Electromechanical Brake Force Sensor Layout for Precise Brake Control
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Solution Overview
Problem
Current electromechanical braking systems lack precise control over braking force distribution and adaptation to component wear or performance changes, leading to potential inaccuracies in braking force application.
Innovation Solution
Integration of a force sensor aligned with the spindle and cup gear in the caliper assembly, which senses reaction forces and adjusts motor torque via a controller to ensure accurate braking force application, using a thrust bearing to transfer reaction forces and a load flange to stabilize the force sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a force sensor is integrated into the caliper assembly to sense reaction forces, then measurement precision of braking force is improved, but device complexity increases
Solution Approach 1:
The force sensor is integrated directly into the caliper assembly structure, merging the sensing function with the existing mechanical components. The sensor is positioned to directly measure reaction forces at the pivot point, combining force measurement capability with the brake's structural elements rather than adding a separate independent sensing system.
Solution Approach 2:
A thrust bearing is introduced as an intermediary component between the cup gear and the force sensor. This bearing transfers the reaction forces from the mechanical drive components to the force sensor, enabling accurate force measurement while isolating the sensor from direct mechanical complexity and facilitating easier integration.
2Reliability
If a thrust bearing is added to transfer reaction forces to the force sensor, then reliability of force sensing is improved, but device complexity increases
Solution Approach 1:
The thrust bearing serves as a specialized intermediary that reliably transfers axial reaction forces from the cup gear assembly to the force sensor. This component ensures accurate force transmission while maintaining rotational freedom, providing a dependable connection between the mechanical drive and the sensing element.
Solution Approach 2:
The thrust bearing performs multiple functions: it transfers reaction forces to the sensor, supports axial loads, and allows rotational movement of the cup gear. By combining these functions in a single component, the design achieves reliable force sensing without proportionally increasing complexity.
3Manufacturing precision
If the force sensor is aligned with the spindle and cup gear, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The force sensor is integrated into the existing alignment structure of the spindle and cup gear assembly. By utilizing the natural axial alignment already present in these components, the design achieves precise sensor positioning without requiring separate alignment mechanisms or complex adjustment procedures.
Solution Approach 2:
The alignment features and mounting structures are localized to specific regions where the sensor interfaces with the spindle and cup gear assembly. This concentrates the precision requirements to critical local areas rather than requiring high precision throughout the entire assembly, simplifying the overall manufacturing process.
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 control of braking force distribution across wheels, adapting to changes in component performance and wear, ensuring accurate and consistent braking, with the added benefit of reduced costs and packaging complexity using a button-type force sensor.
Implementation Method 1
A force sensor is aligned with the spindle and cup gear for sensing a reaction force applied to the piston during the braking operation
Data Source
AI summary
An assembly for an electromechanical brake of a vehicle having a caliper assembly driven by a motor includes a cup gear or a drive disk for receiving torque from the motor and transferring the torque to a spindle. A piston is coupled to the spindle or a ball ramp and moves axially relative to the spindle in response to rotation of the spindle to brake the vehicle during a braking operation. A force sensor is aligned with the spindle and cup gear for sensing a reaction force applied to the piston during the braking operation. A thrust bearing is provided for transferring the reaction force from the cup gear to the force sensor.