Brake Caliper Interface Sensor for Accurate Braking Torque
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Solution Overview
Problem
Current braking force and torque measurement systems in vehicle braking systems face challenges in accurately measuring braking force and torque due to the influence of tightening forces, requiring more precise and compact sensors that can differentiate between axial and braking forces effectively.
Innovation Solution
A braking force detection device is designed with a low-friction body and a caliper-hub-holder connection element that decouples tightening forces from braking forces, using a sensor element to detect deformations and generate electrical signals representative of the braking force, allowing for accurate measurement at the fixing interface between the brake caliper and hub holder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If strain sensors are used to detect braking forces at the brake caliper support-hub interface, then braking force measurement capability is provided, but the measurement accuracy deteriorates due to heavy conditioning by tightening torque and axial forces
Solution Approach 1:
The brake caliper support is segmented into distinct functional zones: a first area that receives and isolates axial tightening forces from the screw, and a second area that transmits only braking forces to the sensor device. This segmentation allows the sensor to measure braking forces without interference from tightening forces, directly resolving the measurement accuracy problem caused by force coupling.
Solution Approach 2:
The harmful axial tightening forces are extracted and directed to a dedicated first area of the brake caliper support, separate from the second area where braking forces are transmitted to the sensor. By taking out the interfering axial forces from the measurement path, the sensor device can accurately detect only the braking forces without being heavily conditioned by tightening torque.
2Ease of operation
If compact sensor devices are used to minimize size for easy integration, then ease of installation is improved, but measurement reliability deteriorates due to difficulty in differentiating between axial and braking forces
Solution Approach 1:
Different areas of the brake caliper support are assigned different functional qualities: the first area is designed to receive and isolate axial forces, while the second area is designed to transmit only braking forces to the sensor. This local differentiation of functional qualities allows the compact sensor device to reliably distinguish between axial and braking forces based on the localized force transmission path, without requiring complex sensor design.
3Strength
If screw tightening is used to fix the brake caliper to the hub holder, then mechanical connection is achieved, but measurement accuracy deteriorates because the tightening torque creates axial forces that interfere with braking force detection
Solution Approach 1:
The brake caliper support acts as an intermediary structure with a specific geometric design that mediates between the screw tightening forces and the sensor measurement. The first area of the support receives axial forces from the screw, while the second area transmits only braking forces to the sensor device. This intermediary structure with differentiated areas allows the mechanical connection to remain strong while preventing the interference of tightening forces from reaching the sensor.
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 solution provides accurate and reliable measurement of braking torque by minimizing the effect of tightening forces, ensuring the detected deformations and strains are representative of the braking force, thus enhancing the precision and reliability of braking torque determination.
Implementation Method 1
The caliper-hub-holder connection element is susceptible to deformation so that the deformations and/or strains locally present in the caliper-hub-holder connection element depend on the overall force acting on the caliper-hub-holder connection element
Implementation Method 2
a low-friction body (2) and a caliper-hub-holder connection element (3) The low-friction body is configured to minimize the effect of tightening forces on the detection device
Data Source
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AI summary
A device 1 for detecting a braking force, applied by a brake caliper 10 on a hub holder 20, upon a braking event, and due to the braking event, is described. The device is adapted to be mounted at a fastening interface (i, ii) between the brake caliper 10 and the hub holder or brake caliper support 20, by tightening means 60 which apply a tightening force. The device 1 comprises a low-friction body 2, a caliper- hub-holder element 3, a sensor element 4, and an electrical interface 5. The low-friction body 2, in the form of a washer or discoidal plate, is adapted to be put into close contact the brake caliper 10 and the hub holder 20, at the fixing interface (i, ii). The caliper- hub-holder connection element 3 is connected and integral with the low-friction body, and is adapted to be mechanically connected, when the detection device 1 is mounted, to both the brake caliper 10 and the hub holder 20, to determine a mechanical connection through which the braking force is at least partially discharged. The caliper- hub-holder connection element 3 is susceptible of deformation so that the strains and/or stresses present in the caliper- hub-holder connection element 3 depend on the overall force acting on the caliper- hub-holder connection element 3. The low-friction body 2 is configured to decouple the tightening forces from the braking forces to minimize the effect of the tightening forces on the detection device 1 so that the deformations and/or strains of the caliper- hub-holder connection element 3 are representative of the aforesaid force derived from the braking event. The sensor element 4 is connected to the caliper- hub-holder connection element 3 and is configured to detect a strain present in the caliper- hub-holder connection element 3 and to generate at least one electrical signal S indicative of the detected strain and representative of the braking force. The electrical interface 5 is connected to the aforesaid sensor element 4 for conducting and making available said at least one generated electrical signal S. A corresponding method and system for determining a braking torque are also described.