Mobile Brake Test Stand Calibration Device Torque Arm
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Solution Overview
Problem
Existing calibration devices for brake test benches are complex to transport and assemble, prone to errors, and do not accurately measure high braking forces, leading to inadequate calibration and reliability issues.
Innovation Solution
A calibration device with a measuring wheel interacting with brake test rollers, a controllable braking device, a torque arm, and a force measuring sensor, which determines the counterforce during braking, allowing for precise measurement of braking forces without floor support, and utilizing a ramp with ballast to increase contact pressure and prevent slippage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional calibration devices are used, then they can measure braking forces, but they are complex to transport and assemble
Solution Approach 1:
The calibration device is divided into separate modular components including a frame assembly, a measuring wheel assembly, and a braking device assembly. These segments can be independently transported and assembled on-site, significantly improving ease of transport and assembly while reducing overall structural complexity.
Solution Approach 2:
A torque arm serves as an intermediary element that connects the braking device to the measuring wheel, transferring the braking force through a defined mechanical path. This intermediary component simplifies the overall structure by providing a clear force transmission path and reducing the need for complex direct connections.
2Measurement precision
If traditional calibration devices are used, then they can perform calibration, but they are prone to errors and do not accurately measure high braking forces
Solution Approach 1:
The device replaces complex mechanical force transmission systems with a simplified torque-based measurement system. The torque arm and force measuring sensor provide a direct mechanical-to-electrical conversion that reduces mechanical error sources and improves measurement accuracy for high braking forces.
Solution Approach 2:
The force measuring sensor provides real-time feedback on the braking force applied to the measuring wheel. This feedback mechanism allows for continuous monitoring and adjustment, reducing measurement errors and improving reliability by ensuring accurate force application throughout the calibration process.
3Reliability
If the measuring wheel is used without sufficient contact pressure, then the device is simpler to operate, but slippage occurs during braking
Solution Approach 1:
The device applies preliminary downward force on the measuring wheel through the frame assembly before braking begins. This pre-loading ensures sufficient contact pressure between the measuring wheel and the brake test roller, preventing slippage during the actual braking measurement while maintaining operational simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device provides accurate and reliable calibration of brake test benches, capable of measuring high braking forces with reduced error, improved ease of use, and increased robustness, ensuring precise measurement and calibration across the entire range.
Implementation Method 1
at least one force measuring sensor (20) designed to determine the counterforce acting at the support point
Implementation Method 2
utilizing a ramp with ballast to increase contact pressure and prevent slippage
Implementation Method 3
a controllable braking device (16) for controllable braking of the measuring wheel
Data Source
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AI summary
The invention relates to a calibration device (10, 110, 210, 310, 410) for a brake test stand (50) with two brake test rollers (58) mounted parallel by a distance Ar. It is proposed that the device includes at least one measuring wheel (14) cooperating with the brake test rollers (58), a braking device (16) for controllable braking of the measuring wheel (14), a torque arm (18) by which the braking device (16) is supported at a support point for dissipating a counterforce occurring during braking of the measuring wheel (14), at least one force sensor (20) designed to determine the counterforce acting at the support point, and a calibration evaluation device (22) coupled to the force sensor (20) for processing and/or displaying measured values acquired by the force sensor (20).Furthermore, a method for operating such a calibration device (10, 110, 210, 310) is proposed, which comprises the steps: - placing the calibration device (10, 110, 210, 310, 410) on the brake test stand (50), - driving the measuring wheel (14) by means of the brake test rollers (58), - actuating the brake device (16), - determining the resulting counterforce, - transmitting the measured values to the calibration evaluation device (22), and - determining a braking force by means of the calibration evaluation device (22).