Brake Caliper Interface Sensor for Accurate Braking Torque Measurement
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Solution Overview
Problem
Existing technologies face challenges in accurately measuring braking force and torque applied by brake calipers, as direct measurement is difficult and indirect methods are prone to errors due to axial forces from tightening screws.
Innovation Solution
A detection device is mounted at the fixing interface between the brake caliper and the hub holder, featuring a low-friction body, a caliper-hub-holder connection element susceptible to deformation, and sensors to detect these deformations, thereby minimizing the effect of tightening forces on the measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If indirect measurement methods are used to determine braking torque, then measurement can be implemented, but measurement precision deteriorates due to axial forces from tightening screws
Solution Approach 1:
The device segments the force measurement by using a connection element that specifically measures lateral (shear) forces at the interface, separating this measurement from the axial tightening forces. The connection element is designed to be sensitive only to lateral forces while being insensitive to axial forces, thus segmenting the measurement function to achieve both measurability and precision.
Solution Approach 2:
The connection element acts as an intermediary between the brake caliper and hub holder that specifically transmits and measures lateral forces. This intermediary component isolates the measurement from the disturbing axial forces, allowing indirect measurement to be implemented while maintaining precision through the selective force transmission properties of the connection element.
2Ease of operation
If sensor devices are made miniaturized and compact, then ease of integration improves, but device complexity increases to achieve functional requirements
Solution Approach 1:
The device merges multiple functions into a single integrated unit: the connection element serves both as the mechanical connector between caliper and hub holder and as the force-sensing element. The sensor is integrated directly into the connection element structure, combining mechanical connection and measurement functions in one component, which simplifies integration while managing complexity through functional consolidation.
Solution Approach 2:
The connection element is designed with multi-functionality, serving as both a structural connector and a measurement sensor. This universal component performs mechanical fastening while simultaneously providing force measurement capabilities, reducing the need for separate components and simplifying integration into the braking system.
3Strength
If tightening forces are applied to secure brake caliper, then mechanical connection is achieved, but measurement precision deteriorates due to interference with braking force detection
Solution Approach 1:
The connection element has different local properties: it is designed to be rigid and strong in the axial direction to withstand tightening forces, while being compliant and sensitive in the lateral direction to detect braking forces. This local differentiation of mechanical properties allows the same component to achieve both strong mechanical connection and precise force detection without interference.
Solution Approach 2:
The device exploits parameter changes in the connection element's mechanical response: axial stiffness is designed to be high to resist tightening forces, while lateral stiffness is designed to be low to allow detection of braking forces. By changing the stiffness parameters in different directions, the system achieves both secure mechanical connection and accurate force measurement.
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 more accurate and reliable measurements of braking force and torque by decoupling tightening forces from braking forces, ensuring that the detected deformations represent the actual braking torque with minimal disturbance from axial forces.
Implementation Method 1
at least one sensor element (4) which is operatively connected to the caliper-hub-holder connection element (3) and which is configured to detect a deformation and/or strain present in the caliper-hub-holder connection element (3) and generate at least one electrical signal (S)
Implementation Method 2
a low-friction body (2) configured to decouple the tightening forces (generated by the tightening means) from the braking forces
Data Source
AI summary
A detection device for detecting a braking force applied by a brake caliper on a hub holder is configured to be mounted at a fastening interface between the brake caliper and the hub holder and has a low-friction body, a caliper-hub-holder connection element, a sensor element, and an electrical interface. The low-friction body puts into contact the brake caliper and the hub holder at the fixing interface. The caliper-hub-holder connection element, configured to be mechanically connected to the brake caliper and the hub holder, is susceptible of deformation. The low-friction body decouples tightening forces from the braking forces to minimize the effect of the tightening forces on the detection device. The sensor element detects strains and generates electrical signals indicative of detected strains and representative of the braking force. The electrical interface is connected to the sensor element for conducting and making available the generated electrical signals. A method and a system for determining a braking torque are also provided.