Brake Caliper Load Sensor Layout for Modular EV Brake Assembly
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Solution Overview
Problem
Existing brake load measuring devices for electric motor vehicles face challenges in quality assurance during assembly, requiring complete brake system assembly for component testing, and lack a modular design that allows easy integration with vehicle electrical systems.
Innovation Solution
A structurally variable brake load measuring device with an electrical plug-in interface that can be directly connected to a vehicle's electrical system, featuring a central housing component with integrated electrical sensors and a modular design for easy verification and assembly, allowing separate testing before full brake system integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a brake load measuring device is integrated into the brake caliper, then brake load measurement capability is added, but the overall weight of the brake system increases
Solution Approach 1:
The measuring device is integrated directly into the brake caliper structure, merging the measurement function with the existing brake component. This eliminates the need for separate mounting structures and reduces overall system weight while maintaining measurement capability.
Solution Approach 2:
The brake caliper is designed to serve multiple functions: both brake application and load measurement. By making the caliper a multi-functional component that houses the measuring device, the patent avoids adding dedicated separate components, thereby reducing weight.
2Measurement precision
If the measuring device is mounted on the brake caliper, then brake load measurement is enabled, but the structural complexity of the brake system increases
Solution Approach 1:
The measuring device is merged with the brake caliper structure, combining two functions into one component. This integration reduces the number of separate parts and simplifies the overall system architecture while enabling measurement capability.
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
Enables precise measurement of braking forces/torques without media breaks, simplifies assembly and logistics, and ensures functional verification in a division-of-labor industrial process, reducing manufacturing and assembly complexities.
Implementation Method 1
a first strain gauge arranged to measure strain in a first direction and a second strain gauge arranged to measure strain in a second direction that is perpendicular to the first direction
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
In order to provide a newly improved brake load measuring device for a motor vehicle brake, a brake load sensor (8a, b, c) is inserted centrally into a transverse receiving hole (16) in a housing in alignment between the pistons (9a, b) to provide an integral piston stop, so that the pistons (9a, b) sit in mutual alignment and diametrically opposite each other on either side of the brake load sensor (8a, b, c). In a special embodiment of the invention a separated arrangement with a distanced offset Δ is proposed to protect the load measurement sensor system.