Brake Caliper Torque Sensing With a Deformable Washer Interface
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Solution Overview
Problem
Existing brake force and torque detection systems face challenges in achieving precise and reliable measurements due to the complexity of designing sensors that are both sensitive and structurally sound, often resulting in either low sensitivity at low braking torques or fragility under high stresses.
Innovation Solution
A detection device comprising a first functional element in contact with the brake caliper, a second functional element in contact with the hub holder, and a sensing element within a deformable portion, which transfers and measures forces to generate an electrical signal representative of braking torque, while maintaining structural integrity and sensitivity across a wide range of torques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor is made highly deformable to increase sensitivity to acting forces, then sensitivity is improved, but structural strength deteriorates causing fragility under high stresses
Solution Approach 1:
The sensor is divided into a first functional element in contact with the brake caliper and a second functional element in contact with the hub holder, connected by a deformable portion. This segmentation allows the deformable portion to be optimized for sensitivity while the functional elements maintain structural strength.
Solution Approach 2:
Different portions of the sensor have different mechanical properties: the first and second functional elements are designed for structural strength to withstand high braking forces, while the deformable portion is designed for high sensitivity to detect small deformations. This local differentiation resolves the contradiction between overall strength and local sensitivity.
2Strength
If the sensor is made structurally sound to withstand high braking stresses, then strength is improved, but sensitivity deteriorates especially at low braking torques
Solution Approach 1:
The sensor structure separates the load-bearing functional elements from the measurement-critical deformable portion, allowing each to be optimized for its specific function without compromising the other.
Solution Approach 2:
The deformable portion is specifically engineered with local quality differences - it has controlled thickness and material properties that maximize deformation response to small forces while the overall sensor structure maintains strength through its functional elements.
3Device complexity
If indirect measurement methods are used to estimate braking torque, then device complexity is reduced, but measurement precision deteriorates
Solution Approach 1:
The patent replaces complex indirect estimation methods with a direct mechanical measurement system. The sensor directly measures the force acting on the brake caliper through controlled deformation, providing accurate braking torque data without complex calculation algorithms.
4Reliability
If a robust sensor structure is designed to withstand high stresses, then reliability is improved, but ease of manufacture deteriorates due to complexity
Solution Approach 1:
The deformable portion is designed as a thin-walled structure that is easy to manufacture using standard forming processes. This thin-walled design provides the necessary flexibility for sensitive detection while maintaining sufficient strength through optimized geometry and material selection.
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 device provides accurate and precise force measurements over a wide dynamic range, from high to low braking torques, ensuring robustness and ease of installation, enabling effective real-time braking torque detection for advanced braking systems.
Implementation Method 1
a sensing element (13) comprised in said deformable portion (120) and configured to detect said force acting on it, or a quantity related to said force, and to generate at least one electrical signal (V) dependent on the force (or on the quantity related to said force) detected by said sensing element (13)
Implementation Method 2
by virtue of the friction phenomenon which develops at the caliper-sensor interface, receive said forces acting at various points of the brake caliper generated during braking
Data Source
AI summary
A detection device is described for detecting a force acting in a detection portion of a brake caliper and representative of a braking torque acting on the brake caliper when braking. The device is adapted to being mounted between the brake caliper detection portion and a corresponding hub holder by means of fixing and clamping means. When mounted and in the absence of forces acting on it, the detection device is shaped as a washer or plate extending mainly along a reference plane. The device may have a first functional element, a second functional element, a positioning element, and a sensing element.