阅读说明：本技术 夹钳引导组件 (Clamp guide assembly ) 是由 马丁·P·泰勒 肖恩·克利里 马修·麦克金 里法特·马勒基 于 2018-11-06 设计创作，主要内容包括：本申请涉及夹钳引导组件。披露了一种用于重型车辆盘式制动器的夹钳引导组件。夹钳引导组件,所述夹钳组件包括具有引导部分的引导销；引导孔,所述引导孔具有安排成用来接收所述引导部分并且允许其相对轴向滑动的引导表面；以及磨损传感器,所述磨损传感器安排成用来检测所述引导销相对于所述引导孔的位置；其中,所述引导销和所述引导表面具有不同的截面轮廓以便在它们之间沿其长度的至少一部分限定至少一个空隙,并且磨损传感器至少部分地容纳在所述空隙内。(The present application relates to a clamp guide assembly. A caliper guide assembly for a heavy vehicle disc brake is disclosed. A clamp guide assembly including a guide pin having a guide portion; a guide bore having a guide surface arranged to receive the guide portion and allow relative axial sliding thereof; and a wear sensor arranged to detect the position of the guide pin relative to the guide hole; wherein the guide pin and the guide surface have different cross-sectional profiles so as to define at least one void therebetween along at least a portion of the length thereof, and a wear sensor is at least partially received within the void.)

1. A caliper guide assembly for a heavy vehicle disc brake, the caliper guide assembly comprising:

a guide pin having a guide portion;

a guide bore having an opening and a guide surface arranged to receive the guide portion and to allow relative axial sliding of the guide portion;

a wear sensor arranged to detect a position of the guide pin relative to the guide hole, the wear sensor comprising a signal processing portion; and

a cover arranged to close the opening of the guide bore,

wherein the signal processing part is mounted to the cover.

2. The clamp guide assembly of claim 1, wherein the signal processing portion is at least partially enclosed within the cover.

3. The clamp guide assembly of claim 2, wherein the wear sensor comprises a sensor probe, and wherein the sensor probe is at least partially encapsulated within the cover.

4. The caliper guide assembly of claim 2, wherein the wear sensor includes a connector portion including a connector for a cable arranged to extend to a vehicle to which the caliper guide assembly is fitted, and wherein the connector portion is at least partially encapsulated within the cover.

5. The clamp guide assembly of claim 2, wherein the cover is at least partially formed of a plastic resin material.

6. The clamp guide assembly according to claim 1, wherein the cover includes a cap portion having a distal end face for closing the opening of the guide bore and a skirt portion arranged to extend into the guide bore, and wherein the signal processing portion is mounted to the cap portion.

7. The clamp guide assembly of claim 6, wherein the signal processing portion is at least partially encapsulated within the cap portion.

8. The guide assembly according to claim 1, wherein a void is provided within the assembly accessible from the opening of the guide bore, and wherein the void is defined in part by the cover.

9. The clamp guide assembly of claim 8, wherein the signal processing portion is located at least partially within the void.

10. The clamp guide assembly of claim 8, wherein the wear sensor includes a sensor probe mounted to the cover and extending into the void.

11. The caliper guide assembly of claim 8, wherein the void is at least partially disposed within a recess of the guide pin.

12. A jaw guide assembly according to claim 1, wherein a connector portion is mounted to the cover, the connector portion providing a connector for a cable arranged to extend to a vehicle to which the jaw guide assembly is fitted.

13. The clamp guide assembly of claim 1, wherein the wear sensor is a hall effect type sensor.

14. The caliper guide assembly of claim 1, wherein the guide hole is provided in a caliper of a heavy-duty vehicle disc brake.

15. A heavy vehicle disc brake comprising the caliper guide assembly of claim 14.

16. A method of manufacturing a cover for a clamp guide assembly, the method comprising:

providing a wear sensor configured to detect a position of the guide pin relative to a guide hole, the guide hole having an opening and a guide surface arranged to receive a guide portion of the guide pin and allow relative axial sliding of the guide portion, the wear sensor having a signal processing portion; and

integrally molding the signal processing portion into the cover such that the signal processing portion is at least partially encapsulated within the cover,

wherein the cover is adapted to close the opening of the guide hole.

17. The method of claim 16, wherein the wear sensor comprises a sensor probe, the method comprising the step of integrally molding the sensor probe into the cover such that the sensor probe is at least partially encapsulated within the cover.

18. A method according to claim 16, wherein the wear sensor comprises a connector portion comprising a connector for a cable arranged to extend to a vehicle fitted with the clamp guide assembly, the method comprising the step of integrally moulding the connector portion into the cover such that the connector portion is at least partially encapsulated within the cover.

19. The method of claim 16, wherein the cover is at least partially formed of a plastic resin material.

20. The method of claim 16, wherein the cover includes a cap portion having a tip face adapted to close the opening of the guide bore and a skirt portion adapted to extend into the guide bore, and wherein the signal processing portion is integrally molded into the cap portion such that the signal processing portion is at least partially encapsulated within the cap portion.

Technical Field

The present invention relates to a disc brake and in particular, but not exclusively, to a guide assembly for slidably mounting a caliper of a disc brake and incorporating a wear sensor.

Background

Disc brakes are commonly used to brake heavy vehicles such as trucks, buses and buses.

Disc brakes conventionally comprise a brake carrier and a caliper. The brake carrier is arranged to support brake pads on each side of the rotor. The caliper is slidably mounted to the brake carrier by two or more guide assemblies such that when the disc brake is actuated, the caliper can slide relative to the brake carrier so that the two brake pads are pushed onto the rotor in a clamping action to effect braking.

The guide assembly typically includes a guide pin along which the clamp can slide and a bore disposed within the clamp for receiving the guide pin.

To achieve free sliding of the caliper over a wide range of operating conditions, the guide assembly must take into account manufacturing tolerances, heating or cooling effects in use, and accommodate flexing of the disc brake due to braking torque.

Further, it is desirable to provide wear of brake pad friction material to a vehicle operator to know when to replace brake pads to maintain safe operation of the disc brake. However, known wear sensing arrangements can be expensive and may constrain the design of other portions of the brake. Further, known arrangements may be susceptible to environmental contamination and to damage.

Disclosure of Invention

The present invention seeks to alleviate the problems associated with the prior art.

Accordingly, a first aspect of the present invention provides a caliper guide assembly for a heavy vehicle disc brake. The clamp guide assembly includes: a guide pin having a guide portion; a guide bore having a guide surface arranged to receive the guide portion and allow relative axial sliding thereof; and a wear sensor arranged to detect the position of the guide pin relative to the guide hole; wherein a gap is provided radially between the guide portion and the guide hole, and the wear sensor is at least partially accommodated within the gap.

Advantageously, this arrangement enables otherwise surplus space in the disc brake to be used for wear detection. Further, the space is well protected against the influence of the surrounding environment.

Optionally, the guide portion and the guide surface have different cross-sectional profiles to define the void along at least a portion of their lengths.

Optionally, the guide surface has a non-circular, preferably substantially constant cross-section.

Advantageously, it has been found that a generally non-circular guide surface is easier to manufacture than a non-circular pin.

Optionally, the guide surface has an elliptical cross-section.

Advantageously, it has been found that an oval cross-section is effective for smooth guidance while providing space for the wear sensor.

Optionally, the guide pin has a substantially circular, preferably substantially constant, outer profile.

Advantageously, this arrangement has been found to be easy to manufacture.

Optionally, the guide hole is a through hole and the assembly further comprises a cover to close one opening of the through hole, and wherein the wear sensor is optionally mounted to the cover.

Advantageously, the cover inhibits contamination of the guide assembly and wear sensor, and by optionally mounting the wear sensor to the cover, assembly and disassembly of the sensor may be simplified, and the cover may provide secure mounting.

Optionally, the wear sensor comprises a portion molded into the cover.

Optionally, the sensor comprises a portion that is overmolded or at least partially encapsulated into the cover.

Advantageously, this is an efficient way of manufacturing the cover while also protecting the sensor.

Optionally, the wear sensor extends from the cover into the void in a self-supporting manner.

Optionally, the guide surface is a bushing surface separately mounted to the guide bore.

Advantageously, the use of a bushing allows the use of a suitable guide material that may be different from the brake caliper. Manufacturing such a bushing may simplify its forming if the guide surface has a non-circular inner contour.

Optionally, a guide hole is provided in the caliper of the heavy vehicle disc brake.

Advantageously, providing the aperture in the caliper may allow the braking to be achieved more compactly than providing the aperture in the bracket.

Optionally, the guide pin further comprises a mounting portion operable to mount the caliper guide assembly to a brake bracket of a heavy vehicle disc brake.

Optionally, the guide pin further comprises a mounting portion configured for mounting to a brake bracket of a heavy vehicle disc brake.

Optionally, the wear sensor is a hall effect sensor or an optical sensor.

Advantageously, these types of sensors are compact, inexpensive and reliable.

A second aspect of the invention provides a disc brake incorporating a caliper guide assembly according to the first aspect of the invention.

Another aspect of the invention provides a heavy vehicle disc brake including a caliper guide assembly having a guide pin, the caliper guide assembly having: a guide portion; a guide bore having a guide surface arranged to receive the guide portion and allow relative axial sliding thereof; and a wear sensor arranged to detect the position of the guide pin relative to the guide hole; wherein a gap is provided radially between the guide portion and the guide hole, and the wear sensor is at least partially accommodated within the gap.

Optionally, the heavy vehicle disc brake further comprises a second caliper guide assembly.

Optionally, the second jaw guide assembly comprises a second guide pin having a second guide portion and a second guide bore having a second guide surface, wherein the second guide portion and the second guide surface have substantially the same cross-sectional profile.

A third aspect of the invention provides a caliper guide assembly for a heavy vehicle disc brake. The clamp assembly includes a guide pin having a guide portion; a guide bore having a guide surface arranged therethrough for receiving the guide portion and allowing relative axial sliding thereof; and a wear sensor arranged to detect the position of the guide pin relative to the guide hole; wherein a void is provided within the assembly accessible from the opening of the guide bore and the wear sensor is at least partially located in the void.

Optionally, the clearance may be provided at least partially within the recess of the guide pin.

Advantageously, this allows additional space to accommodate the sensor.

Optionally, the sensor directly senses the position of the guide pin relative to the sensor.

Advantageously, such an arrangement avoids the need for additional components, such as magnets that interact within the sensor.

A fourth aspect of the present invention provides a wear sensor for use in a caliper guide assembly, the wear sensor comprising a probe configured to extend into a gap between a guide pin and a bore of the caliper guide assembly.

Optionally, the wear sensor is arranged to be mounted to the inside extremity of the bore and the probe is arranged to extend laterally outwardly from the inside extremity of the bore.

Optionally, the wear sensor is mounted to a cap arranged to close the inside end of the hole.

Drawings

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 is an isometric view of a disc brake having a pilot assembly of first and second embodiments of the present invention;

FIG. 2 is an isometric cross-sectional plan view of the guide assembly shown in FIG. 1 in a plane passing through the centers of the two guide assemblies with the caliper in a brake pad unworn position;

FIG. 3 shows an isometric view of the same cross-section as FIG. 2;

FIG. 4 shows the same cross-sectional view as FIG. 2, but with the brake pads worn;

FIG. 5 shows the same isometric cross-sectional view as FIG. 3, but with the brake pads worn;

FIG. 6 shows an enlarged cross-sectional view of the guide assembly of the first embodiment of the present invention;

FIG. 7 shows an enlarged cross-sectional view of the guide assembly in plane 6-6;

FIG. 8 shows an exploded cross-sectional view of the guide assembly of the first embodiment of the present invention; and is

Fig. 9 is an enlarged cross-sectional view of a guide assembly of a second embodiment of the present invention.

Detailed Description

Fig. 1 depicts an embodiment of a disc brake 8. The disc brake includes a caliper 20 slidably mounted relative to a brake bracket 30 by two guide pin assemblies. Typically, the tongs 20 have a housing 22 formed of cast iron or steel. Typically, the brake bracket 30 is also formed of cast iron or steel.

The brake carrier 30 carries an inboard brake pad 50a and an outboard brake pad 50 b. A rotor 40 (see fig. 2) rotatable about an axis extending in the axial direction a is positioned between the brake pads. An air actuator (not shown) is provided to move inboard brake pad 50a into frictional contact with the rotor via an actuating mechanism (not shown) housed within caliper housing 22 and acting on inboard brake pad 50 a. When inboard brake pad 50a is pushed toward and contacts the rotor, caliper 20 is caused to slide inboard along first caliper guide assembly 10a and second caliper guide assembly 10 b.

As the caliper 20 slides inboard, it moves the outboard brake pad 50b toward the rotor 40. Thus, the rotor 40 becomes clamped between the inboard and outboard brake pads, and the rotation of the rotor is frictionally restrained.

To minimize the possibility of the guide assembly becoming jammed or bound due to thermal expansion, flexing under load, wear, or the like, preventing or limiting sliding of the tongs 20, the first guide assembly 10a has clearance to allow the guide assembly to freewheel even if the guide assembly is not in its nominal position. The first guide assembly 10a is a guide assembly according to a first embodiment of the present invention.

The second guide assembly 10b is longer than the first guide and comprises a circular guide bush and a complementary circular guide sleeve. The second guide assembly 10b is a guide assembly according to a second embodiment of the present invention. Although the disc brake 8 is shown with a guide assembly according to both the first and second embodiments of the invention, in practice a disc brake will typically be fitted with one or the other guide assembly of the invention and the other assembly will be conventional.

Referring to fig. 2, 3 and 6, the first guide assembly 10a includes a bore 12a extending parallel to an axis a through the housing 22. The bore 12a has a circular cross-sectional profile to receive the guide pin 11a and at least one guide bushing 13a having a circular outer profile and a non-circular (e.g., elliptical) inner profile to guide the guide pin within the bore.

The guide pin 11a includes a fastener to secure the guide pin to the brake bracket 30. In this first embodiment, the fastener is a bolt 14a that is attached to the brake bracket 30 by being threaded into a threaded hole in the brake bracket.

Referring specifically to fig. 6, the guide pin 11a further includes a guide sleeve 15a that at least substantially surrounds the fastener and on which the clamp 20 slides. The sleeve is a hollow tube of substantially circular cross-sectional profile. The head of the sleeve central bore is stepped so that when tightened onto the brake bracket 30, the bolt 14a can hold the sleeve in place.

The bore 12a of the guide assembly 10a is an elongated hole extending from a first side (inner side) to a second side (outer side) of the caliper housing 22. The caliper 20 is slidably mounted with respect to the brake bracket 30 by a guide pin 11a sliding through a hole 12 a. Therefore, when the disc brake is actuated, the caliper 20 can slide along the guide pin 11a in the axial direction a.

The guide bushing 13a is configured to form a tight fit with the bore 12a and to function as a liner within the bore. For heavy vehicle applications, the internal diameter of the bushing member is typically in the range of 25-40 mm. As can be seen in fig. 2, the guide bush 13a does not extend the full depth of the bore 12 a.

Guide bushing 13a may be made of steel, bronze, plastic, rubber, or any combination thereof, and may include a low friction coating (e.g., PTFE). Guide bushing 13a may have a smooth inner surface or a suitable pattern of depressions to assist the sliding of the jaws and retain lubricant. A coiled bellows seal 17 (fig. 8) surrounds the guide pin 11a and is connected to the brake bracket 30 and the brake caliper 20 to protect the first guide assembly 10a from contamination.

The diameter of the guide pin 11a is selected to correspond to the smallest diameter of the guide bush 13 a. Therefore, the clearance between the guide pin 11a and the guide bush 13a in the tangential direction Y is minimized and thus vibration, noise, pressure, and excessive wear are reduced. The maximum diameter of the bush provides a large clearance between the guide pin and the bush in the circumferential direction X to allow a predetermined amount of play to accommodate manufacturing tolerances, thermal expansion and flexing caused by the braking torque.

With particular reference to fig. 6, 7 and 8, a wear sensor according to a first embodiment of the present invention will now be discussed in more detail.

To inhibit foreign matter from contaminating the first guide assembly 10a, a cap or cover 60a closes the inside end of the bore 12 a. Conventionally, a cap for this purpose is formed of metal and press-fitted to the end of the hole 12 a.

However, in this embodiment, the cover 60a is combined with the wear sensor 62 a. As a result, the configuration of the cover 60a differs somewhat from conventional covers, as discussed below. In this embodiment, the cap 60a continues to include a cap portion 64a having a rounded end face to close the aperture, and a skirt portion arranged to extend inwardly and frictionally engage the surface of the aperture 12 a.

However, in this embodiment, the cap portion 64a is formed of a plastic resin material and is fabricated, for example, over-molded and at least partially encapsulates the components of the wear sensor 62 a. Specifically, in this embodiment, the cap portion 64a partially encapsulates each of the first and second sensor probes 66 at their inboard ends such that the probes extend outboard from the cap parallel to the axis a-a. Further, the cap portion 64a encloses a signal processing portion 68 of the wear sensor 62 a. In this embodiment, the signal processing portion 68 projects inside and is accommodated in a recess at the head of the bolt 14 a.

Finally, on the inner side face of the cap portion 64a, the cap portion 64a also mounts the connector portion 70a of the wear sensor 62 a. In this embodiment, the connector portion 70a provides a suitable connector, for example a plug or socket for a cable arranged to extend to a vehicle (not shown) fitted with a disc brake. This enables the vehicle to provide an indication to the vehicle operator of the wear condition of brake pads 50a and 50b, for example via a display on the vehicle dashboard, or some other audio/visual indicator.

As can be seen clearly in fig. 6 and 7, the feeler 66 extends through the elliptical inner contour of the guide bushing to the outside into the gap provided between the guide pin 11a and the guide bushing 13 a. In this way, the feeler 66 extends alongside the guide sleeve 15a of the guide pin 11a and the relative position of said feeler 66 with respect to the guide sleeve 15a changes as the friction material of the brake pads 50a and 50b wears away during use of the disc brake 8. This can be seen by comparing the position of the probe 66 relative to the guide sleeve 15a in fig. 2 and 3, where the friction material of the brake pads 50a and 50b is unworn, with the position in fig. 4 and 5, where the friction material is substantially completely worn, and the probe 66 has been moved inboard a distance equal to the cumulative wear of the friction material of the outboard pad 50b and any additional material wear of the outboard side of the brake rotor 40.

In the preferred embodiment, the wear sensor 62a is a hall effect sensor, and since the guide sleeve 15a is metallic, relative movement of the probe 66 with respect to the guide sleeve 15a results in a signal from the probe that can be used to deduce the relative movement of the probe and sleeve, and thus wear of the friction material.

In other embodiments, the sensor may be any other suitable sensor, for example, an optical sensor. Further, the sensor probe may be embedded in the guide bush 13a, or in a specific recess provided in the bush to accommodate the probe, without reducing the clearance between the bush and the sleeve due to the presence of the probe. In a further embodiment, if an elastomer (e.g., an elastomer bushing) is used, the probe may be molded (encapsulated) into the bushing to provide a void. In certain embodiments, the signal processing portion and/or the connector portion may be further integrated into the liner rather than into the cover 60 a. Further, the cover, the bushing and the sensor may all be provided as a single component. In alternative embodiments, only a single probe or more than two probes may be used, and the signal processing portion may be dispensed with. The connector may be replaced by a cable arranged to extend to a remote location, for example on a vehicle.

Referring back to fig. 2, in the second embodiment of the present invention, a wear sensor is instead provided on the second guide assembly 10b having the guide bush 13 b.

As noted above, the second guide pin 11b is longer than the first guide pin 11 a. However, the two guide pins use bolts of the same length. This means that the sleeve 15b of the second guide assembly 10b has significant clearance inside the head of the bolt 14 b. The gap is defined by the head of the bolt 14b, the inner portion of the sleeve 15b, and the cap portion 64b of the cover 60b (see fig. 9). In this embodiment, this clearance is utilized to provide space for both the sensor probe 66b, which extends parallel to the axis a-a proximate the inboard end of the sleeve 15b, and the signal processing portion 68b of the wear sensor 62 b.

As in the first embodiment, the cap portion 64b is formed of a suitable plastic resin material and the sensor probe 66b, the signal processing portion 68b and the connector portion 70b are all preferably integrally molded to be at least partially encapsulated within the resin of the cap portion 64 b. As in the first embodiment, the wear sensor 62b is preferably a hall effect type sensor and the movement of the sensor probe 66b relative to the second guide pin 11b (and in particular the sleeve 15b thereof) causes a change in the reading in the wear sensor 62b and thus deduces therefrom the wear of the friction material of the outer brake pad 50 b. It should be noted that by mounting the probe proximate the sleeve, relative movement of the sensor and sleeve can be detected without additional components (e.g., magnets mounted to the pin).

The fact that the inboard and outboard brake pads wear at similar rates and are replaced in pairs such that the outboard brake pad senses its wear by the sensor of the first or second embodiments means that equivalent wear of the inboard brake pad can be inferred. However, it is envisaged that the sensor described above may be used in conjunction with another sensor to determine the actual wear on the inboard brake pad. For example, a sensor monitoring the elongation of the wear adjustment mechanism of a disc brake may be used to measure the total wear of both brake pads and the wear of the inner pad may be calculated from the difference between the total wear and the wear of the outer brake pad.

Embodiments of the pilot assembly are suitable for use with any type of disc brake, including pneumatically, hydraulically, electrically and mechanically actuated disc brakes. However, these embodiments are considered to be particularly advantageous for air-actuated disc brakes for heavy commercial vehicles, where the rotor typically has a diameter of between 30-60cm, which means that the moment and heat effects may be more pronounced than in hydraulic disc brakes for smaller, lighter vehicles.

Although the invention has been described above by reference to one or more preferred embodiments, it should be understood that various changes or modifications may be made without departing from the scope of the invention as defined by the appended claims.