Brake Caliper Sensing Ring for Compact Brake Force Measurement
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Solution Overview
Problem
Existing electromechanical brake calipers face challenges in integrating load sensors due to limited space and harsh operating conditions, leading to increased system size and cost.
Innovation Solution
The integration of a sensing ring with bending elements and strain gauges within the brake caliper, which transfers forces to the bending elements, allowing for accurate measurement of deformations and thus the applied brake force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a load sensor is integrated into the electromechanical brake caliper assembly, then measurement precision of brake force is improved, but device complexity increases due to additional components
Solution Approach 1:
The sensing ring is merged with the loading ring, where the loading ring serves as both a structural load-bearing component and a force transfer element. The bending elements are integrated directly into the sensing ring structure, eliminating the need for separate sensor housings and mounting mechanisms. This merging approach enables brake force measurement while avoiding additional complexity from standalone sensor assemblies.
2Measurement precision
If a load sensor is integrated into the electromechanical brake caliper assembly, then measurement precision of brake force is improved, but the available space for sensor installation is insufficient
Solution Approach 1:
The sensing ring with bending elements is nested within the existing caliper cylinder internal volume. The loading ring is positioned axially within the caliper cylinder, and the sensing ring is nested between the loading ring and the caliper bottom. This nested arrangement utilizes the existing internal space of the caliper assembly without requiring additional external volume or compromising the compact design.
3Measurement precision
If a load sensor is integrated into the electromechanical brake caliper assembly, then measurement precision of brake force is improved, but manufacturing cost increases due to additional components
Solution Approach 1:
The loading ring and sensing ring are merged into a single integrated component structure. The bending elements are formed as an integral part of the sensing ring, eliminating the need for separate sensor housings, mounting brackets, and associated fasteners. This reduction in component count directly lowers manufacturing costs while maintaining measurement functionality.
4Volume of stationary object
If a load sensor is integrated into the electromechanical brake caliper assembly, then system size is reduced by eliminating standalone sensors, but the operating conditions become more harsh due to heat and space constraints
Solution Approach 1:
The bending elements serve as intermediary structures that transfer the mechanical brake force from the loading ring to the measuring devices. This intermediary arrangement allows the measurement function to be decoupled from the high-heat zones near the friction interfaces, as the bending elements can be positioned in cooler regions of the caliper assembly while still accurately sensing the force transmitted through the loading ring.
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
This solution enables precise measurement of brake forces, reduces system size and cost, and improves the reliability of brake systems by integrating sensors directly into the caliper.
Implementation Method 1
The sensing ring includes at least one bending element which can be deformed when the force Fa is applied
Implementation Method 2
The measuring device is located at or attached to the at least one bending element of the sensing ring
Data Source
AI summary
An electromechanical brake caliper assembly includes a caliper cylinder having a proximal open end and a distal end defining a bottom, the distal end and the proximal end further defining a body axis. A loading ring is located inside the caliper cylinder and movable in an axial direction parallel to the body axis. The loading ring can receive a force Fa in operation. A sensing ring is located inside the caliper cylinder between the loading ring and the bottom and includes a bending element which can be deformed when the force Fa is applied. The loading ring is configured to transfer the force Fa to the bending element of the sensing ring, which can cause the bending element to be deformed. The sensing ring further includes at least one measuring device for the detection of deformations. The measuring device is located at or attached to the bending element.