Brake Caliper Force Sensor Assembly for Tangential and Normal Detection
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Solution Overview
Problem
Current technologies face challenges in precisely measuring braking force and torque in vehicle brake systems, particularly due to the limitations of existing sensor devices that can only detect lateral or axial forces with poor precision and are not independent of clamping torque.
Innovation Solution
A device and method for simultaneous detection of tangential and normal forces at a brake caliper or vehicle wheel suspension, utilizing a force sensor assembly integrated into a compact casing that generates electrical signals representative of the detected forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If stress sensors are used to detect lateral or axial forces in brake calipers, then the device can be compact and integrated into the braking system, but the measurement precision and reliability are poor and the measurable force range is limited
Solution Approach 1:
The patent combines multiple sensor elements (strain gauges) in a bridge circuit configuration to detect both lateral and axial forces simultaneously. This merging approach enables the compact sensor device to measure both force components with high precision, resolving the contradiction between compact size and measurement accuracy.
Solution Approach 2:
The sensor device is designed to perform multiple functions: detecting lateral forces, axial forces, and calculating braking torque simultaneously. This multi-functionality allows a single compact device to provide comprehensive braking system monitoring without requiring multiple separate sensors, thereby maintaining compactness while improving measurement precision.
2Device complexity
If only lateral force sensors are used in the brake caliper, then the device structure is simplified, but the measurement results are not independent of clamping torque and precision is compromised
Solution Approach 1:
The sensor device segments the force detection into two independent components: lateral force detection and axial force detection. By using separate sensor elements for each force component and combining their outputs, the device achieves measurement independence from clamping torque while maintaining a relatively simple overall structure.
Solution Approach 2:
The patent introduces an intermediary calculation process that uses both lateral and axial force measurements to compute the true braking torque. This intermediary step eliminates the direct dependence of measurement results on clamping torque, improving reliability while keeping the physical device structure simple.
3Difficulty of detecting and measuring
If indirect calculation methods are used to determine braking torque from other measurements, then direct measurement is avoided, but the precision and reliability of braking force determination are not fully satisfied
Solution Approach 1:
The patent replaces complex mechanical direct measurement systems with an electrical sensing system using strain gauges and bridge circuits. This substitution enables precise measurement of braking forces through electrical signals while avoiding the mechanical complexity of direct force sensors, thereby improving measurement precision without excessive difficulty.
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 accurate measurement of braking force and torque by simultaneously detecting tangential and normal force components, improving the precision and reliability of braking system control.
Implementation Method 1
The force sensor assembly (3) generates a first electrical signal (Sn) representative of the normal force component (fn) and a second electrical signal (St) representative of the lateral or shear force component (ft)
Data Source
AI summary
A detection device for simultaneously detecting tangential and normal components of a force acting at a brake caliper or suspension of a vehicle wheel has a plate-shaped casing having a force sensor assembly for detecting normal and tangential force components and for generating one or more electrical signals representative of detected normal and tangential force components. The detection device has an electrical interface for conducting and making the one or more generated electrical signals available. A device and a system for determining a braking force due to action of a vehicle brake caliper and a brake caliper system with a braking force estimation function are also provided. Methods for simultaneously detecting tangential and normal components of a force acting at a brake caliper or exchanged between an axle and a suspension of the wheel and for determining a braking force due to action of a vehicle brake caliper are also provided.