Electromechanical Brake Caliper Sensing Ring for Compact Force Measurement
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Solution Overview
Problem
Existing electromechanical brake calipers face challenges in integrating load sensors due to limited space and harsh operating conditions, leading to increased system size and cost.
Innovation Solution
An electromechanical brake caliper design that incorporates a sensing ring with bending elements and strain gauges, which measures deformations caused by applied forces, allowing for accurate force measurement within the caliper.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a stand-alone load sensor is integrated into the electromechanical brake caliper, then brake force measurement capability is improved, but the system size and complexity increase due to limited available space
Solution Approach 1:
The patent combines the load sensor functionality with the existing caliper structure by integrating the sensing ring and bending elements directly into the caliper body. The sensing ring is positioned between the loading ring and the caliper bottom, merging the measurement function with the force transmission path that already exists in the brake caliper design.
Solution Approach 2:
The bending elements serve multiple functions: they act as both structural components of the caliper and as sensing elements for force measurement. The sensing ring structure simultaneously provides mechanical support and enables strain measurement through the integrated strain gauges, eliminating the need for separate dedicated sensor components.
2Measurement precision
If a stand-alone load sensor is integrated into the electromechanical brake caliper, then brake force measurement capability is improved, but manufacturing cost increases
Solution Approach 1:
The load sensor functionality is merged with existing caliper components, specifically using the sensing ring and bending elements that are part of the force transmission mechanism. This integration eliminates the need for separate sensor assemblies and reduces the overall component count, leading to lower manufacturing costs.
Solution Approach 2:
The caliper's existing structural components (loading ring, sensing ring, bending elements) serve dual purposes by automatically providing both mechanical function and measurement capability. The strain gauges are applied directly to these existing components, allowing the structure to serve itself as the sensing element without requiring additional dedicated sensor parts.
3Reliability
If a load sensor is installed separately in the electromechanical brake caliper, then measurement reliability is improved, but the system size increases due to harsh operating conditions requiring robust sensors
Solution Approach 1:
The sensor system is merged with the caliper's force transmission components, using the same structural elements (bending elements, sensing ring) that are already designed to withstand harsh operating conditions. This integration allows the sensor to benefit from the inherent robustness of the brake caliper structure without requiring additional protective housing or separate sensor assemblies.
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 solution enables precise measurement of brake forces, reducing system size and cost while maintaining reliability and accuracy, even under harsh conditions.
Implementation Method 1
a sensing ring (30), located inside the caliper cylinder (10) between the loading ring (20) and the bottom (14), wherein the sensing ring (30) comprises at least one bending element (31) which can be deformed when the force Fa is applied to
Implementation Method 2
the sensing ring (30) further comprises at least one measuring device (50) for the detection of stretching and/or compressing deformations, and wherein the measuring device (50) is located at or attached to the at least one bending element (31) of the sensing ring (30)
Data Source
Figure 1~2
Figure 3
Figure 4~6b
AI summary
The present invention generally relates to an electromechanical brake caliper assembly which can be used, for example, in motor vehicles as part of a braking system. The invention also relates to a braking system for a motor vehicle with such a brake arrangement. The invention therefore discloses an electromechanical operable brake caliper, in particular for motor vehicles, comprising: - a caliper cylinder (10) having a proximal open end (11) and a distal end (12) defining a bottom (14), the distal end and the proximal end further defining a body axis (13), - a loading ring (20), located inside the caliper cylinder (10) and movable in an axial direction parallel to the body axis (13), the loading ring (20) is able to receive a force Fa in operation of the brake caliper assembly, - a sensing ring (30), located inside the caliper cylinder (10) between the loading ring (20) and the bottom (14), wherein - the sensing ring (30) comprises at least one bending element (31) which can be deformed when the force Fa is applied to, - the loading ring (20) is designed to transfer the force Fa to the bending element of the sensing ring (30) which can cause the at least one bending element (31) to be deformed, - the sensing ring (30) further comprises at least one measuring device (50) for the detection of stretching and/or compressing deformations, and wherein - the measuring device (50) is located at or attached to the bending element (31) of the sensing ring (30).