The present invention relates to an electric brake device provided with a brake thrust detection sensor.
Generally, an electric brake is configured to have a screw feeding mechanism for converting the rotational force into the translational force (brake thrust), a piston, a brake pad, and a disc, which are arranged in series in an axial direction. The screw feeding mechanism is used for adjusting the distance between the disc and the brake pad to execute brake on/off control operations. The electric brake is required to secure sufficient stroke for the brake pad in order to prevent the contact between the brake pad and the disc, and the resultant wear in a brake-off state. Accordingly, the electric brake is likely to have an axially long structure. Assembly of the above-structured electric brake with the vehicle for storage inside the tire wheel may impose severe restriction on the external dimension in the axial direction.
The electric brake disclosed in Patent Literature 1 has been known as having the brake thrust detection sensor for improving brake operability. The specification in paragraphs 0024 and 0025 as disclosed in the document describes that “The electric disc brake device according to the invention is provided with the thrust bearing for supporting axial loads applied to the input member from the output member via the planetary roller when applying the braking force to the disc rotor. The load sensor is disposed at the back of the thrust bearing to allow detection of the magnitude of the braking force applied to the disc rotor.” and “It is possible to employ the magnetostriction sensor, the strain detection type load sensor, and the magnetic load sensor as the above-described load sensor.”
That is, Patent Literature 1 discloses the brake device provided with the load sensor that is held and compressed between the thrust bearing 28 and the shaft support member 8 so that the magnitude of the braking force can be detected.
Patent Literature 1: Japanese Unexamined Patent Publication No. 2014-7845
The electric brake as disclosed in Patent Literature 1 employs the relatively large-sized load sensor such as the magnetostriction sensor, the strain detection type load sensor, and the magnetic load sensor. The height dimension of the load sensor in addition to the axial dimension makes the overall size of the electric brake longer in the axial direction. It is therefore difficult for the electric brake as disclosed in Patent Literature 1 to provide the compact electric brake for use in vehicle, which matches the external dimension restriction.
It is an object of the present invention to make the brake thrust detection sensor compact to allow usage of the electric brake for vehicle, and to provide the electric brake having axial dimension unaffected by the height dimension of the detection sensor.
To solve the above-described problem, the present invention provides an electric brake which includes an electric motor for generating a rotational force, a rotary shaft which is rotated by the rotational force generated by the electric motor, a piston which is axially moved by a translational force converted from rotation of the rotary shaft, a brake pad which is pressed against a disc in accompany with a translational motion of the piston, a thrust bearing which receives a thrust load applied to the rotary shaft, and a support member which supports the thrust bearing in an axial direction. The thrust bearing includes a first bearing washer which is in contact with the rotary shaft to receive the thrust load, and rotates integrally with the rotary shaft, a second bearing washer which is fixed to the support member, and multiple rolling elements which are held between the first bearing washer and the second bearing washer. The second bearing washer has its surface in contact with the support member provided with a supported portion that is in contact with the support member, and a non-supported portion that is not in contact with the support member. A strain sensor is disposed on the non-supported portion.
The present invention ensures to make the electric brake having the brake thrust detection sensor compact.
The problems, structures, and effects other than those described above will be clarified by explanations of the embodiments as described below.
Embodiments will be described with reference to the drawings.
An electric brake 1 according to a first embodiment of the present invention will be described referring to
The electric motor 3 which generates the rotational force is an electric drive motor such as a brushless motor, a DC motor, and a direct motor, and configured to control rotation of a motor shaft 3a in accordance with current signals and voltage signals from the external controller.
The decelerator 4 is formed by combining a gear 4a fitted with the motor shaft 3a, and a gear 4b fitted with the rotary shaft 5, and configured to decelerate the rotational speed of the motor shaft 3a to transmit large rotational force to the rotary shaft 5.
The rotary shaft 5 with a flange 5a disposed in the substantially center has a spiral groove formed in an outer surface at a side closer to the brake pad 8 than the flange 5a. The thrust bearing 9 allows the rotary shaft 5 to freely rotate around the axis while restraining the axial translational motion. The nut 6 has a spiral groove formed in the inner surface opposite to the groove of the rotary shaft 5. A not-shown rotation regulating guide serves to restrain the nut 6 from rotating. Combination of the rotary shaft 5 with the nut 6 constitutes the screw feeding mechanism such as a ball screw having multiple balls intervened between spiral grooves formed in the rotary shaft 5 and the nut 6. The screw feeding mechanism converts the rotational force of the rotary shaft 5 into the axial translational force of the nut 6.
The piston 7 is connected to the nut 6, and axially moved upon reception of the translational force of the nut 6. The brake pads 8 are provided at both sides of the disc 10 to be held therebetween. In the drawing, a brake pad 8a at the right side is connected to the piston 7, and pressed against the disc 10 as the piston 7 translationally moves. A brake pad 8b at the left side is attached to the housing 2. When the brake pad 8a is pressed against the disc 10, the housing 2 moves toward the decelerator 4 in reaction to pressing of the brake pad 8a against the disc 10 so that the brake pad 8b is pressed against the disc 10. The disc 10 is a circular plate-like member which is operated inter-connectedly with wheels of the vehicle. Upon reception of frictional resistance (braking force) resulting from the force (brake thrust) held by both the brake pads 8, the rotational speed is decelerated.
The peripheral structure of the thrust bearing 9 according to the embodiment will be described in detail.
The thrust bearing 9 includes a pair of bearing washers 9a, 9b, and multiple rolling elements 9c which are held between the bearing washers. As
A track for guiding the rolling elements 9c to orbit is formed on one surface of the bearing washer 9a at the side of the piston 7. The other surface of the bearing washer 9a is allowed to rotate integrally with the rotary shaft 5 while being in abutment on the flange 5a of the rotary shaft 5. A track for guiding the rolling elements 9c to orbit is formed on one surface of the bearing washer 9b at the side of the decelerator 4. The other surface of the bearing washer 9b is abutted on the housing 2 for support and fixation. The multiple rolling elements 9c are held between the bearing washers 9a and 9b, and orbit along the tracks each formed on the bearing washers 9a, 9b, respectively. The rolling element 9c may be spherically shaped or cylindrically shaped. Normally, a not shown holder is provided for keeping the uniform pitch between the rolling elements 9c, and preventing the rolling element 9c from falling out from the track.
The housing 2 has the notch 2c formed in a part of the surface in contact with the bearing washer 9b. The housing 2 may be structured to have a support member independent from the housing 2, for example, a washer for supportively fixing the bearing washer 9b. In this case, the notch 2c is formed in the independent support member. The notch 2c defines the supported portion 9s which is in contact with the housing 2 for receiving the load and the non-supported portion 9n which is not in contact with the housing 2 on the contact surface of the bearing washer 9b. The supported portion 9s and the non-supported portion 9n are formed alongside in a circumferential direction around the rotary shaft 5. The non-supported portion 9n is formed as a circumferential beam structure while having both sides supported with the supported portions 9n, and is likely to generate strain in the circumferential direction.
The strain sensor 11 is installed on the non-supported portion 9n for detecting the strain which occurs in the non-supported portion 9n. It is preferable to install the strain sensor 11 on the center of the non-supported portion 9n. In the beam structure, the bending moment M becomes maximum at the center of the beam, at which the strain becomes large. As a result, improvement in the S/N ratio is expected. The strain sensor 11 may be a strain IC having a piezo-resistance positioned at the center of the upper surface of the silicon chip, and a Wheatstone bridge, an amplifier circuit, a temperature guarantee circuit, or the like produced in the semiconductor process, which is positioned around the piezo-resistance. Using the piezo-resistance effect, the strain exerted to the strain sensor 11 is taken as the resistance change. The strain sensor 11 may be in the form of the strain gauge or the like.
An explanation will be made with respect to a brake thrust detection method for the electric brake 1 according to the embodiment.
Assuming that the two rolling elements 9c exist inside the width W of the notch 2c as illustrated in
[Formula 1]
R1+R2=2 F Formula 1
[Formula 2]
W·R2=F·x+F·(x+P) Formula 2
[Formula 3]
M=W·R1/2−(W/2−x)·F Formula 3
The formula 1 is an equation to calculate the balance of force, the formula 2 is an equation to calculate the balance of moment of force, and the formula 3 is an equation to calculate the bending moment at midpoint of the notch width W.
[Formula 4]
M=(W−P)·F/2 Formula 4
The formula 4 is an equation to calculate the bending moment at midpoint of the notch width W as a result of developing the formulae 1 to 3.
[Formula 5]
ϵ=σ/E=M/EZ=6·M/E·b·h2 Formula 5
The formula 5 is an equation to calculate the strain ϵ of the bearing washer 9b, which occurs at midpoint of the notch width W. The “σ” denotes stress, “E” denotes Young's modulus, “Z” denotes section modulus, “b” denotes a width, and “h” denotes a thickness.
The counterforce of the brake thrust during braking operation is transmitted to the bearing washer 9b via the bearing washer 9a and the rolling elements 9c inside the thrust bearing 9. Referring to
In the case of the beam structure of the non-supported portion 9n, as the rotary shaft 5 is rotated to change the brake thrust, the rolling element 9c orbits to change its position. The position of the load F, thus is shifted. The shifting of the load F changes distribution of the strain which occurs in the non-supported portion 9n. As a result, outputs of the strain sensor 11 fluctuate as the rolling element 9c orbits. The fluctuation will occur every passage of the rolling elements 9c below the non-supported portion 9n, which can be observed as periodic variations.
An explanation will be made with respect to the relation between the number of the rolling elements 9c and fluctuation of the strain which occurs in the position where the strain sensor 11 is disposed on the assumption that the center of the notch width W is set as the position of the strain sensor 11. If the one rolling element 9c passes through the section of the notch width W, substantially no strain occurs when the load F exists around the support point, and the strain becomes maximum when the load exists just below the strain sensor 11, resulting in large periodic variation. If the two rolling elements 9c pass through the section of the notch width W, the strain occurs as one of the loads F exists just below the strain sensor 11 even if the other load exists around the support point. When the load F exists midway between the support point and the strain sensor 11, each strain caused by the two loads F overlaps with each other so that the periodic variation of the strain can be kept small. As the formula 4 indicates, the bending moment M which occurs in the center of the notch width W is expressed by the formula of M=(W−P)F/2 using the notch width W, the pitch P between the rolling elements, and the load F without depending on the position x of the rolling element. If the three rolling elements 9c pass through the section of the notch width W, two different states occur between the support point and the stress sensor 11, that is, the state having one force point and the state having two force points. This may cause bias in the load F between the left and right strain sensors 11, resulting in fluctuation in the strain.
As described above, the notch width W and the pitch P between the rolling elements 9c are set to establish the relation of substantially W=2P so that the two rolling elements 9c always pass through the section of the notch width W. If the width W of the notch 2c is made smaller than twice the pitch P between the rolling elements, the period for which only one rolling element 9c exists in the notch width W during orbiting is prolonged. This makes the periodic variations larger. If the width W of the notch 2c is made larger than twice the pitch P between the rolling elements, the period for which the three rolling elements 9c exist in the width W of the notch 2c during orbiting is prolonged. This makes the periodic variations larger. The notch width W and the pitch P between the rolling elements are set to establish the relation of substantially W=2P to keep the period for which the two rolling elements 9c pass through the notch width W during orbiting. This makes it possible to suppress occurrence of the periodic variations.
When setting the relation between the width W of the notch 2c and the pitch P between the rolling elements 9c to W=2P, the strain which occurs in the center of the notch width W is proportional to the bending moment M as represented by the formula 5, and is inversely proportional to the Young's modulus E and the section modulus Z of the bearing washer 9b. That is, as the bending moment M fluctuates less, the fluctuation of the strain ϵ reduced.
As the example of
Referring to the example of
In the case where the notches 2c are formed at positions where the circumference around the rotary shaft 5 as the center is divided into two equal sections, the number of the rolling elements 9c is set to an odd number. When the rolling element 9c passes below one of the strain sensors 11, the midpoint between the rolling elements 9c is positioned below the other strain sensor 11. When the rolling element 9c passes just below the strain sensor 11, the value of the detected strain becomes maximum. When the rolling element 9c is at the furthest position from the strain sensor 11, the value of the detected strain becomes minimum. Those values are observed as periodic variations. The phases of the left and the right strain sensors 11L, 11R are shifted to be made different from each other by 180° to calculate the average value 11AVG. As a result, the periodic variation may be offset by each other as represented by
The electric brake 1 of the embodiment includes the electric motor 3, the rotary shaft 5 having a thread groove, which is rotated by the rotational force of the electric motor 3, the nut 6 which is screwed with the thread groove of the rotary shaft 5, and axially movable, the brake pad 8 thrusted by the nut 6, the thrust bearing 9 which receives the thrust load applied to the rotary shaft 5, and the housing 2 which supports the thrust bearing 9 to store a part of the component. The thrust bearing 9 includes the bearing washer 9a that comes in contact with the rotary shaft 5 for receiving the thrust load, the bearing washer 9b that comes in contact with the housing 2 to receive the thrust load, and the multiple rolling elements 9c held between the bearing washers 9a and 9b. The supported portion 9c of the bearing washer 9b, which is in contact with the housing 2 has the non-supported portion 9n formed as its part, on which the strain sensor 11 is disposed. The non-supported portion 9n of the bearing washer 9b is defined by the notch 2c formed in the support member 2. The multiple notches 2c are formed horizontally symmetrically on the circumference around the axis at an equal interval. The width W of the notch 2c is twice the pitch P between the rolling elements 9c. The strain sensor 11 is disposed on the center of the width W of the notch 2c. The odd numbered rolling elements 9c are arranged so that each phase of timing at which the rolling elements 9c pass below the left and the right strain sensors is made different by 180°.
The electric brake may be made further compact by integrating the load sensors with the thrust bearing, which are axially arranged. It is possible to provide the electric brake with excellent operability as a result of executing the feedback control by detecting the brake thrust.
An electric brake according to a second embodiment of the present invention will be described referring to
The two supported portions 9s of the bearing washer 9b as illustrated in
Like the first embodiment, the non-supported portion 9n of the bearing washer 9b is formed so that the strain that occurs in the non-supported portion 9n is detected. This makes it possible to detect the brake thrust. Compared with the first embodiment, this embodiment allows the housing 2 to keep high rigidity, and contributes to reduction in the cost for machining the housing 2.
Like the first embodiment, the above-described structure ensures to make the electric brake compact by integrating the axially arranged load sensors with the thrust bearing of the electric brake 1. The embodiment further provides the electric brake with excellent operability as a result of executing the feedback control by detecting the brake thrust.
1 . . . electric brake,
2 . . . housing,
2
c . . . notch,
3 . . . electric motor,
3
a . . . motor shaft,
4 . . . decelerator,
4
a,
4
b . . . gear,
5 . . . rotary shaft,
5
a . . . flange,
6 . . . nut,
7 . . . piston,
8, 8a, 8b . . . brake pad,
9 . . . thrust bearing,
9
a,
9
b . . . bearing washer,
9
c . . . rolling element,
9
d . . . base,
9
s . . . supported portion,
9
n . . . non-supported portion,
10 . . . disc,
11, 11L, 11R . . . strain sensor
Number | Date | Country | Kind |
---|---|---|---|
2018-223382 | Nov 2018 | JP | national |
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/JP2019/032775 | 8/22/2019 | WO | 00 |