Drum Brake Carrier Deformation Sensing for Braking Force Measurement
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Solution Overview
Problem
Existing drum brake systems face challenges in accurately and cost-effectively determining braking force or torque, as they often rely on complex and costly sensors in the force flow between the actuator and brake shoe.
Innovation Solution
A drum brake system with a carrier connected to a supporting bearing, equipped with a deformation sensor to measure the deformation of the carrier, which is proportional to the braking force or torque, using a ductile metal carrier that elastically deforms during braking, allowing for precise determination of braking force or torque through capacitive, inductive, piezoelectric, or resistive sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a pressure sensor is used to determine braking force in the brake cylinder, then the braking force can be calculated, but the system becomes complex and costly
Solution Approach 1:
The patent extracts the measurement function from the brake cylinder pressure sensor system and relocates it to the carrier structure. The carrier itself becomes the sensing element through its elastic deformation, eliminating the need for complex pressure sensor arrangements in the force flow between actuator and brake shoe.
Solution Approach 2:
The carrier acts as an intermediary element that transfers the supporting force from the brake shoe to the housing while simultaneously serving as the measurement element. Its elastic deformation mediates between the mechanical force transmission and the electrical signal generation by the deformation sensor.
2Measurement precision
If a force sensor is placed on the supporting bearing to measure supporting force, then braking force can be determined, but the device complexity and cost increase
Solution Approach 1:
The patent merges the structural function of the carrier (supporting and transmitting force) with the measurement function (detecting deformation proportional to braking force). This combination eliminates the need for separate force sensors on the supporting bearing, reducing manufacturing cost and complexity.
Solution Approach 2:
The carrier serves itself by using its own elastic deformation as the measurement mechanism. Instead of requiring an external force sensor, the carrier's structural response to load directly provides the measurement signal through the deformation sensor, making the system self-measuring.
3Reliability
If the carrier is made from metal for durability, then reliability improves, but the carrier may undergo permanent deformation under high stress
Solution Approach 1:
The patent carefully controls the stress parameters in the carrier by dimensional design, ensuring that the maximum mechanical stress remains below the yield point of the metal material. This parameter control allows the carrier to undergo elastic deformation for measurement purposes while maintaining permanent structural integrity and reliability.
4Measurement precision
If the carrier is dimensioned for elastic deformation measurement, then measurement accuracy improves, but the carrier may be less durable under extreme loads
Solution Approach 1:
The patent applies local quality by creating a specific deformation region in the carrier with controlled geometric features that concentrate elastic deformation in a localized area. This allows the majority of the carrier structure to maintain high strength and durability while a specific local region provides the necessary elastic deformation for accurate measurement.
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 simple, reliable, and cost-effective measurement of braking force or torque by detecting carrier deformation, ensuring high accuracy and durability while reducing manufacturing costs and avoiding hysteresis.
Implementation Method 1
the carrier undergoes only an elastic, in particular a linear elastic, deformation during the operation of the drum brake
Implementation Method 2
the supporting force created during the braking procedure, imparted and transmitted to the supporting bearing by the at least one brake shoe, is transmitted from the supporting bearing to the carrier, which effects a deformation of the carrier which is proportional to the braking force or the braking torque
Data Source
AI summary
A drum brake with a carrier, a deformation sensor, and at least one brake shoe. The carrier is connected to a supporting bearing for the at least one brake shoe. The deformation sensor is designed to determine a deformation of the carrier. A brake system includes at least one such drum brake, and a vehicle with such a brake system or with at least one such drum brake.