Electric Brake Load Sensing via Torsion Spring Deflection

A torsion spring is introduced as an intermediary element between the sun gear and input gear. The torsion spring mechanically couples these two gears while allowing relative rotation, and its deflection serves as a direct mechanical indicator of the braking force being applied. This intermediary mechanism converts the complex interaction between gears into a simple, measurable deflection of the torsion spring.

The patent replaces complex mechanical force measurement mechanisms with a magnetic position sensor that detects the angular position of the torsion spring. Instead of using mechanical linkages, levers, or force sensors to measure braking force, the system uses magnetic field interaction to non-contactly detect the spring's deflection angle, which directly correlates to the applied braking force.

The system implements a closed-loop feedback control mechanism where the magnetic position sensor continuously monitors the angular position of the torsion spring, which reflects the actual braking force being applied. This information is fed back to the controller, which compares the measured force with the desired force and adjusts the motor torque accordingly. This feedback loop enables the system to adapt to component wear and performance variations by automatically compensating for changes in the braking system's characteristics.

The load sensing device and feedback control system enable the braking system to self-regulate and self-correct. Instead of requiring external monitoring or manual adjustment for component wear, the system automatically detects changes in its own performance through the torsion spring deflection and adjusts its operation accordingly, making the system self-sufficient in maintaining optimal braking force.