Brake Torque Sensor Assembly With Integrated Mounting Connection
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Solution Overview
Problem
Existing brake assemblies lack a convenient and cost-effective method to detect braking torque without altering their structure, and existing solutions for torque measurement are not stable and reliable.
Innovation Solution
A torque sensor with a high-strength metal casing and a magnetic deformation part that generates a magnetic field, integrated with a sensor chip to convert magnetic field changes into electrical signals, is fitted between the caliper support and mounting bracket, replacing traditional bolts for secure connection and torque detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a torque sensor is added to the brake assembly, then torque detection capability is improved, but device complexity and installation difficulty increase
Solution Approach 1:
The torque sensor integrates multiple functions into a single component: the casing serves as both the sensor housing and the mounting connection element that replaces traditional bolts. The deformation part is integrated into the casing wall itself, eliminating the need for separate sensor mounting hardware and simplifying the overall brake assembly structure.
Solution Approach 2:
The casing performs multiple functions simultaneously: it protects the sensor chip element, provides structural support, enables torque detection through the deformation part, and serves as the mounting connection element with fixing ends for securing the sensor to the brake assembly. This multi-functionality reduces the number of separate components needed.
2Ease of operation
If traditional bolt connections are used to secure caliper support to mounting bracket, then installation is simple, but torque detection capability is lost
Solution Approach 1:
The torque sensor merges the mounting connection function (replacing bolts) with the torque detection function into a single integrated component. The casing with its fixing ends provides the secure connection while the deformation part simultaneously enables torque measurement, eliminating the need for separate sensor mounting hardware.
Solution Approach 2:
The casing serves as both the structural mounting element (with fixing ends for secure connection) and the torque sensing element (with integrated deformation part). This multi-functionality allows the same component to both secure the caliper support to the mounting bracket and detect torque, simplifying installation while enabling measurement.
3Measurement precision
If existing torque measurement solutions are implemented, then torque detection is achieved, but reliability and stability are insufficient
Solution Approach 1:
The deformation part utilizes the natural elastic deformation properties of the casing material under torque load. The curved or contoured design of the deformation part optimizes the stress distribution and deformation characteristics, enhancing the reliability of the torque measurement while maintaining detection stability.
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 convenient installation, stable and reliable torque detection without altering the brake assembly structure, while providing secure connection and low overall cost.
Implementation Method 1
the deformation part is magnetic, and configured to generate a magnetic field
Implementation Method 2
the sensor chip element is close to the deformation part, and configured to detect a change in magnetic field caused by minute deformation experienced by the deformation part
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A torque sensor (1), having a sensor head and a transmission part (3), wherein the sensor head comprises a base (101), a sensor chip element (102) and a casing (2), the casing (2) being substantially columnar, and the casing (2) having a receiving space provided therein for receiving the base (101), the sensor chip element (102) and at least a portion of the transmission part (3), characterized in that the casing (2) is made of a high-strength metal; a first fixing end (21) and a second fixing end (22) are formed on an outer surface of the casing (2), for the purpose of mounting the torque sensor (1) on a vehicle body.