Electromechanical Brake Force Sensor Structure for Wide Force Ranges
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Solution Overview
Problem
Existing force sensors for electromechanical brakes face challenges in achieving high sensitivity and flexibility to accommodate varying force ranges without increasing complexity and cost, particularly in applications requiring higher force measurements.
Innovation Solution
A force sensor apparatus with a force-compliant element featuring 'L' shaped semiconductor strain gauges, a modular design without grooves or with reduced grooves, and a flexible circular force interface diameter, coupled with a printed circuit board and environmental seals, allows for enhanced sensitivity and adaptability to different force ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a separate force sensor is installed in the brake caliper to measure braking force, then measurement precision is improved, but device complexity and installation difficulty increase
Solution Approach 1:
The patent combines the force sensing function with the existing brake caliper structure by integrating a load cell into the brake pad mounting mechanism. This merging eliminates the need for separate force sensors and reduces system complexity while maintaining measurement capability.
Solution Approach 2:
The brake caliper structure is designed to serve multiple functions: it provides mechanical braking force application and simultaneously serves as the force measurement sensor. The load cell integrated into the mounting mechanism measures both the braking force and the pad wear force, making the structure multi-functional.
2Device complexity
If brake pad wear is measured using existing brake caliper structures, then device complexity is reduced, but measurement precision deteriorates due to inability to separate wear force from braking force
Solution Approach 1:
The patent segments the force measurement into two distinct components: braking force measurement and wear force measurement. The load cell is positioned to specifically measure the wear force component separately from the braking force, allowing precise measurement of pad wear while maintaining simple device architecture.
3Measurement precision
If multiple sensors are installed to measure both braking force and pad wear, then measurement precision is improved, but manufacturing cost and installation difficulty increase
Solution Approach 1:
The patent merges the measurement of braking force and pad wear into a single integrated load cell system. This single sensor measures both parameters simultaneously through its positioning and orientation, eliminating the need for multiple separate sensors and reducing manufacturing complexity.
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 design achieves high sensitivity and reduced stress, enabling effective force measurement in both high and low force applications with reduced assembly complexity and cost, suitable for both front and rear calipers in electromechanical brakes.
Implementation Method 1
a load cell (40) is integrated into the brake caliper (10) to measure the force applied by the brake pad (20) to the brake disc (30)
Data Source
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AI summary
In a particular embodiment, a force sensor apparatus is disclosed that includes a force-compliant element that deforms in response to applications of forces to the force sensor apparatus. The force sensor apparatus also includes a sensing element coupled to an upper region of the force-compliant element and configured to generate one or more signals indicating an amount that the force-compliant element deforms in response to the application of forces to the force sensor apparatus. The force-compliant element has a bottom region that includes a force-receiving surface and an outer region surrounding the force-receiving surface. In this example embodiment, the outer region is substantially level. In a particular embodiment, the outer region is absent any grooves. Alternatively, the outer region may have one or more small grooves.