Brake Actuator Support Plate Sensing for Symmetrical Brake Force
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Solution Overview
Problem
Existing electromechanical vehicle brake systems face challenges in achieving stable and symmetrical brake force settings across opposite wheels, as current methods involving motor position and current estimation are complex, and the use of torque or force sensors is expensive and space-intensive.
Innovation Solution
A brake actuator assembly with a spindle drive and a support plate subjected to bending moments, equipped with a stress sensor, allows for accurate inference of brake force from measured bending moments, enabling symmetrical brake force setting with low tolerance, and using strain gauges for cost-effectiveness and space efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If torque or force sensors are used in the power train of the brake actuator assembly, then measurement precision of brake force is improved, but device complexity and installation space increase
Solution Approach 1:
The patent introduces a support plate as an intermediary element between the spindle drive and the brake piston. This support plate serves as a mediator that transfers the braking force while allowing stress measurement through strain gauges, avoiding the need for complex torque or force sensors in the power train.
Solution Approach 2:
The patent replaces the mechanical torque/force sensor system with a strain gauge measurement system on the support plate. This substitution uses electrical resistance changes in the strain gauges to measure stress, replacing the need for mechanical sensors and their associated complexity.
2Measurement precision
If torque or force sensors are used in the power train of the brake actuator assembly, then measurement precision of brake force is improved, but installation space occupied increases
Solution Approach 1:
The patent merges the support plate with the existing brake actuator assembly structure. The support plate is integrated into the brake caliper assembly, combining the function of supporting the spindle drive with the function of providing a measurement platform, thereby eliminating the need for separate sensor mounting space.
Solution Approach 2:
The patent uses strain gauges that can be directly applied to the surface of the support plate, creating a measurement system that copies the structural form of the support plate itself. This allows measurement functionality to be added without significant additional space, as the strain gauges conform to the existing geometry.
3Strength
If the support plate stiffness is increased to ensure reliable supporting under high brake force, then strength is improved, but measurement precision of bending moment may deteriorate
Solution Approach 1:
The patent carefully selects and optimizes the stiffness parameter of the support plate. The support plate is designed with specific dimensional parameters and material properties that provide sufficient strength to support high brake forces while maintaining enough flexibility to generate measurable bending moments for accurate force determination.
Solution Approach 2:
The patent applies strain gauges at specific locations on the support plate where the bending moment is most pronounced. By placing sensors in regions of high stress concentration, the measurement system achieves high precision even with a relatively stiff support plate structure.
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 enables precise and symmetrical brake force setting across vehicle wheels with reduced installation space requirements and cost, ensuring reliable support even under high brake forces while maintaining sensor accuracy and longevity.
Implementation Method 1
The at least one stress sensor can be a strain gauge. Strain gauges are particularly inexpensive and additionally have a small installation space requirement.
Data Source
AI summary
A brake actuator assembly for a vehicle brake, in particular an electromechanical vehicle brake, is provided, having a brake piston for a brake pad, which brake piston is movable between a retracted position and an extended position, a brake calliper, in which a space for a brake rotor is formed and in which the brake piston is movable, and a spindle drive coupled with the brake piston for moving the brake piston. A rotatably mounted spindle of the spindle drive bears axially against a support plate which is fixed in the axial direction, such that the support plate is subjected to a bending moment when the brake piston is extended, wherein at least one stress sensor for measuring the bending moment is arranged on the support plate. A method for producing a brake actuator assembly is further provided.