Brake Torque Sensor Calibration Device
Abstract
:1. Introduction
2. Brake System
- Service brakes, the main feature of which is foot control. During operation, they must act on all vehicle wheels and vehicle sets and their effect must be variable. They must ensure a reduction in speed or a complete stop of the vehicle while maintaining the desired direction.
- Emergency brakes, which, unlike service brakes, do not have to act on every single wheel of the vehicle or set of vehicles. In case of failure, they replace the service brakes, and it is important that they act on at least one wheel on each side. Emergency brakes often work with less effect than service brakes.
- Parking brakes, the main task of which is to prevent a stationary vehicle from moving off a slope even if there is no driver in the vehicle.
- Auxiliary brakes, which are characterized by maintaining a constant speed of the vehicle, but also by reducing it. In this way, they increase the effect of the service brake while lightening it, thereby extending its service life [35].
2.1. Types of Brake Systems
- Drum brakes—use drum-shaped housing where the brake shoes are pressed against the inner surface to create friction. They are durable and cost-effective for rear wheels.
- Disc brakes—use a disc-shaped rotor that rotates with the wheel and the brake pads press against it to brake. Due to better heat dissipation and stopping power, they are usually used in front-wheel and high-performance vehicles.
2.2. Residual Torque
3. Description of the Measuring Device
- Bases 1 and 2 serve to fix the universal plate and the brake disc. Base 2 is equipped at one end with a simple mechanism for clamping the torque sensor.
- A universal plate serves to fasten the measured brake caliper.
- A brake disc is used for measurements. It is fixed through the flange on base 2.
- Gearbox system with an el. motor, which serves to rotate the brake disc.
- Torque sensor, which is used to measure the residual torque on the brake disc.
- Type: T4A.
- Accuracy class: 0.1.
- Nominal (measuring) range: 10 Nm; 20 Nm.
- Nominal (measurement) sensitivity: 2 mV/V < ±0.2%.
- Amount of rotation at the nominal (measuring) torque: 0.9° for a 10 Nm sensor and 1.1° for a 20 Nm sensor.
4. Calibration Equipment Models
4.1. Design of a Calibration Device with a Threaded Rod
- denotes the force in the treaded rod [N].
- denotes the distance between the shaft axis and the treaded rod axis (Figure 4).
- denotes the mean screw diameter [m].
- denotes the pitch angle of the thread [rad].
- denotes the friction angle [rad].
- denotes the friction coefficient in a thread.
- denotes the mean diameter of the contact surface [m].
- denotes the force on a handle of a threaded screw deduced by an operator [N].
- denotes the diameter of a threaded screw handle [m].
4.2. Design with the Angular Gearbox
- denotes the torque on the gearbox input [Nm].
- denotes the force induced by an operator [N].
- denotes the wheel radius [m].
- denotes the mechanical efficiency of the gearbox.
4.3. Design with Weight Carriers
- , denote the gravitational forces due to the weights [N].
- , denote the lengths of the arms that the weights act on [m].
4.4. Design with a Calibration Wheel
- denotes the force moment [Nm].
- denotes the force induced by the calibration weight [N].
- denotes the length of the arm on which the force F acts [m].
- denotes the weight of the weight [kg].
- denotes the local gravity acceleration [m/s2].
5. Calculation of the Calibration Device Error
- is the mass of the given weight [kg].
- is the value of the given calibration weight [N].
- is the local gravitational acceleration [m/s2].
- is the mass of the weight increased or reduced by the tolerance value [kg].
- is the value of the mass of the given calibration weight [kg].
- is the tolerance value for the given weight [kg].
- is the actual diameter of the calibration wheel enlarged or reduced by the uncertainty of the 3D scanner [m].
- is the actual diameter of the calibration wheel [m].
- is the uncertainty of the 3D scanner [m].
- is the maximum or minimum radius of the calibration wheel [m].
- is the actual diameter of the calibration wheel enlarged or reduced by the uncertainty of the 3D scanner [m].
- is half the thickness of the steel strip [m].
- is the maximum or minimum value of the torque induced by the given weight [Nm].
- is the maximum or minimum value of the calibration weight [N].
- is the maximum or minimum value of the radius of the calibration wheel [m].
- is the sum of the maximum or minimum torque value induced for a given combination of calibration weights [Nm].
- is the maximum or minimum torque value induced by the given weight [Nm].
- is the range of deviations from the nominal value [Nm].
- is the sum of maximum torque values for a given combination of calibration weights [Nm].
- is the sum of the minimum torque values for the given combination of calibration weights [Nm].
- is the standard uncertainty of the considered source [Nm].
- is the range of deviations from the nominal value of torque [Nm].
- k is the value of the chosen approximation of the probability distribution, while for this type of approximation of the distribution, the uniform distribution was chosen.
6. Calibration Measurements That Were Performed
7. Discussion
8. Conclusions
- The necessity of exactly setting the torque sensor and the standard on “one axis” and maintaining the stability of this position.
- Ensuring the temperature stability of the measuring device.
- Selecting a suitable accuracy class for the reference sensor.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Aspect | Drum Brakes | Disc Brakes |
---|---|---|
Design | Enclosed design with brake shoes inside a drum | Open design with brake pads gripping a rotor |
Heat dissipation | Less efficient heat dissipation | More efficient heat dissipation |
Cooling | Limited cooling due to enclosed design | Better cooling due to open design |
Brake fade | More susceptible to brake fade | Less susceptible to brake fade |
Stopping distances | Generally longer stopping distances | Shorter stopping distances |
Maintenance | Require periodic adjustments for optimal performance | Require less maintenance and adjustments |
Noise | Produce less noise during braking | Can produce more noise during braking |
Corrosion | Generally less susceptible to corrosion | More susceptible to corrosion in rotor and caliper |
Brake dust | Generate less brake dust | Generate more brake dust |
Complex components | Simpler design with fewer components | More complex with calipers, pistons, and rotors |
Typically more affordable | Generally more expensive | |
Parking brake | Integrated parking brake mechanism | Parking brake functionality may vary |
Weight | Heavier compared to disc brakes | Lighter compared to drum brakes |
Type of Brake | Advantages | Disadvantages |
---|---|---|
Disc brake with a floating caliper | Better heat dissipation, smaller built-in dimensions, lower weight, | Uneven-wear brake pads; option to use (at most) two brake pistons |
Disc brake with a fixed caliper | lower residual torque Possibility of using several brake pistons; stronger construction | Higher weight, larger dimensions |
Standard | EURO 1 | EURO 2 | EURO 3 | EURO 4 | EURO 5 | EURO 6 | EURO 7 |
---|---|---|---|---|---|---|---|
Valid from | July 1992 | January 1996 | January 2000 | January 2005 | September 2009 | September 2014 | November 2026 |
CO [g/km] Petrol diesel | 2.72 2.72 | 1.0 2.2 | 0.64 2.3 | 0.5 1.0 | 0.5 1.0 | 0.5 1.0 | 0.5 1.0 |
PM [g/km] Diesel eng. | 0.14 | 0.08–0.1 | 0.05 | 0.025 | 0.005 | 0.0045 | 0.0045 |
PM [g/km] Petrol eng. | - | - | - | - | 0.005 * | 0.0045 * | 0.0045 |
PM [g/km] Brakes, tires | - | - | - | - | - | - | 0.003 EL 0.007 CE, 0.007 HY |
Variant of Calibration Device | Advantages | Disadvantages |
---|---|---|
1. Threaded rod | The possibility of simple clamping on the measuring table. | More time-consuming setting of the torque value using a threaded rod and it was problematic to set the torque sensor with the standard on one axis. Bearings that would cause resistance during calibration. |
2. Angular gearbox | Easier and faster setting of the torque value, which could be set in both directions of rotation. | Problematic axial adjustment of the torque sensor to the standard and the introduction of errors due to the effect of rolling bearings. Higher mass and size due to the gearbox. |
3. Weight carriers | Simpler and lighter construction. | There is an imperfect alignment of the system caused by friction between the arm and the weight carriers. There remains a problem with the axial adjustment of the torque sensor to the standard and with errors caused by the rolling of bearings. |
4. Calibration wheel | Eliminated errors due to friction from rolling bearings, problematic adjustment of the measuring assembly, and relatively massive construction. Easy handling and good positioning of the calibration device on the measuring device. The universality of using the calibration device for various measuring devices of the laboratory. The system can stabilize itself into an equilibrium position. | A need to adapt the thickness of the steel strip to the load. |
Weight Value [N] | Max. Mass Value [kg] | Max. Weight Value [N] | Min. Mass Value [kg] | Min. Weight Value [N] |
---|---|---|---|---|
2.5 | 0.25488519 | 2.50004903 | 0.25487519 | 2.49995095 |
5 | 0.50976538 | 5.00004902 | 0.50975538 | 4.99995094 |
10 | 1.01953076 | 10.00009805 | 1.01951076 | 9.99990187 |
50 | 5.09765382 | 50.00049042 | 5.09755382 | 49.99950957 |
Calibrated Weight Value [N] | Value of Torque [Nm] | Min. Value of Torque [Nm] | Max. Value of Torque [Nm] |
---|---|---|---|
2.5 | 0.5 | 0.50024294 | 0.50026556 |
5 | 1 | 1.00049568 | 1.00052131 |
10 | 2 | 2.00099136 | 2.00104262 |
50 | 10 | 10.00495686 | 10.00521313 |
Required Torque Value [Nm] | Calibrated Weight Value [N] | Combination of Weights | Maximum Torque Tolerance σMmax [Nm] | Minimum Torque Tolerance σMmin [Nm] |
---|---|---|---|---|
0.5 | 2.5 | 1 × 2.5N | 0.50026556 | 0.50024294 |
1 | 5 | 1 × 5N | 1.00052131 | 1.00049568 |
2 | 10 | 1 × 10N | 2.00104262 | 2.00099136 |
3 | 15 | 1 × 10N + 1 × 5N | 2.23723366 | 2.23717635 |
4 | 20 | 2 × 10N | 2.82990161 | 2.82982912 |
5 | 25 | 2 × 10N + 1 × 5N | 3.00156393 | 3.00148704 |
7 | 35 | 3 × 10N + 1 × 5N | 3.60743089 | 3.60733847 |
9 | 45 | 4 × 10N + 1 × 5N | 4.12525504 | 4.12514937 |
10 | 50 | 1 × 50N | 10.00521313 | 10.00495686 |
15 | 75 | 1 × 50N + 2 × 10N + 1 × 5N | 10.44574917 | 10.44548162 |
Required Torque Value [Nm] | Calibrated Weight Value [N] | The Range of Deviation Changes ± [Nm] | [Nm] |
---|---|---|---|
0.5 | 2.5 | 0.00002262 | 0.000011310 |
1 | 5 | 0.00002563 | 0.000012815 |
2 | 10 | 0.00005126 | 0.000025630 |
3 | 15 | 0.00005731 | 0.000028655 |
4 | 20 | 0.00007249 | 0.000036245 |
5 | 25 | 0.00007689 | 0.000038445 |
7 | 35 | 0.00009242 | 0.000046210 |
9 | 45 | 0.00010567 | 0.000052835 |
10 | 50 | 0.00025627 | 0.000128135 |
15 | 75 | 0.00026755 | 0.000133775 |
Required Torque Value [Nm] | Calibrated Weight Value [N] | Standard Uncertainty of the Considered Source [Nm] |
---|---|---|
0.5 | 2.5 | 0.0000065298 |
1 | 5 | 0.0000073987 |
2 | 10 | 0.0000147975 |
3 | 15 | 0.0000165439 |
4 | 20 | 0.0000209261 |
5 | 25 | 0.0000221962 |
7 | 35 | 0.0000266793 |
9 | 45 | 0.0000305043 |
10 | 50 | 0.0000739788 |
15 | 75 | 0.000077235 |
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Kowalski, S.; Barta, D.; Dižo, J.; Dittrich, A. Brake Torque Sensor Calibration Device. Appl. Sci. 2024, 14, 7927. https://doi.org/10.3390/app14177927
Kowalski S, Barta D, Dižo J, Dittrich A. Brake Torque Sensor Calibration Device. Applied Sciences. 2024; 14(17):7927. https://doi.org/10.3390/app14177927
Chicago/Turabian StyleKowalski, Sławomir, Dalibor Barta, Ján Dižo, and Aleš Dittrich. 2024. "Brake Torque Sensor Calibration Device" Applied Sciences 14, no. 17: 7927. https://doi.org/10.3390/app14177927