Disc Brake Caliper Force Measurement via External Sensor
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Solution Overview
Problem
Existing electromechanically operated disc brakes face challenges in determining application force with high design and manufacturing complexity, and existing force sensors are prone to failure and costly to maintain due to harsh operating conditions and complex assembly.
Innovation Solution
A disc brake design that utilizes the proportional relationship between brake caliper spread and applied force, employing a single easily installed sensor attached to the outside of the caliper, which measures relative movement using a Hall sensor to minimize interference from thermal expansion and operational stresses, allowing for low-cost and low-maintenance operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If force sensors are installed inside the brake mechanism to detect clamping force, then measurement precision is improved, but device complexity and ease of repair deteriorate due to difficult access and high susceptibility to failure
Solution Approach 1:
The sensor is extracted from the internal brake mechanism and relocated to the external caliper surface. The retaining clip, originally an internal component, is repurposed as a mounting base for the sensor on the caliper's outer surface, allowing force measurement without internal installation
Solution Approach 2:
The retaining clip serves as an intermediary element between the caliper structure and the sensor. It provides a mounting interface that transfers the caliper's mechanical movement to the sensor without requiring the sensor to be integrated into the high-stress internal brake mechanism
2Measurement precision
If multiple sensors are installed on pressure pieces or adjusting spindles to measure application force, then measurement precision is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
Multiple measurement functions are merged into a single sensor system. By measuring the caliper spread (the overall expansion of the caliper body during braking), the system captures the cumulative effect of all braking forces without requiring individual sensors on each pressure piece or adjusting spindle
Solution Approach 2:
The single sensor system performs multiple measurement functions simultaneously. The caliper spread measurement provides information about application force while avoiding the need for separate sensors on various brake components, reducing both cost and complexity
3Measurement precision
If a sensor system is installed to detect clamping force in electromechanically operated disc brakes, then control precision is improved, but design and manufacturing complexity increase
Solution Approach 1:
The caliper structure itself provides the measurement function through its natural deformation during braking. The retaining clip leverages the existing caliper spread mechanism, allowing the brake system to self-report its application force without adding complex external measurement infrastructure
Solution Approach 2:
The system measures a different physical parameter (caliper spread) that correlates with application force rather than measuring force directly. This parameter change simplifies the measurement approach by using the caliper's own geometric response to braking load
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
This design reduces operational costs and maintenance efforts by using a simple, robust sensor system that provides accurate feedback on braking force with minimal interference from thermal changes and wear, enabling reliable operation with reduced assembly complexity.
Implementation Method 1
the sensor is designed as a Hall sensor in correspondence with the retaining bracket forming the base element or with a separate base element attached thereto
Data Source
AI summary
The invention relates to a disk brake comprising a brake caliper (1) which engages over a brake disk (5) and which comprises a caliper head (2) and a caliper back (3) connected thereto by tension struts (4). Brake linings (6) are received in the brake caliper, are radially secured by means of a retaining bracket (8) that extends in the axial direction of the brake disk (5) and can be forced against both sides of the brake disk (5). The disk brake further comprises an measuring device which is connected to an evaluation unit for determining the brake application force and which is designed in such a manner that the measuring device comprises two base elements that can be displaced relative each other in the direction of brake application, one of the elements being a sensor (12) and the other being a corresponding element actively connected thereto. One base element is arranged on the retaining bracket (8) which is clamped on one side of the caliper head (2) or on the caliper back (3) and the other base element is arranged on the brake caliper (1) on the side opposite the side on which the retaining bracket (8) is clamped.