A detection device for inductive sensors in commercial vehicles

Abstract

The utility model relates to a kind of detection device of inductive sensor in commercial vehicle, belong to vehicle parts detection technical field, including pedal assembly, communication module, PCB circuit board and the power module for the power supply of entire device, and the main control module, detection circuit, state indicating module and display module on PCB circuit board.This utility model integrates pedal assembly, power module, main control module and display module in one, device can be independently completed detection without relying on whole vehicle ECU system or external power supply, it can be used in any scene, such as vehicle offline, assembly line side or after-sales maintenance site, to realize rapid diagnosis, greatly improve the flexibility and response speed of detection.

Description

Technical Field

[0001] This utility model belongs to the field of vehicle parts inspection technology, specifically relating to a detection device for inductive sensors in commercial vehicles. Background Technology

[0002] As important transportation tools, the reliability of the braking and clutch systems of commercial vehicles is directly related to driving safety. In the electronic control systems of modern commercial vehicles, inductive sensors (such as Hall sensors) are usually installed on the brake pedal and clutch pedal to monitor changes in pedal travel or state in real time and transmit signals to the vehicle's ECU to achieve control and feedback of key functions.

[0003] However, in actual production assembly and after-sales maintenance, the testing of these sensors faces numerous challenges. Currently, diagnosis mainly relies on indirect methods using the vehicle's ECU system or signal measurement using general-purpose instruments, lacking dedicated and efficient testing methods. Existing testing methods have significant shortcomings: reliance on the vehicle's power supply and ECU system complicates the testing process and makes rapid troubleshooting impossible when the vehicle is offline or partially assembled. Utility Model Content

[0004] The purpose of this utility model is to address the deficiencies in the existing technology by providing a detection device for an inductive sensor in a commercial vehicle, including a pedal assembly, a communication module, a PCB circuit board, a power supply module for powering the entire device, and a main control module, a detection circuit, a status indication module, and a display module mounted on the PCB circuit board. The pedal assembly includes a brake switch sensor detection unit and a clutch sensor detection unit. The input of the communication module is connected to the brake switch sensor to be tested installed in the brake switch sensor detection unit and the clutch sensor to be tested installed in the clutch sensor detection unit. The input of the detection circuit and the input of the status indication module are both connected to the output of the communication module. The output of the detection circuit is connected to the input port of the main control module. The display module is connected to the output of the main control module. A further improvement to this technical solution is that the pedal assembly also includes a pedal base, a brake switch bracket and a clutch bracket fixed on the pedal base, a support shaft fixed between the brake switch bracket and the clutch bracket, a brake switch sensor to be tested that can be detachably mounted on the brake switch bracket, and a clutch sensor to be tested that can be detachably mounted on the clutch bracket.

[0005] Further improvements to this technical solution include a brake switch sensor detection unit comprising a brake pedal arm assembly, a brake connecting fork, a push rod, and a brake return spring. The brake pedal arm assembly is rotatably mounted on a support shaft, and the brake return spring is sleeved on the support shaft. One end of the brake return spring is fixed to the pedal base, and the other end is fixed to the brake pedal arm assembly, providing automatic return force for the brake pedal arm assembly. The brake pedal arm assembly is connected in sequence to the push rod of the brake air chamber inside the pedal base via the brake connecting fork and the push rod.

[0006] A further improvement to this technical solution is that the clutch sensor detection unit includes a clutch pedal arm assembly, a clutch master cylinder push rod fork, a clutch master cylinder push rod, and a clutch return spring. The clutch pedal arm assembly is rotatably mounted on a support shaft, and the clutch return spring is sleeved on the support shaft. One end of the clutch return spring is fixed to the pedal base, and the other end of the clutch return spring is fixed to the clutch pedal arm assembly, providing automatic return force for the clutch pedal arm assembly. The clutch pedal arm assembly is connected to the clutch master cylinder push rod inside the pedal base via the clutch master cylinder push rod fork.

[0007] Further improvements to this technical solution include the adoption of an aviation connector for the communication module.

[0008] Further improvements to this technical solution include a detection circuit comprising a brake switch sensor detection sub-circuit and a clutch sensor detection sub-circuit. The brake switch sensor detection sub-circuit includes resistors R1 and R2. The first end of resistor R1 is connected to the output terminal of the communication module, and the second end of resistor R1 is connected to the input terminal of the main control module and the first end of resistor R2. The second end of resistor R2 is grounded. The clutch sensor detection sub-circuit includes resistors R3 and R4. The first end of resistor R3 is connected to the output terminal of the communication module, and the second end of resistor R3 is connected to the input terminal of the main control module and the first end of resistor R4. The second end of resistor R4 is grounded.

[0009] Further improvements to this technical solution include a display module comprising an LCD screen, capacitor C1, a variable resistor R5, and capacitor C2. The first pin of the LCD screen is connected to the power supply module and grounded through capacitor C1. The second pin of the LCD screen is connected to the active terminal of the variable resistor R5. The first terminal of the variable resistor R5 is grounded, and the second terminal of the variable resistor R5 is connected to the power supply module. The third to thirteenth pins of the LCD screen are all connected to the microcontroller. The fourteenth pin of the LCD screen is connected to the power supply module and grounded through capacitor C2.

[0010] Further improvements to this technical solution include a status indication module comprising a brake switch sensor indication circuit and a clutch sensor indication circuit. The brake switch sensor indication circuit comprises a resistor R6 and a diode D1. The first end of the resistor R6 is connected to the output terminal of the communication module, the second end of the resistor R6 is connected to the positive terminal of the diode D1, and the negative terminal of the diode D1 is grounded. The clutch sensor indication circuit comprises a resistor R7 and a diode D2. The first end of the resistor R7 is connected to the output terminal of the communication module, the second end of the resistor R7 is connected to the positive terminal of the diode D2, and the negative terminal of the diode D2 is grounded.

[0011] Further improvements to this technical solution include a power module comprising a step-down chip with model number R-78T5.0-1.0 / AC-TRAY.

[0012] Further improvements to this technical solution include the use of a single-chip microcomputer, model STC89C52RC-4OI-PDIP40, in the main control module.

[0013] The beneficial effects of this utility model are as follows: The device achieves integration and portability. By integrating the pedal assembly, power module, main control module, and display module into one unit, the device can independently complete the test without relying on the vehicle's ECU system or an external power source. It can be used in any scenario, such as when the vehicle is offline, at the assembly line, or at the after-sales service site, enabling rapid diagnosis and significantly improving the flexibility and response speed of the test.

[0014] Furthermore, the design principle of this utility model is reliable, the structure is simple, and it has a very wide range of application prospects.

[0015] It is evident that this utility model has outstanding substantive features and significant progress compared with the prior art, and the beneficial effects of its implementation are also obvious. Attached Figure Description

[0016] To more clearly illustrate the technical solution of this utility model, the drawings used in the description will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the detection device.

[0018] Figure 2 This is a right-side view of the detection device.

[0019] Figure 3 This is the circuit diagram of the detection device.

[0020] 111 is the pedal base, 112 is the brake switch bracket, 113 is the clutch bracket, 114 is the mounting bracket, 115 is the support shaft, 121 is the brake pedal arm assembly, 122 is the brake connecting fork, 123 is the push rod, 124 is the brake return spring, 131 is the clutch pedal arm assembly, 132 is the clutch master cylinder push rod fork, 133 is the clutch master cylinder push rod, 134 is the clutch return spring, 140 is the communication module, and 200 is the brake switch sensor to be tested. Detailed Implementation

[0021] To make the objectives, features, and advantages of this utility model more apparent and understandable, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings of the specific embodiments. Obviously, the embodiments described below are only some embodiments of this utility model, and not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0022] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

[0023] like Figure 1 , Figure 2 and Figure 3 As shown, this utility model provides a detection device for an inductive sensor in a commercial vehicle, including a pedal assembly, a communication module 140, a PCB circuit board, and a power supply module for powering the entire device, as well as a main control module, a detection circuit, a status indication module, and a display module mounted on the PCB circuit board; the pedal assembly includes a brake switch sensor detection unit and a clutch sensor detection unit, the input terminal of the communication module 140 is connected to the brake switch sensor to be detected mounted in the brake switch sensor detection unit and the clutch sensor to be detected mounted in the clutch sensor detection unit, the input terminal of the detection circuit and the input terminal of the status indication module are both connected to the output terminal of the communication module 140, and the output terminal of the detection circuit is connected to the input port of the main control module; the display module is connected to the output terminal of the main control module. The power module includes a step-down chip of model R-78T5.0-1.0 / AC-TRAY; the communication module 140 uses a standardized aviation connector of model GX16-4, which is waterproof and dustproof; the four pins of the aviation connector are defined as: brake sensor signal terminal, clutch sensor signal terminal, power positive terminal and ground terminal, respectively. The signal terminal is connected to the signal output lines of the brake switch sensor and clutch sensor under test, respectively. The power positive terminal and ground terminal provide working power to the sensors. The cables are fixed by the clamping nut at the tail of the aviation connector to prevent poor contact caused by pulling.

[0024] The main control module uses a microcontroller of model STC89C52RC-4OI-PDIP40. The microcontroller U1 is also equipped with peripheral circuits, including capacitor C3, reset button SW1, resistor R8, capacitor C4, capacitor C5, crystal oscillator X1, and capacitor C6. The first end of capacitor C3, the first end of reset button SW1, and the first end of resistor R8 are all connected to the reset pin of microcontroller U1. The second end of capacitor C3 and the second end of reset button SW1 are both connected to the VCC power supply. The second end of resistor R8 is grounded. The first end of capacitor C4 and the first end of crystal oscillator X1 are both connected to the first clock pin of microcontroller U1. The first end of capacitor C5 and the second end of crystal oscillator X1 are both connected to the second clock pin of microcontroller U1. The second ends of capacitors C4 and C5 are both grounded. The power supply pin of microcontroller U1 is connected to the VCC power supply and grounded through capacitor C6.

[0025] Specifically, the pedal assembly also includes a pedal base 111, a brake switch bracket 112 and a clutch bracket 113 fixed on the pedal base 111, and a support shaft 115 fixed between the brake switch bracket 112 and the clutch bracket 113; mounting brackets 114 are respectively provided on the brake switch bracket 112 and the clutch bracket 113, and the brake switch sensor to be tested is detachably (e.g., threaded connection) mounted on the brake switch bracket 112, and the clutch sensor to be tested is detachably mounted on the clutch bracket 113.

[0026] Furthermore, the brake switch sensor detection unit includes a brake pedal arm assembly 121, a brake connecting fork 122, a push rod 123, and a brake return spring 124. The brake pedal arm assembly 121 is rotatably mounted on the support shaft 115. The brake return spring 124 is sleeved on the support shaft 115. One end of the brake return spring 124 is fixed to the pedal base 111, and the other end is fixed to the brake pedal arm assembly 121, providing automatic return force for the brake pedal arm assembly 121. The brake pedal arm assembly 121 is connected in sequence to the push rod of the brake air chamber inside the pedal base 111 through the brake connecting fork 122 and the push rod 123. For ease of carrying, the PCB circuit board can be integrated and installed inside the pedal base 111. The display screen and the diode indicator lights of the status indicator module are both installed on the rear housing of the pedal base 111 for easy observation of the detection results.

[0027] The brake pedal arm assembly 121 adopts a seamless steel pipe welded structure, with an anti-slip pedal welded to the end. The pedal surface has transverse anti-slip grooves to increase friction. The brake pedal arm assembly 121 is rotatably mounted on the support shaft 115 in the middle via an oil-impregnated bearing. The inner ring of the bearing is interference-fitted with the support shaft 115, while the outer ring is clearance-fitted with the bushing of the pedal arm assembly, ensuring smooth rotation of the pedal arm without jamming.

[0028] The brake return spring 124 is a cylindrical helical compression spring made of 60Si2Mn. The spring is sleeved on the outside of the support shaft 115. One end is fixed to the boss of the pedal base 111 by a spring hook, and the other end is fixed to the brake pedal arm assembly 121. In its natural state, the spring is in a pre-compressed state, providing the initial return force for the pedal arm.

[0029] The brake connecting fork 122 is a forged part, hinged to one end of the transmission arm opposite the brake pedal arm in the brake pedal arm assembly 121 (the brake pedal arm and transmission arm are fixed to both ends of the bushing, and the brake pedal arm, transmission arm, and corresponding bushing are integrally formed) via a pin. A nylon bushing is installed between the pin and the connecting fork. The push rod 123 is a hollow piston rod, one end of which is threaded to the brake connecting fork 122, and the other end is connected to the push rod of the brake chamber inside the pedal base 111 via a ball joint. The ball joint can rotate 360° to avoid jamming torque when the pedal is operated. The brake chamber is a diaphragm type chamber adapted to heavy trucks to simulate the braking power transmission process of a real vehicle.

[0030] Furthermore, the clutch sensor detection unit includes a clutch pedal arm assembly 131, a clutch master cylinder push rod fork 132, a clutch master cylinder push rod 133, and a clutch return spring 134. The clutch pedal arm assembly 131 is rotatably mounted on the support shaft 115. The clutch return spring 134 is sleeved on the support shaft 115. One end of the clutch return spring 134 is fixed to the pedal base 111, and the other end of the clutch return spring 134 is fixed to the clutch pedal arm assembly 131, providing automatic return force for the clutch pedal arm assembly 131. The clutch pedal arm assembly 131 is connected to the push rod of the clutch master cylinder inside the pedal base 111 through the clutch master cylinder push rod fork 132.

[0031] The clutch pedal arm assembly 131 is symmetrically arranged with the brake pedal arm assembly 121 and is also mounted on the support shaft 115 via an oil-impregnated bearing. The clutch return spring 134 is sleeved on the support shaft 115 near the clutch bracket 113, with one end fixed to the boss of the pedal base 111 and the other end fixed to the clutch pedal arm assembly 131, providing return force to match the operating resistance characteristics of the clutch pedal. It is hinged to one end of the drive arm on the opposite side of the clutch pedal arm in the clutch master cylinder push rod fork 132 (the clutch pedal arm and drive arm are respectively fixed to both ends of the bushing, and the corresponding bushings of the clutch pedal arm, drive arm, and bushing are integrally formed). The U-shaped groove of the push rod fork is adapted to the ball head of the clutch master cylinder push rod 133, and axial fixation is achieved through a cotter pin.

[0032] The clutch master cylinder is a single-chamber hydraulic master cylinder. The master cylinder push rod is rigidly connected to the piston inside the master cylinder. When the pedal arm rotates, it pushes the push rod to reciprocate through the push rod fork, simulating the power transmission process of clutch disengagement and engagement.

[0033] In addition, the detection circuit includes a brake switch sensor detection sub-circuit and a clutch sensor detection sub-circuit. The brake switch sensor detection sub-circuit includes resistors R1 and R2. The first end of resistor R1 is connected to the output terminal of communication module 140, and the second end of resistor R1 is connected to the input terminal of the main control module and the first end of resistor R2. The second end of resistor R2 is grounded. The clutch sensor detection sub-circuit includes resistors R3 and R4. The first end of resistor R3 is connected to the output terminal of communication module 140, and the second end of resistor R3 is connected to the input terminal of the main control module and the first end of resistor R4. The second end of resistor R4 is grounded.

[0034] In addition, the display module includes an LCD screen, capacitor C1, variable resistor R5, and capacitor C2. The first pin of the LCD screen is connected to the power module and grounded through capacitor C1. The second pin of the LCD screen is connected to the active terminal of variable resistor R5. The first terminal of variable resistor R5 is grounded, and the second terminal of variable resistor R5 is connected to the power module. The third to thirteenth pins of the LCD screen are all connected to the microcontroller. The fourteenth pin of the LCD screen is connected to the power module and grounded through capacitor C2.

[0035] Furthermore, the status indication module includes a brake switch sensor indication circuit and a clutch sensor indication circuit. The brake switch sensor indication circuit includes a resistor R6 and a diode D1. The first end of the resistor R6 is connected to the output terminal of the communication module 140, the second end of the resistor R6 is connected to the positive terminal of the diode D1, and the negative terminal of the diode D1 is grounded. The clutch sensor indication circuit includes a resistor R7 and a diode D2. The first end of the resistor R7 is connected to the output terminal of the communication module 140, the second end of the resistor R7 is connected to the positive terminal of the diode D2, and the negative terminal of the diode D2 is grounded.

[0036] The working principle of the detection device is as follows: The brake switch sensor and / or clutch sensor to be tested are installed on the corresponding mounting bracket 114. When the operator depresses the pedal in the brake pedal arm assembly 121 and / or clutch pedal arm assembly 131 (simulating the action of a real vehicle pedal), the output terminal of the communication module 140 can output the detection signal detected by the sensor and output a 24V power supply containing the power supply after the brake switch (i.e., the power path formed after the brake switch is depressed) and / or the power supply after the clutch (i.e., the power path formed after the clutch is depressed), sensing the signal from the brake pedal arm assembly 121 and / or clutch pedal arm assembly 131, and then transmitting the sensed signal through an aviation connector. The signal is sent to the microcontroller via the detection circuit and displayed via diodes in the status indicator module. If the indicator light is off, it indicates an abnormality in the corresponding sensor. Simultaneously, the voltage is displayed on the screen connected to the microcontroller. Operators combine the voltage readings with the diode status to make a judgment. Specifically, when the pedal assembly is pressed, the sensor generates an electrical signal, which is transmitted to the detection circuit via the communication module (aviation connector). The detection circuit consists of a voltage divider resistor network (e.g., resistors R1 and R2 in the brake sensor sub-circuit), which reduces the sensor output signal to a safe range (from 24V to 5V) before inputting it to the main control module (STC89C52 microcontroller) for threshold judgment. The core of the status indicator module is the diode circuit (e.g., diode D1 and resistor R6 in the brake sensor indicator circuit). Under normal conditions, the sensor outputs a valid high-level signal, and current flows through the resistor to the positive terminal of the diode, causing the diode to conduct and illuminate, thus lighting the indicator light. If the sensor malfunctions (e.g., internal open circuit or short circuit), there is no signal output or insufficient signal voltage, causing the circuit current to be interrupted, the diode to fail to conduct, and the indicator light to remain off. After the test is completed, release the pedal arm. The return spring will cause the pedal arm to reset, the sensor will stop outputting signals, and the device will return to the ready state, ready for the next test.

[0037] The above description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A detection device for an inductive sensor in a commercial vehicle, characterized in that, It includes a pedal assembly, a communication module (140), a PCB circuit board and a power supply module that powers the entire device, as well as a main control module, a detection circuit, a status indication module and a display module integrated on the PCB circuit board; The pedal assembly includes a brake switch sensor detection unit and a clutch sensor detection unit. The input terminal of the communication module (140) is connected to the brake switch sensor to be detected installed in the brake switch sensor detection unit and the clutch sensor to be detected installed in the clutch sensor detection unit. The input terminal of the detection circuit and the input terminal of the status indication module are both connected to the output terminal of the communication module (140). The output terminal of the detection circuit is connected to the input port of the main control module. The display module is connected to the output of the main control module.

2. The detection device for inductive sensors in commercial vehicles according to claim 1, characterized in that, The pedal assembly also includes a pedal base (111), a brake switch bracket (112) fixed on the pedal base (111), and a clutch bracket (113). A support shaft (115) is fixed between the brake switch bracket (112) and the clutch bracket (113). The brake switch sensor to be tested is detachably mounted on the brake switch bracket (112), and the clutch sensor to be tested is detachably mounted on the clutch bracket (113).

3. The detection device for inductive sensors in commercial vehicles according to claim 2, characterized in that, The brake switch sensor detection unit includes a brake pedal arm assembly (121), a brake connecting fork (122), a push rod (123), and a brake return spring (124). The brake pedal arm assembly (121) is rotatably mounted on a support shaft (115). The brake return spring (124) is sleeved on the support shaft (115). One end of the brake return spring (124) is fixed on the pedal base (111), and the other end of the brake return spring (124) is fixed on the brake pedal arm assembly (121), providing automatic return force for the brake pedal arm assembly (121). The brake pedal arm assembly (121) is connected to the push rod of the brake air chamber inside the pedal base (111) in sequence through the brake connecting fork (122) and the push rod (123).

4. The detection device for inductive sensors in commercial vehicles according to claim 2, characterized in that, The clutch sensor detection unit includes a clutch pedal arm assembly (131), a clutch master cylinder push rod fork (132), a clutch master cylinder push rod (133), and a clutch return spring (134). The clutch pedal arm assembly (131) is rotatably mounted on a support shaft (115). The clutch return spring (134) is sleeved on the support shaft (115). One end of the clutch return spring (134) is fixed on the pedal base (111), and the other end of the clutch return spring (134) is fixed on the clutch pedal arm assembly (131), providing automatic return force for the clutch pedal arm assembly (131). The clutch pedal arm assembly (131) is connected to the push rod of the clutch master cylinder inside the pedal base (111) through the clutch master cylinder push rod fork (132).

5. The detection device for inductive sensors in commercial vehicles according to claim 1, characterized in that, The communication module (140) uses an aviation connector.

6. The detection device for an inductive sensor in a commercial vehicle according to claim 1, characterized in that, The detection circuit includes a brake switch sensor detection sub-circuit and a clutch sensor detection sub-circuit. The brake switch sensor detection sub-circuit includes resistors R1 and R2. The first end of resistor R1 is connected to the output terminal of the communication module (140), and the second end of resistor R1 is connected to the input terminal of the main control module and the first end of resistor R2. The second end of resistor R2 is grounded. The clutch sensor detection sub-circuit includes resistors R3 and R4. The first end of resistor R3 is connected to the output terminal of the communication module (140), and the second end of resistor R3 is connected to the input terminal of the main control module and the first end of resistor R4. The second end of resistor R4 is grounded.

7. The detection device for an inductive sensor in a commercial vehicle according to claim 1, characterized in that, The display module includes an LCD screen, capacitor C1, variable resistor R5, and capacitor C2. The first pin of the LCD screen is connected to the power module and grounded through capacitor C1. The second pin of the LCD screen is connected to the active terminal of variable resistor R5. The first terminal of variable resistor R5 is grounded, and the second terminal of variable resistor R5 is connected to the power module. The third to thirteenth pins of the LCD screen are all connected to the microcontroller. The fourteenth pin of the LCD screen is connected to the power module and grounded through capacitor C2.

8. The detection device for inductive sensors in commercial vehicles according to claim 1, characterized in that, The status indication module includes a brake switch sensor indication circuit and a clutch sensor indication circuit. The brake switch sensor indication circuit includes a resistor R6 and a diode D1. The first end of the resistor R6 is connected to the output terminal of the communication module (140), and the second end of the resistor R6 is connected to the positive terminal of the diode D1. The negative terminal of the diode D1 is grounded. The clutch sensor indication circuit includes a resistor R7 and a diode D2. The first end of the resistor R7 is connected to the output terminal of the communication module (140), and the second end of the resistor R7 is connected to the positive terminal of the diode D2. The negative terminal of the diode D2 is grounded.

9. The detection device for an inductive sensor in a commercial vehicle according to claim 1, characterized in that, The power module includes a step-down chip with model number R-78T5.0-1.0 / AC-TRAY.

10. The detection device for an inductive sensor in a commercial vehicle according to claim 1, characterized in that, The main control module uses a single-chip microcomputer with model number STC89C52RC-4OI-PDIP40.

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