. Figure 1 As shown, the specific scheme is as follows: A brake disc sample display area is set up on the demonstration table 2, including a new brake disc 16, a brake disc with extreme wear 17, a deformed brake disc 18, and a brake disc with cracks 19. Example 3

[0022] Traditional teaching aids rely solely on physical buttons for control, which limits the operating distance in multi-person teaching scenarios, and frequent manual pressing can easily lead to button wear and tear. This embodiment adds a remote control module to achieve wireless control within a 10-meter range, forming a dual control mode and improving operational convenience. Figure 2 As shown, the remote control module installed on the back of demonstration stand 2 uses a 12V 6-channel remote control switch, model QM1006, which communicates wirelessly with the handheld remote control. The power supply end is connected to the 12V output end with an isolated power conversion module, and the signal end is connected in parallel in the control circuit of the four buttons. Example 4

[0023] Traditional running light strips are directly exposed, making them susceptible to damage from impacts and bending. Furthermore, their messy wiring affects aesthetics. This embodiment uses a transparent flexible tube for protection and fixation, ensuring visual appeal while improving durability and standardization. Figure 1 As shown, the flowing light strip 11 is threaded through a transparent flexible tube and fixed to the front of the demonstration stand 2 by a buckle. The transparent flexible tube is made of aging-resistant PVC material, and the buckle is made of plastic with a spacing of 10-15cm.

[0024] Teaching demonstration process Equipment startup: When the 220V power supply is connected, the isolated power conversion module starts working. At this time, the panel ambient light 20 and the title backlight 21 light up, indicating that the equipment is ready. Braking Demonstration: Pressing the brake button 12 or the corresponding key on the handheld remote triggers the braking circuit via the interlock module. The master cylinder push rod motor 7 actuates, its push rod pushing the brake push rod of the master cylinder 9. At this time, the flowing light strip 11 simulates brake fluid flowing through the pipeline to the ABS pump 10, and then distributed to the four brake calipers 4. At the brake calipers 4, the push rod of the slave cylinder push rod motor 5 drives the piston of the brake caliper 4 to move. Under pressure, the piston pushes the inner brake pads towards the brake disc 8 and makes them fit. Simultaneously, the brake caliper 4 as a whole moves to the other side of the brake disc 8 under the action of the guide pin until the outer brake pads also fit tightly against the brake disc 8. The brake pads on both sides tightly clamp the brake disc 8, simulating the vehicle braking process and achieving a deceleration effect. At the same time, the light strip controller drives the flowing light strip 11 to display a green flowing pattern, clearly showing the path of brake fluid flowing from the master cylinder 9 through the ABS pump 10 to the brake calipers 4. After the button is released, the master cylinder push rod motor 7 and the slave cylinder push rod motor 5 reverse and reset. The brake caliper 4 piston returns to its original position under the drive of the master cylinder push rod motor 7, the brake pads separate from the brake disc 8, and the flowing light strip 11 stops flowing. Oil Change Demonstration: Press the oil change button 13 or the corresponding key on the handheld remote control to switch the interlock module to oil change mode. The LED strip controller controls the flowing LED strip 11 to circulate, simulating the cycle of brake fluid flowing from the reservoir through the master cylinder 9, ABS pump 10, to the four brake calipers 4, and then back to the reservoir. Teachers can use the brake disc sample display area to explain the relationship between oil change timing and brake disc wear, such as how excessive brake disc wear can lead to brake fluid contamination and performance degradation, requiring timely brake fluid replacement. Fault Simulation: Pressing fault button 14 or the corresponding key on the handheld remote triggers the interlock module's fault logic. The sequential light strip 11 flashes green mixed with yellow, simulating an air intake fault in the hydraulic system. At this time, the brake caliper push rod motor 5 only performs 1 / 3 of its stroke, simulating poor braking. Using the semi-sectioned left rear brake caliper 4 as an example, the instructor can explain the fault mechanism: when air enters the hydraulic system, it is compressible, causing the brake fluid pressure to be insufficiently applied to the brake caliper piston, preventing the brake pads from generating enough braking force and thus affecting braking performance. Parking Demonstration: Press the parking button 15 or the corresponding key on the handheld remote control. The interlock module drives the parking push rod motor 6 to operate. The push rod of the parking push rod motor 6 pulls the brake drum cable of the left rear brake caliper 4. Under the action of the cable, the brake shoes inside the brake drum open outward and tightly adhere to the inner wall of the brake drum, thus achieving the parking braking effect. The trainee can clearly observe the process of the brake shoes and brake drum clamping together through the half-section.

[0025] At the same time, the teacher, with the help of the master cylinder structure diagram 22, explained the structural and principle linkage between the parking brake and the service brake, such as how the parking brake locks the wheels through mechanical structure, and its synergistic role with the service brake system in the overall vehicle braking safety system. Throughout the demonstration, the interlock module, model YYS-2, ensured independent operation under each working condition, avoiding action conflicts and guaranteeing the safety and accuracy of the demonstration. The brake disc sample display area allowed for the readily available use of brake disc samples in different states, aiding in the explanation of the characteristics and countermeasures of disc braking systems under various wear and fault conditions. This strengthened the connection between theoretical knowledge and practical examples, enhancing the teaching effectiveness.

[0026] The foregoing has shown and described the main features and advantages of this utility model. It will be apparent to those skilled in the art that the specific embodiments of this utility model are not limited to the details of the exemplary embodiments described above. Furthermore, without departing from the spirit or essential characteristics of this utility model, the inventive concept and design ideas of this utility model can be implemented in other specific forms, and these should be equivalently included within the protection scope disclosed in the technical solution of this utility model. Therefore, in all respects, the embodiments should be considered exemplary and non-limiting. The scope of this utility model is defined by the appended claims rather than the foregoing description, and thus it is intended that all changes falling within the meaning and scope of the equivalent elements of the claims be included within this utility model.

[0027] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A maintenance teaching aid for a disc brake system, comprising a frame body (1) and a demonstration platform (2) mounted thereon, wherein the frame body (1) is provided with locking casters (3), and four brake calipers (4) are mounted on the demonstration platform (2), the four brake calipers (4) being the left and right sides of the front wheel and the left and right sides of the rear wheel, characterized in that: Four slave cylinder push rod motors (5), parking push rod motors (6), and master cylinder push rod motors (7) are installed on the demonstration platform (2) to replace the original hydraulic oil power and simulate handbrake power; the piston components of the four brake calipers (4) are connected to the push rods of the four slave cylinder push rod motors (5). The two brake calipers (4) on the right side are arranged vertically on the plane of the demonstration platform (2), and the two brake calipers (4) on the left side are arranged parallel to the plane of the demonstration platform (2). Brake discs (8) are installed on both. The left rear brake caliper (4) adopts a half-section structure, and the pull rope of its brake drum is connected to the push rod of the parking push rod motor (6). A master cylinder is also installed on the demonstration platform (2). (9) The brake push rod of the ABS pump (10) and the master cylinder (9) are connected to the push rod of the master cylinder push rod motor (7), and the oil supply and return lines between the two are replaced by the flowing light strip (11). The oil inlets of the four brake calipers (4) are connected to the oil outlet of the ABS pump (10) through the flowing light strip (11). A brake button (12), an oil change button (13), a fault button (14) and a parking button (15) are installed on the demonstration platform (2). The four buttons are connected to each push rod motor and the flowing light strip (11) through the control module assembly to simulate the working status and oil flow of the four brake calipers (4) under braking, oil change, fault and parking conditions.

2. The disc brake system maintenance teaching aid according to claim 1, characterized in that: The control module assembly is installed on the back of the demonstration stand (2) and includes an isolated power conversion module, a power transformer module, an interlock module, two relay modules and a light strip controller. An external 220V AC power supply passes through a leakage current protector and an isolated power conversion module to supply 12V DC power to the interlock module and the two relay modules respectively. The light strip controller is connected to the power conversion module through the power transformer module and provides it with 5V low voltage power. Four buttons are connected in series in the four-way control circuit between the power conversion module and the interlock module. The three output terminals of the interlock module for braking, oil change and fault are connected to the flowing light strip (11) through the light strip controller. The one output terminal of the interlock module for braking is electrically connected to the master pump push rod motor (7) through one of the relay modules. The four sub-pump push rod motors (5) are connected in parallel with the master pump push rod motor (7). The one output terminal of the interlock module for parking is electrically connected to the parking push rod motor (6) through another relay module.

3. The disc brake system maintenance teaching aid according to claim 1, characterized in that: A brake disc sample display area is set up on the demonstration table (2), which includes four types: new brake disc (16), brake disc with extreme wear (17), deformed brake disc (18), and brake disc with cracks (19).

4. The disc brake system maintenance teaching aid according to claim 2, characterized in that: A panel ambient light (20) and a title backlight (21) are installed on the front of the demonstration stand (2), and both are powered by a power conversion module. The panel ambient light (20) is arranged on the front edge of the demonstration stand (2), and the title backlight (21) is arranged in the title area.

5. A disc brake system maintenance teaching aid according to any one of claims 1 to 4, characterized in that: A remote control module is installed on the back of the demonstration stand (2) and is powered by a power conversion module. The remote control module is connected in parallel in the control circuit of the four buttons and its wireless communication is connected to the handheld remote control.

6. The disc brake system maintenance teaching aid according to claim 5, characterized in that: A two-dimensional planar schematic diagram (22) of the brake master cylinder structure is provided on the front of the demonstration stand (2).

7. The disc brake system maintenance teaching aid according to claim 5, characterized in that: The flowing light strip (11) is threaded through a transparent flexible tube and fixed to the front of the demonstration stand (2) by a buckle.

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