Disc brake assembly with sensor assembly

Abstract

A disc brake assembly is disclosed, comprising a brake caliper, a retainer band, and a sensor assembly. The retainer band is mounted to the brake caliper and extends across the brake pad assembly. The sensor assembly is mounted to the retainer band and generates a signal indicating the position of the brake pad assembly.

Description

Technical Field

[0001] This disclosure relates to a disc brake assembly having a sensor assembly that can be mounted to a retainer band. background

[0002] U.S. Patent No. 10,309,470 discloses a brake caliper assembly with a retainer band.

[0003] Overview

[0004] In at least one embodiment, a disc brake assembly is provided. The disc brake assembly may include a brake caliper, a retainer band, and a sensor assembly. The brake caliper defines a cavity for receiving a brake pad assembly. The retainer band is mounted to the brake caliper and extends across the cavity and the brake pad assembly. The sensor assembly is mounted to the retainer band and generates a signal indicating the position of the brake pad assembly.

[0005] In at least one embodiment, a disc brake assembly is provided. The disc brake assembly may include a brake bracket, a brake caliper, a retainer band, and a sensor assembly. The brake caliper is mounted to the brake bracket. The brake pad assembly is received within the brake bracket. The retainer band is mounted to the brake caliper and extends across the brake pad assembly. The sensor assembly is mounted to the retainer band. The sensor assembly includes a sensor for detecting the position of the brake pad assembly. Attached Figure Description

[0006] Figure 1 This is a perspective view of an example brake assembly with sensor components.

[0007] Figure 2 yes Figure 1 A top view of the brake assembly.

[0008] Figure 3 yes Figure 2 An enlarged view of a portion of the brake assembly in its first position.

[0009] Figure 4 This is an enlarged view showing the brake assembly in the second position.

[0010] Figure 5 yes Figure 3 A magnified view of a portion of the image shows the locator features spaced apart from the sensor components.

[0011] Figure 6 This is an enlarged view showing the positioner features of the contact sensor assembly.

[0012] Figure 7This is an enlarged view showing the positioner features spaced apart from the sensor assembly and mounted on another bushing spring.

[0013] Figure 8 It shows the contact sensor assembly and is set with... Figure 7 A magnified view of the locator features on the same bushing spring.

[0014] Figure 9 This is a perspective view of a second configuration of the brake assembly and sensor assembly.

[0015] Figure 10 yes Figure 9 An enlarged view of the brake assembly, showing the brake assembly in the first position.

[0016] Figure 11 This is an enlarged view showing the brake assembly in the second position. Detailed Implementation

[0017] As requested, detailed embodiments of the invention are disclosed herein; however, it should be understood that the disclosed embodiments are merely examples of how the invention can be implemented in various forms and alternative forms. The drawings are not necessarily to scale; some features may be exaggerated or minimized to show details of specific components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but rather serve only as a representative basis for teaching those skilled in the art to employ the invention in various ways.

[0018] refer to Figure 1 An example of a disc brake assembly 10 is shown. The disc brake assembly 10 can be provided as part of a vehicle, such as a truck, bus, agricultural equipment, military transport or armament vehicle, or as cargo loading equipment for land, air, or sea vessels. In at least one configuration, the disc brake assembly 10 may include a brake bracket 20, a brake caliper 22, at least one brake pad assembly 24, a retainer band 26, and a sensor assembly 28. One or more pad springs 30 may also be provided for the disc brake assembly 10.

[0019] The brake bracket 20 can facilitate the mounting of the disc brake assembly 10. For example, the brake bracket 20 can be securely mounted to a vehicle component, such as an axle assembly or joint. The brake bracket 20 can receive and support the brake pad assembly 24 and can include an opening through which the brake rotor 40 can extend. In this way, the brake bracket 20 can straddle the brake rotor 40 and can help position the brake pad assembly 24 on opposite sides of the brake rotor 40.

[0020] The brake caliper 22 can be mounted on the brake bracket 20 and can support various components of the disc brake assembly 10. Additionally, the brake caliper 22 can help position the brake pad assembly 24 relative to the brake rotor 40 to aid in braking the vehicle, as will be discussed in more detail below. In at least one configuration, the brake caliper 22 may include a caliper housing 50 and a caliper bridge 52.

[0021] refer to Figure 1 and Figure 2 The caliper housing 50 may be movably mounted on the brake bracket 20. For example, the caliper housing 50 may be slidable along a pair of guide pins that may be fixedly mounted on the brake bracket 20. The caliper housing 50 may receive or support various components that may contribute to actuating the brake pad assembly 24. For example, the caliper housing 50 may support a pushrod 60 that protrudes from an internal cavity of the caliper housing 50.

[0022] Main Reference Figure 2 A tappet 60 extends from the caliper housing 50 toward the brake rotor 40 to engage the brake pad assembly 24. The tappet 60 may be movable relative to the caliper housing 50 along axis 62, allowing it to move toward and away from the brake rotor 40. For example, an actuator may extend the tappet 60 to actuate the brake pad assembly 24, disposed between the caliper housing 50 and the brake rotor 40, into engagement with the brake rotor 40. A reaction force may then move the caliper housing 50 and the caliper bridge 52 relative to the brake support 20 to actuate the brake pad assembly 24, disposed between the caliper bridge 52 and the brake rotor 40, into engagement with opposite sides of the brake rotor 40, thereby helping to slow the rotation of the brake rotor 40 and the associated vehicle wheels. Alternatively, one or more biasing members, such as a retraction spring, may be provided to facilitate the retraction of the brake pad assembly 24 away from the brake rotor 40 when braking is not desired.

[0023] The clamp bridge 52 can be fixedly positioned relative to the clamp housing 50. The clamp bridge 52 can be integrally formed with the clamp housing 50, or it can be a separate component mounted to the clamp housing 50. For example, the clamp bridge 52 can be engaged or secured to the clamp housing 50 using one or more fasteners such as bolts. In at least one configuration, the clamp bridge 52 can cooperate with the clamp housing 50 to define a cavity 70, which in Figure 2 The best example is shown in the image.

[0024] The cavity 70 may at least partially receive the brake pad assembly 24 and the brake rotor 40. The cavity 70 may be configured as a large through-hole that can be surrounded by the brake caliper 22. A portion of the brake caliper 20 may extend into the cavity 70 and may assist in positioning the brake pad assembly 24. The brake pad assembly 24 may be inserted into the cavity 70 and mounted on the brake bracket 20 or removed from the cavity 70 and the brake bracket 20 when the retainer band 26 is removed.

[0025] Main reference Figure 2 A pair of brake pad assemblies 24 can be received in the brake support 20. The brake pad assemblies 24 can be disposed on opposite sides of the brake rotor 40 and can have similar or identical configurations. In at least one configuration, the brake pad assembly 24 may include a backing plate 80 and a friction material 82.

[0026] The backplate 80 can be a structural member of the brake pad assembly 24. The backplate 80 can be constructed as a generally flat plate and can be made of any suitable material such as a metal alloy. A pusher 60 can engage the backplate 80 of the brake pad assembly 24, which is positioned between the brake rotor 40 and the caliper housing 50. For example, the pusher 60 can engage the side of the backplate 80 that is opposite to the brake rotor 40 and can be positioned opposite to the friction material 82. Another backplate 80 of the brake pad assembly 24 can engage the caliper bridge 52.

[0027] Friction material 82 can be disposed on the side of back plate 80 that faces brake rotor 40. Friction material 82 can contact brake rotor 40 during vehicle braking.

[0028] The retainer band 26 can be removably mounted to the brake caliper 22. For example, the retainer band 26 can be removed from the brake caliper 22 to facilitate the removal or replacement of the brake pad assembly 24, and can be mounted on the brake caliper 22 to prevent the removal of the brake pad assembly 24. For example, the retainer band 26 can extend across the cavity 70 of the brake pad assembly 24 and the brake caliper 22 to help retain the brake pad assembly 24 in the brake bracket 20 when the retainer band 26 is secured to the brake caliper 22. When the retainer band 26 is mounted and secured to the brake caliper 22, the retainer band 26 can engage or contact the brake pad assembly 24 or the pad spring 30.

[0029] A pad spring 30 (if provided) may be at least partially disposed within the cavity 70. The pad spring 30 may apply a biasing force to components received within the cavity 70, such as the brake pad assembly 24 or the tappet 60. In the illustrated configuration, three pad springs 30 are shown; however, it is contemplated that a fewer number of pad springs 30 may be provided. The pad springs 30 may be spaced apart from each other and may extend from the retainer band 26 into the cavity 70. For example, from... Figure 2 From the angle shown, the uppermost pad spring 30 can extend from the retainer band 26 to the tappet 60, the middle pad spring 30 can extend from the retainer band 26 to the first brake pad assembly 24, and the remaining pad spring 30 can extend from the retainer band 26 to the second brake pad assembly 24.

[0030] In at least one configuration and as referenced Figure 2 As best shown, the retainer band 26 may extend along axis 90. Axis 90 may be oriented to extend between a first end 100 and a second end 102 of the retainer band 26. Thus, the retainer band 26 and axis 90 may extend substantially parallel to the axis of rotation of the brake rotor 40, and substantially parallel to the brake pad assembly 24 along its actuable axis 62. As used herein, the term "substantially parallel" means identical to or very close to parallel, and includes features or axes parallel to each other within ±2°.

[0031] The first end 100 of the retainer band 26 can be mounted to the clamp housing 50. For example, the first end 100 can contact the clamp housing 50 and can optionally be received in an opening, recess, or slot in the clamp housing 50.

[0032] The second end 102 of the retainer band 26 can be positioned opposite to the first end 100. The second end 102 can be disposed on and secured to the clamp bridge 52, such as by a fastener 104 like a bolt. The fastener 104 can extend through a hole in the retainer band 26. In at least one configuration, the second end 102 can be offset from the first end 100 in a generally vertical direction, such that the second end 102 is positioned closer to the axis of rotation of the brake rotor 40, rather than the first end 100 being positioned closer to that axis of rotation.

[0033] Main reference Figure 3 The retainer band 26 may also include an inner side 110, an outer side 112, a first lateral side 114, and a second lateral side 116.

[0034] The inner side 110 may face the brake bracket 20, the brake pad assembly 24, and the brake rotor 40. The pad spring 30 may engage or contact the inner side 110.

[0035] The outer side 112 can be configured to be opposite to the inner side 110. In this way, the outer side 112 can face away from the brake bracket 20 and the brake pad assembly 24.

[0036] A first lateral side 114 may extend between an inner side 110 and an outer side 112. For example, the first lateral side 114 may extend from the inner side 110 to the outer side 112. The first lateral side 114 may be configured to be substantially perpendicular to the inner side 110, the outer side 112, or portions thereof. The term "substantially perpendicular" is used herein to refer to features or axes that are the same as or very close to being perpendicular, and includes features perpendicular to each other within ±2°. Additionally, the first lateral side 114 may extend between a first end 100 and a second end 102. For example, the first lateral side 114 may extend from the first end 100 toward the second end 102, from the second end 102 toward the first end 100, or from the first end 100 to the second end 102.

[0037] The second lateral side 116 can be configured opposite to the first lateral side 114. Additionally, the second lateral side 116 can extend between the inner side 110 and the outer side 112. For example, the second lateral side 116 can extend from the inner side 110 to the outer side 112. Furthermore, the second lateral side 116 can extend between the first end 100 and the second end 102. For example, the second lateral side 116 can extend from the first end 100 toward the second end 102, from the second end 102 toward the first end 100, or from the first end 100 to the second end 102. In at least one configuration, the first lateral side 114 or a portion thereof can be configured substantially parallel to the second lateral side 116. The designation of the first lateral side 114 and the second lateral side 116 can be opposite to the designation shown.

[0038] Main Reference Figure 2 and Figure 3 The sensor assembly 28 can generate a signal indicating the position of the brake pad assembly 24. This signal, or a change thereof, can be used to determine the braking stroke or travel of the brake pad assembly 24. The sensor assembly 28 can be mounted to the retainer band 26. Furthermore, the sensor assembly 28 can be spaced apart from and not in contact with other components of the disc brake assembly 10, such as the brake bracket 20, brake caliper 22, brake pad assembly 24, pad spring 30, or combinations thereof.

[0039] The length of sensor assembly 28 may be shorter than the length of retainer band 26. Thus, sensor assembly 28 may extend across a portion of cavity 70. For example, sensor assembly 28 may extend at least partially across one or more brake pad assemblies 24, brake rotor 40, tappet 60, or combinations thereof. In the illustrated configuration, sensor assembly 28 extends across the first brake pad assembly 24 and brake rotor 40, and partially across the second brake pad assembly 24 and tappet 60. In at least one configuration, sensor assembly 28 may include sensor 120 and may optionally include mounting bracket 122.

[0040] Sensor 120 may be positioned adjacent to retainer band 26. For example, sensor 120 may be positioned adjacent to and able to contact a first lateral side 114 or a second lateral side 116 of retainer band 26.

[0041] Sensor 120 can be of any suitable type. For example, sensor 120 can be a variable resistance sensor, such as a linear potentiometer or a membrane sensor. Sensor 120 can be packaged such that sensor 120 is water- or waterproof and dust- or moisture-proof, thereby allowing sensor 120 to be mounted externally to disc brake assembly 10 while withstanding the expected environmental conditions.

[0042] Sensor 120 can be configured to directly or indirectly detect the position of brake pad assembly 24. For example, sensor 120 can detect positioner feature 130, which may be movable with brake pad assembly 24 and movable relative to sensor 120. Sensor 120 can generate a signal based on the position of positioner feature 130. Positioner feature 130 can be provided for brake pad assembly 24, pad spring 30, tappet 60, or combinations thereof. For illustrative purposes, positioner feature 130 is positioned relative to… Figures 4 to 6 and Figures 9 to 11 On the bushing spring 30 extending from the tappet 60, in Figure 7 and Figure 8 In the configuration shown, the positioner feature 130 is disposed on the pad spring 30 extending from the first brake pad assembly 24.

[0043] Positioner feature 130 can have any suitable configuration. For example, positioner feature 130 can be integrally formed with brake pad assembly 24, pad spring 30, or tappet 60, or it can be provided as a separate component. In the illustrated configuration, positioner feature 130 is configured as a protrusion on pad spring 30 extending away from brake bracket 20 and cavity 70. Thus, positioner feature 130 can be located on the side of pad spring 30 opposite to the axis of rotation of brake pad assembly 24 and brake rotor 40.

[0044] Sensor 120 can be a non-contact sensor or a contact sensor. In a non-contact configuration, sensor 120 can be spaced apart from and not in contact with locator feature 130, such as... Figure 5 , Figure 7 , Figure 10 and Figure 11As shown. In a non-contact configuration, the locator feature 130 can be detected in any suitable manner, including but not limited to auditory, capacitive, inductive, optical, magnetic, or combinations thereof. For example, the locator feature 130 can be configured to actuate the sensor 120 or a magnet that can be detected by the sensor 120. For example, a magnetic field generated by a magnet can attract movable features of the sensor 120, such as an arm that can be operatively connected to a sliding contact of the sensor 120. When the locator feature 130 moves relative to the sensor 120, the movement of the sliding contact can change the effective length of the conductor of the sensor 120. As another example, a membrane potentiometer can have a conductive membrane that can be deformed by the magnetic field of a magnet or actuated in response to a magnetic field generated by a magnet, and thus can be used to sense the position of the locator feature 130.

[0045] In a contact configuration, the positioner feature 130 can contact the sensor 120 and can apply a force detectable by the sensor 120. An example of a contact configuration is shown in... Figure 6 and Figure 8 As shown in the diagram. For example, locator feature 130 may contact sensor 120 or a movable part of sensor 120, such as a sliding element of an arm, or may deformable elements of sensor 120, such as a conductive film. When provided in a contact configuration, locator feature 130 may or may not be a magnet.

[0046] Main reference Figure 5 One or more positioning features may be provided to inhibit movement of the positioner feature 130. The positioning features may extend from the component on which they are mounted. For example, a first positioning feature 140 and a second positioning feature 142 may extend from the bushing spring 30 and engage the positioner feature 130 to inhibit movement of the positioner feature 130 relative to the bushing spring 30. The first positioning feature 140 and the second positioning feature 142 may be arranged along the travel direction of the brake bushing assembly. For example, the first positioning feature 140 and the second positioning feature 142 may be positioned on opposite sides of the positioner feature 130, such that the first positioning feature 140 is positioned between the clamp housing 50 and the positioner feature 130, while the second positioning feature 142 is positioned between the clamp bridge member 52 and the positioner feature 130. In at least one configuration, the positioning features may not be positioned between the sensor 120 and the positioner feature 130.

[0047] refer to Figure 3The mounting bracket 122 (if provided) can connect the sensor 120 to the retainer band 26. In at least one configuration, the mounting bracket 122 can be positioned on the outer side 112 of the retainer band 26. For example, the mounting bracket 122 can extend across the outer side 112 and may have retention features, such as hooks positioned at the distal end. The retention features may extend along the second lateral side 116 toward or to the inner side 110 of the retainer band 26. It is also contemplated that this orientation may be reversed. The mounting bracket 122 may be spaced apart from and may not contact other components of the disc brake assembly 10, such as the brake bracket 20 and the brake caliper 22.

[0048] refer to Figures 9 to 11 The sensor assembly 28' shown does not have a mounting bracket. For example, the sensor assembly 28' can be attached to the retainer band 26 in any suitable manner (such as by adhesive, fasteners, etc.). The sensor assembly 28' can be disposed on a lateral side of the retainer band 26, such as a first lateral side 114 or a second lateral side 116, and is depicted having a... Figures 1 to 8 The sensor 120' shown has a thinner profile. In this configuration, the sensor 120' can be configured as a membrane sensor. It is also contemplated that the sensor assembly 28' can be disposed on the inner side 110 of the retainer band 26.

[0049] By Figure 3 and Figure 4 and Figure 10 and Figure 11 A comparison is made to best understand the movement detected by sensors 120 and 120'. Figure 3 and Figure 10 In the diagram, brake assembly 10 is shown in a first position, wherein brake pad assembly 24 is retracted and spaced apart from brake rotor 40. Figure 4 and Figure 11 In the diagram, brake assembly 10 is shown in a second position, wherein brake pad assembly 24 extends to engage brake rotor 40 and apply friction to brake rotor 40. The signals generated by sensors 120, 120' can vary with the position of brake pad assembly 24, and therefore the position of positioner feature 130 varies accordingly.

[0050] The sensor assemblies 28, 28' described above can communicate with a control system (such as a braking control system that may include a microprocessor-based controller). Communication can occur wirelessly or via wires or cables.

[0051] The brake assembly described above can allow for the provision of a sensor assembly that generates a signal indicating the position of the brake pad assembly. This signal can be used to determine whether the brake assembly is operating as intended. For example, the signal can be used to monitor or detect movement of the brake pad assembly when braking is requested (i.e., during the brake stroke) or when adjusting the position of the tappet or one or more brake pad assemblies to compensate for wear of the friction material (e.g., operation of a wear adjuster mechanism that adjusts the operating clearance between the friction material and the brake rotor). If no movement is detected when braking is requested, the signal from the sensor can indicate potential traction on the brake pad assembly or a problem with the operation of the brake pad actuation system or the wear adjuster mechanism. In response, a notification can be provided to the vehicle operator or maintenance system.

[0052] As described above, the sensor assembly can be positioned outside the brake caliper, eliminating the need to provide space inside the brake caliper to house the sensor assembly. Furthermore, providing the sensor assembly externally eliminates potential leakage paths between the brake caliper's interior and the surrounding environment. For example, when providing an externally mounted sensor assembly, wires or cables do not need to be routed through holes in the brake caliper assembly to reach the sensor assembly.

[0053] The sensor assembly can be mounted onto the brake pad belt, allowing for easy access for installation or removal and enabling visual inspection without disassembling the brake assembly. Furthermore, the sensor assembly can be installed during the manufacturing process of the brake assembly or added as an aftermarket product to provide additional functionality. Additionally, the sensor assembly is compatible with a variety of brake assembly models that can be manufactured by different companies.

[0054] While exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms of the invention. Rather, the terminology used herein is descriptive rather than restrictive, and it should be understood that various changes can be made without departing from the spirit and scope of the invention. Furthermore, features of various implementations of the embodiments can be combined to form other embodiments of the invention.

Claims

1. A disc brake assembly, comprising: Brake caliper, the brake caliper defining a cavity for receiving a brake pad assembly; A retainer band, which is mounted to the brake caliper and extends across the cavity and the brake pad assembly; as well as A sensor assembly, which is mounted to the retainer band and generates a signal indicating the position of the brake pad assembly, wherein the sensor assembly is spaced apart from the brake pad assembly and does not contact the brake pad assembly.

2. The disc brake assembly as claimed in claim 1, wherein, The sensor assembly includes a sensor and a mounting bracket for attaching the sensor to the retainer band.

3. The disc brake assembly as claimed in claim 2, wherein, The retainer band includes an inner side facing the brake pad assembly and an outer side configured opposite to the inner side, wherein the mounting bracket is disposed on the outer side.

4. The disc brake assembly as claimed in claim 2, wherein, The retainer band includes an inner side facing the brake pad assembly, an outer side configured opposite to the inner side, and a first lateral side extending between the inner side and the outer side, wherein the sensor is configured adjacent to the first lateral side.

5. The disc brake assembly as claimed in claim 2, wherein, The retainer band extends across the second brake pad assembly received in the cavity, and the sensor assembly extends at least partially across the brake pad assembly and the second brake pad assembly.

6. The disc brake assembly as claimed in claim 4, wherein, The mounting bracket engages with the retainer band on a second lateral side opposite to the sensor.

7. A disc brake assembly, comprising: Brake bracket; Brake caliper, the brake caliper being mounted to the brake bracket; Brake pad assembly, the brake pad assembly being received in the brake bracket; A retainer band, which is mounted to the brake caliper and extends across the brake pad assembly; as well as A sensor assembly mounted to the retainer band and including a sensor for detecting the position of the brake pad assembly, wherein the sensor assembly is spaced apart from the brake pad assembly and does not contact the brake pad assembly.

8. The disc brake assembly as claimed in claim 7, wherein, The sensor is a variable resistance sensor.

9. The disc brake assembly of claim 7, wherein, The sensor is a linear potentiometer.

10. The disc brake assembly of claim 7, wherein, The sensor is a membrane sensor actuated in response to a magnetic field generated by a magnet.

11. The disc brake assembly of claim 7, wherein, The sensor detects positioner features that can move with the brake pad assembly.

12. The disc brake assembly of claim 11, wherein, The locator features contact with the sensor.

13. The disc brake assembly of claim 11, wherein, The locator feature is spaced apart from the sensor and does not contact the sensor.

14. The disc brake assembly of claim 11, wherein, The locator is characterized by a magnet.

15. The disc brake assembly of claim 11, wherein, The positioner feature is disposed on a bushing spring extending from the retainer band.

16. The disc brake assembly of claim 15, wherein, The positioner feature is disposed on the side of the bushing spring facing away from the brake bushing assembly.

17. The disc brake assembly of claim 15, wherein, The pad spring is mounted to the brake pad assembly.

18. The disc brake assembly of claim 15, wherein, The pad spring is mounted to a tappet, which is movable relative to the brake caliper and extends from the brake caliper to the brake pad assembly.

19. The disc brake assembly of claim 15, further comprising: A first positioning feature and a second positioning feature, the first positioning feature and the second positioning feature extending from the bushing spring and engaging the positioner feature to inhibit movement of the positioner feature.

20. The disc brake assembly of claim 19, wherein, The first positioning feature and the second positioning feature are positioned on opposite sides of the positioner feature and arranged along the travel direction of the brake pad assembly, such that the first positioning feature and the second positioning feature are not positioned between the positioner feature and the sensor.

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