Brake Pad Sensor Calibration Under Real Braking Forces
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Solution Overview
Problem
Current quality control methods for sensor-equipped brake pads are limited, as they cannot be applied to a substantial number of pads and are impractical for non-traditional types, lacking the ability to simulate real braking conditions for sensor calibration.
Innovation Solution
An automatic calibration device for sensor-equipped brake pads, featuring a fixed supporting base, control panel, pad retaining means, and mechanical stress sensors that replicate typical vehicle braking forces, including normal and shear forces, to ensure accurate calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional quality control methods are used for brake pads, then the inspection process is simple, but only a limited number of pads can be inspected and 100% quality control cannot be achieved
Solution Approach 1:
The brake pad sensor performs self-calibration by comparing its measurements against reference values stored in memory during a calibration phase, eliminating the need for complex external calibration equipment and enabling 100% quality control inspection
Solution Approach 2:
The patent replaces traditional mechanical quality control methods with an electronic sensor-based system that uses electronic signals and digital processing to measure and calibrate brake pad characteristics, enabling automated inspection of all pads
2Reliability
If sensor-equipped brake pads are manufactured, then functional monitoring capability is improved, but the calibration process becomes complex and time-consuming
Solution Approach 1:
Reference measurement values are pre-stored in memory during manufacturing, and the calibration process automatically retrieves and compares these pre-stored values during sensor calibration, significantly reducing calibration time while maintaining reliability
Solution Approach 2:
The sensor performs automatic calibration by comparing its measurements against pre-stored reference values and adjusting its output accordingly, creating a self-correcting feedback mechanism that reduces calibration time and ensures accuracy
3Manufacturing precision
If sample-based quality control is used, then the control process is simple, but it cannot be applied to a substantial number of pads and defects may be missed
Solution Approach 1:
Each brake pad sensor performs self-calibration using pre-stored reference values, enabling every pad to be inspected with high precision without requiring complex external calibration equipment, thus achieving both high manufacturing precision and high inspection throughput
Solution Approach 2:
The patent replaces mechanical sample-based inspection with an automated electronic sensor system that can rapidly measure and calibrate every brake pad produced, simultaneously achieving high precision and high throughput
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 100% quality control of brake pads by simulating real braking conditions, providing precise measurements and reports, ensuring consistent performance and reducing defects.
Implementation Method 1
a mechanical stress means generating on said pad a normal force in combination with a shear force or a normal force in combination with a torque and configured so as to reproduce the typical forces acting upon said pad during real braking of a vehicle
Data Source
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AI summary
In the device (1) for automatic calibration of sensor-equipped brake pads comprising a friction material (26) and a support plate or backplate (12), there is provided a supporting base (2) for stabilising the device (1) during the operation thereof, at least one control panel (6) for managing the device (1), a pad retaining means, a mechanical stress means generating on the pad a normal force in combination with a shear force or a normal force in combination with a torque and configured so as to reproduce the typical forces acting upon the pad during real braking of a vehicle, sensors for detecting the normal force and shear force or sensors for detecting the normal force and the torque.