Disc brake assembly having a sensor assembly attached to a retraction spring

Abstract

A disc brake assembly includes at least one brake pad retraction spring and a sensor assembly. The brake pad retraction spring extends between a pair of brake pad assemblies. The sensor assembly includes at least one sensor and a wiring harness. The sensor is disposed on the brake pad assembly. The wiring harness is attached to the brake pad retraction spring.

Description

Technical Field

[0001] The present invention relates to a disc brake assembly having a sensor assembly attached to a brake pad retraction spring. background

[0002] A disc brake having a spring is disclosed in US Pat. No. 4,491,204.

[0003] Overview

[0004] In at least one embodiment, a disc brake assembly is provided. The disc brake assembly includes a pair of brake pad assemblies, at least one brake pad retraction spring, and a sensor assembly. The brake pad retraction spring extends between the brake pad assemblies and biases the brake pad assemblies away from each other. The sensor assembly includes at least one sensor and a wiring harness. The sensor is disposed on the brake pad assembly. The wiring harness is electrically connected to the sensor and attached to the brake pad retraction spring. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Figure 1 is a perspective view of an example of a brake assembly with the sensor assembly omitted for clarity.

[0006] Figure 2 yes Figure 1 Exploded view of the brake assembly.

[0007] Figure 3 yes Figure 1 Top view of the brake assembly.

[0008] Figure 4 yes Figure 3 An enlarged view of a portion of the housing including the sensor assembly and showing the pad spring and retention band in phantom line for clarity.

[0009] Figures 5 to 8 An example of the attachment features used to attach the wiring harness of the sensor assembly to the brake pad retraction spring is shown.

[0010] Figure 9 and Figure 10 Shows an example of a wiring harness being clamped by the coils of a brake pad retraction spring.

[0011] Figure 11 An example showing a wiring harness threaded through the coil hole of a brake pad retraction spring.

[0012] Figures 12 to 19 yes Figure 4 Enlarged views of a portion of the brake assembly are shown illustrating additional sensor assembly configurations. DETAILED DESCRIPTION

[0013] As required, detailed embodiments of the present invention are disclosed herein; however, it should be understood that the disclosed embodiments are merely examples of the invention that may be embodied in various and alternative forms. The drawings are not necessarily to scale; some features may be exaggerated or minimized to illustrate details of particular components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

[0014] 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, farm equipment, military transport or munitions vehicle, or the disc brake assembly can be provided as part of cargo loading equipment for land, air, or marine vessels. In at least one configuration, the disc brake assembly 10 can include a brake carrier 20, a brake caliper 22, at least one brake pad assembly 24, one or more pad springs 26, a retaining band 28, and one or more brake pad retraction springs 30. The disc brake assembly 10 can also include a sensor assembly 32, an example of which is shown in FIG. Figure 4 Best shown in .

[0015] The brake bracket 20 can facilitate installation of the disc brake assembly 10. For example, the brake bracket 20 can be fixedly mounted to a component of the vehicle, such as an axle assembly or a steering knuckle. 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 manner, the brake bracket 20 can straddle the brake rotor 40 and help position the brake pad assemblies 24 on opposite sides of the brake rotor 40.

[0016] The brake caliper 22 can be mounted to the brake carrier 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 facilitate braking of the vehicle, as will be discussed in greater detail below. In at least one configuration, the brake caliper 22 can include a caliper housing 50 and a caliper bridge 52.

[0017] refer to Figure 1 and Figure 2The caliper housing 50 can be movably disposed on the brake carrier 20. For example, the caliper housing 50 can be slidable along a pair of guide pins that can be fixedly disposed on the brake carrier 20. The caliper housing 50 can receive or support various components that can facilitate actuation of the brake pad assembly 24. For example, the caliper housing 50 can support at least one tappet 60 that can protrude from an interior cavity of the caliper housing 50.

[0018] refer to Figure 2 , the tappet 60 can extend from the caliper housing 50 toward the brake rotor 40 to engage the brake pad assembly 24. The tappet 60 can be movable toward and away from the brake rotor 40. For example, the actuator can 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. The reaction force can then cause the caliper housing 50 and the caliper bridge 52 to move relative to the brake carrier 20 to actuate the brake pad assembly 24 disposed between the caliper bridge 52 and the brake rotor 40 into engagement with the opposite side of the brake rotor 40, thereby helping to slow the rotation of the brake rotor 40 and the associated vehicle wheel.

[0019] 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 can be a separate component mounted to the clamp housing 50. For example, the clamp bridge 52 can be coupled or secured to the clamp housing 50 with 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 the cavity 70.

[0020] The cavity 70 can at least partially receive the brake pad assembly 24 and the brake rotor 40. The cavity 70 can be configured as a large through-hole that can be surrounded by the brake caliper 22. A portion of the brake carrier 20 can extend into the cavity 70 and can help position the brake pad assembly 24. The brake pad assembly 24 can be inserted into the cavity 70 and installed on the brake carrier 20, or removed from the cavity 70 and the brake carrier 20 when the retention band 28 is removed.

[0021] Main references Figure 2 and Figure 3, a pair of brake pad assemblies 24 can be received in the brake carrier 20 and the cavity 70. The brake pad assemblies 24 can be disposed on opposite sides of the brake rotor 40 and can have similar or identical configurations. For ease of reference, the brake pad assembly 24 disposed between the brake rotor 40 and the tappet 60 can be referred to as the inboard brake pad assembly, while the brake pad assembly 24 disposed between the brake rotor 40 and the caliper bridge 52 can be referred to as the outboard brake pad assembly. Also for ease of reference, the brake pad assemblies 24 may be referred to below as the "first brake pad assembly" and the "second brake pad assembly." The first brake pad assembly and the second brake pad assembly can be the inboard brake pad assembly and the outboard brake pad assembly, respectively, or vice versa. In at least one configuration, the brake pad assembly 24 can include a backing plate 80 and a friction material 82.

[0022] The backing plate 80 can be a structural member of the brake pad assembly 24. The backing plate 80 can be configured as a generally flat plate and can be made of any suitable material, such as a metal alloy. The lifter 60 can engage the backing plate 80 of the inboard brake pad assembly 24. For example, the lifter 60 can engage a side of the backing plate 80 that can face away from the brake rotor 40 and can be positioned opposite the friction material 82. The backing plate 80 of the outboard brake pad assembly 24 can engage the caliper bridge 52. The backing plate 80 can also include a first hole 84 and a second hole 86 that can facilitate installation of the brake pad retraction spring 30. In at least one configuration, the first hole 84 and the second hole 86 can be positioned above the friction material 82.

[0023] The friction material 82 may be disposed on a side of the backing plate 80 that may face the brake rotor 40. The friction material 82 may contact the brake rotor 40 during vehicle braking.

[0024] The pad springs 26, if provided, can be at least partially disposed in the cavity 70. The pad springs 26 can apply a biasing force to components received in the cavity 70, such as the brake pad assembly 24 or the tappet 60. In the illustrated configuration, two pad springs 26 are shown; however, it is contemplated that a different number of pad springs 26 can be provided. The pad springs 26 can be spaced apart from one another and can extend from the retention band 28 into the cavity 70. For example, one pad spring 26 can extend from the retention band 28 to the inboard brake pad assembly 24, and another pad spring 26 can extend from the retention band 28 to the outboard brake pad assembly 24.

[0025] The retention band 28 can extend across the brake pad assembly 24 and the cavity 70 of the brake caliper 22 to help retain the brake pad assembly 24 in the brake carrier 20 when the retention band 28 is secured to the brake caliper 22. The retention band 28 can be removably mounted to the brake caliper 22. For example, a first end of the retention band 28 can be mounted to the caliper housing 50, while a second end of the retention band 28, disposed opposite the first end, can be mounted to the caliper bridge 52. The second end can be secured to the caliper bridge 52 in any suitable manner, such as with a fastener 90 (e.g., a bolt). The retention band 28 can be removed from the brake caliper 22 to facilitate removal and replacement of the brake pad assembly 24, and can be mounted on the brake caliper 22 to prevent removal of the brake pad assembly 24. The retention band 28 may engage or contact the brake pad assembly 24 , the pad spring 26 , the brake pad retraction spring 30 , or a combination thereof when the retention band 28 is installed and secured to the brake caliper 22 .

[0026] Main references Figure 2 and Figure 3 , the disc brake assembly 10 can be provided with at least one brake pad retraction spring 30. The brake pad retraction spring 30 can facilitate retraction of the brake pad assembly 24 away from the brake rotor 40 when no braking force is applied. In this way, the brake pad retraction spring can bias the brake pad assembly 24 away from the brake rotor 40 and away from each other. For example, first and second brake pad retraction springs 30 can be provided, the first brake pad retraction spring and the second brake pad retraction spring can extend from the retention band 28 in opposite lateral directions or from the Figure 3 The perspective shown extends left and right. The brake pad retraction spring 30 can extend between the inboard brake pad assembly 24 and the outboard brake pad assembly 24. For example, the brake pad retraction spring 30 can extend from the back plate 80 of the inboard brake pad assembly 24 to the back plate 80 of the outboard brake pad assembly 24.

[0027] The brake pad retraction spring 30 can be provided in various configurations. As an example, and as referenced Figure 2 and Figure 4 As best shown, the brake pad retraction spring 30 may include a first end 100 , a second end 102 , a spring coil 104 , a first arm 106 , a second arm 108 , and optionally one or more anti-rotation features 110 .

[0028] The first end 100 can be mounted to the brake pad assembly 24. For example, the first end 100 of the brake pad retraction spring 30 can be inserted into and received in the first aperture 84 of the backing plate 80 of the brake pad assembly 24. In at least one configuration, the first end 100 can be non-coplanar with the spring coil 104, the first arm 106, the anti-rotation feature 110, or a combination thereof when the brake pad retraction spring 30 is installed or when the brake pad retraction spring 30 is not installed and is in a free or uncompressed state.

[0029] The second end 102 can be disposed opposite the first end 100. The second end 102 can be mounted to another brake pad assembly 24. For example, the second end 102 of the brake pad retraction spring 30 can be inserted into and received in the second hole 86 of the backing plate 80 of the other brake pad assembly 24. In at least one configuration, the first end 100 can be non-coplanar with the spring coil 104, the second arm 108, the anti-rotation feature 110, or a combination thereof when the brake pad retraction spring 30 is installed or when the brake pad retraction spring 30 is not installed and is in a free or uncompressed state.

[0030] In a configuration having two brake pad retraction springs 30 , the first end 100 and the second end 102 of one brake pad retraction spring 30 may be mounted to the first brake pad assembly 24 and the second brake pad assembly 24 , respectively, while the first end 100 and the second end 102 of the other brake pad retraction spring 30 may be mounted to the second brake pad assembly 24 and the first brake pad assembly 24 , respectively.

[0031] The spring coil 104 can be disposed between the first end 100 and the second end 102. The spring coil 104 can engage the retention band 28. For example, the spring coil 104 can contact a side of the retention band 28 that can face the brake rotor 40 and the cavity 70. In this way, the retention band 28 can prevent the spring coil 104 from moving away from the brake rotor 40 or the brake pad return spring 30 from rotating away from the brake rotor 40. Figure 4 As best shown, the coil 104 can define a coil bore 120 that can extend about and surround an axis 122. The coil bore 120 and the axis 122 can be surrounded by one or more turns or spirals comprising the coil 104. For example, as shown in FIG. Figures 9 to 11 As best shown, the coil 104 can include a first coil portion 124 and a second coil portion 126 that can at least partially define the coil aperture 120 and can be continuous with one another. The first coil portion 124 and the second coil portion 126 can be stacked or arranged along the axis 122 such that the first coil portion 124 can be disposed above the second coil portion 126.

[0032] refer to Figure 4 , the first arm 106 can extend from the coil 104 toward the first end 100. In at least one configuration, the first arm 106 can include an arm bend 130 that can be disposed between and spaced apart from the coil 104 and the first end 100. In the illustrated configuration, the first arm 106 is provided without the anti-rotation feature 110; however, it is contemplated that the first arm 106 can also be provided with an anti-rotation feature.

[0033] The second arm 108 can be spaced apart from the first arm 106. The second arm 108 can extend from the spring coil 104 toward the second end 102. The second arm 108 can have the same configuration as the first arm 106 or a different configuration. In the illustrated configuration, the second arm 108 is provided with an anti-rotation feature 110.

[0034] The brake pad retraction spring 30 may optionally be provided with one or more anti-rotation features 110. The anti-rotation feature 110 may be provided between the spring coil 104 and the first end 100, between the spring coil 104 and the second end 102, or both. The anti-rotation feature 110 may engage the brake pad assembly 24, the pad spring 26, or both to resist rotation of the brake pad retraction spring 30 toward the brake rotor 40, thereby preventing the brake pad retraction spring 30 from contacting the brake rotor 40. For example, the anti-rotation feature 110 may be provided over at least a portion of the corresponding brake pad assembly 24 and may contact the corresponding brake pad assembly 24 to resist rotation of the spring coil 104 away from the retention band 28 and toward the brake rotor 40. Figures 2 to 4 and Figures 12 to 19 In the illustrated configuration, the anti-rotation feature 110 is depicted as a spring coil. In such a configuration, the coil of the anti-rotation feature 110 can define a hole 140 that can be surrounded by one or more turns or spirals comprising the coil. The anti-rotation feature 110 can be disposed between the pad spring 26 and the backing plate 80. Alternatively, the pad spring 26 or a portion thereof can be disposed between the backing plate 80 and the anti-rotation feature 110.

[0035] refer to Figure 4 , an example of a sensor assembly 32 is shown. The sensor assembly 32 can be configured to detect and communicate a condition or property of the disc brake assembly 10. The sensor assembly 32 can include one or more sensors 150 and a wiring harness 152. Additionally, one or more attachment features 154 can be associated with the sensor assembly 32.

[0036] The sensor 150 may be configured to provide a signal indicative of one or more properties associated with the disc brake assembly 10. As an example, the sensor 150 may detect or provide a signal indicative of wear of the friction material 82. Figure 4 In the illustrated configuration, four sensors 150 are shown; however, it is contemplated that a different number of sensors may be provided. The sensors 150 may be located in any suitable location. In the illustrated configuration, each sensor 150 is disposed on the back plate 80 of the brake pad assembly 24 and protrudes from the back plate 80 toward the brake rotor 40. After the friction material 82 has sufficiently worn, the sensors 150 may contact the brake rotor 40 during braking and provide a signal that may indicate wear of the friction material 82 and that the brake pad assembly 24 should be replaced. It is contemplated that the signal may be generated by the sensor 150 or may be associated with opening or closing an electrical circuit. For example, engagement of the brake rotor 40 with the sensor 150 may sever or otherwise interrupt a normally continuous electrical circuit, thereby causing a change in one or more electrical properties (such as current or voltage) that may be detected or identified by an electronic controller that may receive the signal in a manner known to those skilled in the art.

[0037] The wiring harness 152 may be electrically connected to the sensors 150 . The wiring harness 152 may include one or more conductors or wires that may extend from one or more sensors 150 .

[0038] In summary, the wiring harness can be configured to have sufficient length to move with the brake pad assembly when the brakes are applied and released. As a result, the wiring harness can flex, bend, or otherwise move during braking. The wiring harness can also move in response to vibrations that can be transmitted to the disc brake assembly while the vehicle is in motion. If the disc brake assembly is not properly configured, the wiring harness may be susceptible to damage during operation of the disc brake assembly. For example, if the wiring harness moves into contact with the brake rotor or becomes pinched between the brake pad assembly and the brake rotor, the wiring harness may be damaged. By attaching the wiring harness to one or more brake pad retraction springs, potential damage to the wiring harness can be avoided.

[0039] The harness 152 can be attached to the brake pad retraction spring 30 using one or more attachment features 154, can be attached directly to the brake pad retraction spring 30, or a combination thereof. The attachment features 154 can be separate from the brake pad retraction spring 30 and the harness 152. Direct attachment can utilize the brake pad retraction spring 30 or the harness 152 itself to facilitate attachment. Both types of attachment techniques will now be discussed.

[0040] refer to Figure 4, the attachment feature 154 can attach the wire harness 152 to the brake pad retraction spring 30 in a manner that allows limited movement of the wire harness 152 relative to the brake pad retraction spring 30 and / or the attachment feature 154, or prevents movement of the attached portion of the wire harness 152 relative to the brake pad retraction spring 30 and / or the attachment feature 154. The attachment feature 154 can have any suitable configuration. Figures 5 to 8 , some examples of attachment features 154 are shown.

[0041] exist Figure 5 , an attachment feature 154 is shown that can be configured as a tubular structure that can partially or completely surround the wire harness 152, the brake pad retraction spring 30, or both. The attachment feature 154 can be a tape (which can have an adhesive backing), a tube (which can or can not be a split-flow type), a clip, a rope, a strap, a hook-and-loop fastener, etc. It is also contemplated that the attachment feature can be an adhesive and can not completely surround the wire harness 152, the brake pad retraction spring 30, or both.

[0042] exist Figure 6 , the attachment feature 154 is configured as a coil spring. The coil spring can define a coil spring passage 160 through which the brake pad retraction spring 30 and the wire harness 152 can extend. For example, the coil spring can extend in a helical shape around the brake pad retraction spring 30 and the wire harness 152, and thus can define the coil spring passage 160 within the helical shape.

[0043] exist Figure 7 , the attachment feature 154 is also configured as a coil spring that defines a coil spring passage 160. The brake pad retraction spring 30 and the wire 152 can extend together through a portion of the coil spring passage 160 to help retain the wire 152 on the brake pad retraction spring 30. However, the coil spring and a portion of the coil spring passage 160 can receive the wire 152 but not the brake pad retraction spring 30, thereby applying a biasing force to the wire 152. As a result, the coil spring and the portion of the coil spring passage 160 that receives the wire 152 but not the brake pad retraction spring 30 can help control the movement of the portion of the wire 152 received in the coil spring passage 160 by applying a biasing force to the wire 152, such as might occur when the coil spring attempts to move to a straightened state. In this way, the coil spring can help guide the wire 152 away from the brake rotor 40 or where the wire 152 might become pinched between movable components of the disc brake assembly 10. The coils of the attachment feature 154 and the coil spring passage 160 can be of constant size or can have different sizes. For example, the area of ​​the coil spring passage 160 that receives both the wire harness 152 and the brake pad retraction spring 30 can be larger than the area that receives only one of these components.

[0044] exist Figure 8 , two attachment features 154 configured as coil springs are shown. The coil springs can define two or more coil spring passages. At least one coil spring passage can receive the brake pad retraction spring 30 but not the wiring harness 152, while another coil spring passage can receive the wiring harness 152 but not the brake pad retraction spring 30. In the configuration shown, the coil springs can define a first coil spring passage 160, a second coil spring passage 160', and optionally a third coil spring passage 160". The brake pad retraction spring 30 can extend through the first coil spring passage 160. The wiring harness 152 can extend through the second coil spring passage 160' and the third coil spring passage 160".

[0045] The second coil spring path 160' can be defined by coils of the coil spring that can be offset from the coils defining the first coil spring path 160. As such, the second coil spring path 160' can be disposed along a different coil spring axis than the first coil spring path 160. In at least one configuration, the second coil spring path 160' can extend from a first end of the coil spring.

[0046] The third coil spring path 160" can be defined by coils of the coil spring that can be offset from the coils defining the first coil spring path 160. As such, the third coil spring path 160" can be disposed along a different coil spring axis than the first coil spring path 160. In at least one configuration, the third coil spring path 160" can extend from a second end of the coil spring that can be disposed opposite the first end.

[0047] Attachment feature 154 at Figure 4 and Figures 12 to 19 It should be understood that the generic representation of an attachment feature can represent any of the attachment features discussed herein. It should also be understood that the generic representation of an attachment feature can represent a single attachment feature or a plurality of attachment features.

[0048] refer to Figure 9 、 Figure 10 、 Figure 18 and Figure 19 , some examples of directly attaching the wire harness 152 to the brake pad retraction spring 30 are shown. Direct attachment can occur without utilizing separate attachment features for the brake pad retraction spring 30 and the wire harness 152. For example, the brake pad retraction spring 30, the wire harness 152, or both can be configured to limit or prevent movement of the wire harness 152 relative to the brake pad retraction spring 30 without separate attachment features.

[0049] exist Figure 9 and Figure 10 In the embodiment of the present invention, the coil 104 can be configured to engage and clamp the wire 152. For example, the wire 152 can extend between the first coil portion 124 and the second coil portion 126.

[0050] exist Figure 9 , the wire harness 152 may pass through the coil aperture 120 through an opening defined by the first coil portion 124 (e.g., from above the coil 104 from the perspective shown) or alternatively through an opening defined by the second coil portion 126 (e.g., from below the coil 104 from the perspective shown).

[0051] exist Figure 10 In this embodiment, the wire harness 152 may pass between the first coil portion 124 and the second coil portion 126 without entering the coil hole 120 through the opening defined by the first coil portion 124 and the second coil portion 126 .

[0052] It is also envisaged that Figure 9 and Figure 10 The coil shown may be the coil of the anti-rotation feature 110 rather than the coil 104 from which the first and second arms 106 , 108 of the brake pad retraction spring 30 extend.

[0053] exist Figure 18 and Figure 19 In the embodiment of the present invention, the wire harness 152 can be wrapped around, looped through, or tied to the brake pad retraction spring 30 to limit movement of the wire harness 152 relative to the brake pad retraction spring 30. It is also contemplated that the wire harness 152 can be wrapped around, looped through, or tied to itself. In this way, the wire harness 152 can attach itself to the brake pad retraction spring 30.

[0054] refer to Figure 11 , shows an example of restricting the movement of the wire harness 152 by passing the wire harness 152 through the spring coil hole 120. The size of the spring coil hole 120 can determine the extent to which the movement of the wire harness 152 is restricted. For example, a spring coil hole 120 with a smaller diameter can restrict movement to a greater extent than a hole with a larger diameter due to the reduced area provided by the smaller diameter hole. Figure 11 , the wire harness 152 is not clamped by the spring coil 104. It is also contemplated that Figure 11 The spring coil 104 shown may be the spring coil with which the anti-rotation feature 110 is provided. In such a configuration, the wire harness 152 may be passed through the aperture 140 of the anti-rotation feature 110.

[0055] refer to Figure 4 and Figures 12 to 19An example of routing and attaching a wire harness 152 to one or more brake pad retraction springs 30 will now be discussed. It should be understood that the wire harness 152 can be attached to the brake pad retraction spring 30 using one or more attachment features 154, which can be configured as previously discussed. Furthermore, the wire harness 152 can be directly attached to the brake pad retraction spring 30 using any of the previously discussed direct attachment configurations. In the configurations discussed below, the direct attachment techniques can be substituted for one another.

[0056] exist Figure 4 and Figures 12 to 19 In FIG, the pad spring 26 and the retaining band 28 are simplified and shown in double-dashed lines to more clearly depict the sensor assembly 32. Figures 12 to 19 In the examples, for ease of reference, the sensor assembly is labeled with the number 32 and a superscript letter. In these examples, the brake pad retraction spring 30 and the sensor assembly 32 can be positioned below the pad spring 26, the retaining band 28, or both.

[0057] refer to Figure 4 , a wire harness 152 can be routed from the inside of the disc brake assembly 10 to one or more sensors 150. The wire harness 152 can then be routed laterally along the top of the brake pad assembly 24 in a direction that can extend away from the retention band 28 and toward the end of the brake pad retraction spring 30. The wire harness 152 can then be routed along the arms of the brake pad retraction spring 30. For example, a portion of the wire harness 152 can be routed along the second arm 108 of the brake pad retraction spring 30, which is located to the left of the retention band 28 from the perspective shown, while a portion of the wire harness 152 can be routed along the first arm 106 of the brake pad retraction spring 30, which is located to the right of the retention band 28. One or more attachment features 154 can attach or secure the wire harness 152 to the corresponding arm. The wire harness 152 can then be passed through the coil hole 120 of the coil 104 and can extend to the other arm of the brake pad retraction spring 30. For example, a portion of the wire harness 152 can be routed along the first arm 106 of the brake pad retraction spring 30, located to the left of the retention band 28, while a portion of the wire harness 152 can be routed along the second arm 108 of the brake pad retraction spring 30, located to the right of the retention band 28 from the perspective shown. The same attachment feature 154 or another attachment feature 154 can attach or secure the wire harness 152 to the arms. The wire harness 152 can then be routed along the top of another brake pad assembly 24 to another sensor 150. If the brake pad retraction spring 30 is provided with an anti-rotation feature 110, the wire harness 152 can also be routed through the hole 140 of the anti-rotation feature 110.

[0058] refer to Figure 12, showing the sensor assembly 32 A The configuration of Figure 4 4. The configuration shown is similar. In this configuration, the wire harness 152 can originate or start near the retention band 28. For example, the wire harness 152 can branch off from a location located above the brake rotor 40 and / or the retention band 28. Having the wire harness branches originate or start between the brake pad assemblies 24 or above the brake rotor 40 can allow the branches of the wire harness 152 to travel or move approximately equal distances. Thus, at least one wire harness branch can be configured to have a shorter length than a wire harness that does not originate or start above the brake rotor 40. For example, Figure 4 The configuration in the embodiment adopts the method of viewing the image from the perspective closest to the Figure 4 The inner sensor 150 is guided to the top of the Figure 4 Increasing the length of these harness branches provides additional opportunities for the harness 152 to become pinched or potentially misrouted. Additionally, the harness branches routed to the outboard sensors 150 must be of a greater length to account for not only the routing path of the harness branches, but also the movement of the brake pad retraction spring 30 and the movement of the caliper bridge 52 and outboard brake pad assembly 24 relative to the caliper housing 50 when the brakes are applied or released. Figure 12 In the configuration shown in FIG, the wire harness 152 may or may not pass through the spring coil 104 and may or may not be clamped by the spring coil 104.

[0059] refer to Figure 13 , showing the sensor assembly 32 B The configuration of Figure 4 The configuration shown is the same, except that the wire 152 does not pass through the coil 104. Instead, the wire 152 passes around the coil 104 and extends along an arc from one arm of the brake pad retraction spring 30 to the other arm of the brake pad retraction spring 30.

[0060] refer to Figure 14 , showing the sensor assembly 32 C The configuration of Figure 12 In this configuration, the sensor assembly 32 CA wireless transmitter 170 is included. One or more branches 180, 182 of the wiring harness 152 may extend from the wireless transmitter 170 to one or more sensors 150. The wireless transmitter 170 may wirelessly transmit to or communicate with a controller or control system, which the vehicle may be provided with in a manner known to those skilled in the art. For example, the wireless transmitter 170 may operate using communication principles similar to those associated with wireless tire pressure sensors. The wireless transmitter 170 may be provided in any suitable location. For example, the wireless transmitter may be provided on the retention band 28 or the brake pad retraction spring 30. For example, the wireless transmitter 170 may be provided on the coil 104 of the brake pad retraction spring 30. It is also contemplated that other sensor assembly configurations and wiring harness routings described herein may be provided with the wireless transmitter 170.

[0061] exist Figure 4 、 Figure 12 and Figure 13 , it is contemplated that multiple sensors and associated branches of the wiring harness 152 may be deleted. For example, the sensors 150 to the left of the retention band 28 and the portions of the wiring harness 152 extending therefrom may be deleted, or the sensors 150 to the right of the retention band 28 and the portions of the wiring harness 152 extending therefrom may be deleted. In such a configuration, the wiring harness 152 may be attached to a single brake pad retraction spring 30.

[0062] refer to Figure 15 , showing the sensor assembly 32 D 1 and 2. The configuration of the wire harness 152 in which the wire harness 152 is attached to multiple brake pad retraction springs 30. For example, the wire harness 152 may have a first branch 180 that may be attached to a first brake pad retraction spring 30 and a second branch 182 that may be attached to a second brake pad retraction spring 30. The branches may be attached to the arms of corresponding brake pad retraction springs 30 with attachment features 154 as shown, or may be directly attached as previously discussed.

[0063] refer to Figure 16 , showing the sensor assembly 32 E The configuration of Figure 15The configuration shown is similar. In this configuration, the first branch 180 and the second branch 182 can pass through the coils 104 of different brake pad retraction springs 30 or can be clamped by these coils. For example, the first branch 180 can pass through the coils 104 of one brake pad retraction spring 30 and can be attached to the arm of the brake pad retraction spring 30, while the second branch 182 can pass through the coils 104 of another brake pad retraction spring 30 or can be clamped by these coils and can be attached to the arm of the brake pad retraction spring 30.

[0064] refer to Figure 17 , showing the sensor assembly 32 F 1 , in which the wiring harness 152 is attached to one brake pad retraction spring 30. For example, the first branch 180 and the second branch 182 may be clamped and fixed by the coil 104 of the brake pad retraction spring 30 in a position that can be aligned with the brake rotor 40. The first branch 180 may extend from the coil 104 to one sensor 150, while the second branch 182 may extend from the coil 104 to another sensor 150. The sensors 150 may be provided on different brake pad assemblies 24.

[0065] refer to Figure 18 , showing the sensor assembly 32 G , in which the wiring harness 152 can be wrapped around or tied to one or more brake pad retraction springs 30. For example, the first branch 180 and the second branch 182 of the wiring harness 152 can be wrapped around or tied to the same brake pad retraction spring 30, which can be the brake pad retraction spring 30 that extends to the right of the retention band 28 from the perspective shown. The first branch 180 and the second branch 182 can extend to and engage the coil 104 of the same brake pad retraction spring 30. Before extending to the sensor 150, the first branch 180 can be clamped by or passed through the coil 104. Furthermore, the first branch 180 can extend to the sensor 150 without engaging other brake pad retraction springs 30. The second branch 182 can also extend to the coil 104 of the brake pad retraction spring 30 and then to other brake pad retraction springs 30. For example, from the perspective shown, the second branch 182 can extend from the coil 104 of the right brake pad retraction spring 30 to the coil 104 of the left brake pad retraction spring 30. The second branch 182 can be clamped by or pass through the coil 104 of the other brake pad retraction spring 30. The second branch 182 can then be wrapped around or tied to the arm of the other brake pad retraction spring 30 before extending to the corresponding sensor 150.

[0066] refer to Figure 19, showing the sensor assembly 32 H The configuration of Figure 18 The illustrated configuration is similar. In this configuration, the first branch 180 is clamped by the coil 104 of one brake pad retraction spring, while the second branch 182 is clamped by the same coil 104 and the coil 104 of the other brake pad retraction spring.

[0067] The configurations described above can allow the brake pad retraction spring to help support and guide the sensor assembly wiring harness. Furthermore, the wiring harness can be guided without additional support components, additional channels, or additional components attached to the retention band or the pad shield that can be secured by the retention band, thereby helping to reduce cost and complexity.

[0068] While exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms of the present invention. Rather, the terms used in this specification are illustrative rather than restrictive, and it should be understood that various changes may be made without departing from the spirit and scope of the present invention. Additionally, features of various implemented embodiments may be combined to form further embodiments of the present invention.

Claims

1. A disc brake assembly comprising: a first brake pad assembly and a second brake pad assembly; a first brake pad retraction spring extending between the first brake pad assembly and the second brake pad assembly and biasing the first brake pad assembly and the second brake pad assembly away from each other; as well as A sensor assembly, comprising: a first sensor disposed on the first brake pad assembly; and a wiring harness electrically connected to the first sensor and attached to the first brake pad retraction spring, Wherein, the first brake pad retraction spring has a coil, the coil defining a coil aperture, and wherein the wiring harness passes through the coil aperture.

2. The disc brake assembly according to claim 1, wherein: The sensor assembly includes a second sensor disposed on the second brake pad assembly, wherein the wiring harness is electrically connected to the second sensor.

3. The disc brake assembly of claim 1 , further comprising: a brake caliper defining a cavity for receiving the first brake pad assembly and the second brake pad assembly; and a retention band mounted to the brake caliper and extending across the cavity and the first and second brake pad assemblies, wherein the spring coil engages the retention band.

4. A disc brake assembly comprising: a first brake pad assembly and a second brake pad assembly; a first brake pad retraction spring extending between the first brake pad assembly and the second brake pad assembly and biasing the first brake pad assembly and the second brake pad assembly away from each other; as well as A sensor assembly, the sensor assembly comprising: a first sensor disposed on the first brake pad assembly; and a wiring harness electrically connected to the first sensor and attached to the first brake pad retraction spring, The first brake pad retraction spring includes an anti-rotation feature disposed adjacent to the first brake pad assembly or the second brake pad assembly and defining a hole through which the wiring harness passes.

5. A disc brake assembly comprising: a first brake pad assembly and a second brake pad assembly; a first brake pad retraction spring extending between the first brake pad assembly and the second brake pad assembly and biasing the first brake pad assembly and the second brake pad assembly away from each other; as well as A sensor assembly, the sensor assembly comprising: a first sensor disposed on the first brake pad assembly; and a wiring harness electrically connected to the first sensor and attached to the first brake pad retraction spring, wherein the first brake pad retraction spring has a coil that surrounds an axis and defines a coil hole, wherein the coil has a first coil portion and a second coil portion disposed along the axis, and wherein the wire harness extends between and is clamped by the first coil portion and the second coil portion.

6. A disc brake assembly comprising: a first brake pad assembly and a second brake pad assembly; a first brake pad retraction spring extending between the first brake pad assembly and the second brake pad assembly and biasing the first brake pad assembly and the second brake pad assembly away from each other; as well as A sensor assembly, the sensor assembly comprising: a first sensor disposed on the first brake pad assembly; and A wire harness is electrically connected to the first sensor and attached to the first brake pad retraction spring, wherein the wire harness is attached to the first brake pad retraction spring with an attachment feature that surrounds the wire harness and the first brake pad retraction spring.

7. The disc brake assembly according to claim 6, wherein: The attachment feature is a coil spring defining a coil spring passage through which the first brake pad retraction spring and the wiring harness extend.

8. The disc brake assembly according to claim 6, wherein: The attachment feature is a coil spring that defines a first coil spring path through which the first brake pad retraction spring extends and that defines a second coil spring path through which the wiring harness extends.

9. A disc brake assembly comprising: a first brake pad assembly and a second brake pad assembly; a first brake pad retraction spring extending between the first brake pad assembly and the second brake pad assembly and biasing the first brake pad assembly and the second brake pad assembly away from each other; as well as A sensor assembly, the sensor assembly comprising: a first sensor disposed on the first brake pad assembly; and A wiring harness is electrically connected to the first sensor and attached to the first brake pad retraction spring, wherein the first brake pad retraction spring includes a coil and first and second arms extending from the coil, wherein the wiring harness is attached to the first and second arms.

10. The disc brake assembly of claim 1, wherein: The sensor assembly includes a wireless transmitter, and the wiring harness extends from the first sensor to the wireless transmitter.

11. The disc brake assembly according to claim 10, wherein: The wireless transmitter is disposed on the first brake pad retraction spring.

12. The disc brake assembly of claim 1 , further comprising a second brake pad retraction spring extending between the first brake pad assembly and the second brake pad assembly and biasing the first brake pad assembly and the second brake pad assembly away from each other, wherein The wiring harness is attached to the first brake pad retraction spring and the second brake pad retraction spring.

13. A disc brake assembly comprising: a first brake pad assembly and a second brake pad assembly; a first brake pad retraction spring extending between the first brake pad assembly and the second brake pad assembly and biasing the first brake pad assembly and the second brake pad assembly away from each other; a second brake pad retraction spring extending between the first brake pad assembly and the second brake pad assembly and biasing the first brake pad assembly and the second brake pad assembly away from each other; as well as A sensor assembly, the sensor assembly comprising: a first sensor disposed on the first brake pad assembly; and a wiring harness electrically connected to the first sensor and attached to the first brake pad retraction spring and the second brake pad retraction spring, wherein the wiring harness includes a first branch attached to the first brake pad retraction spring and a second branch attached to the second brake pad retraction spring.

14. The disc brake assembly of claim 13, wherein: The first brake pad retraction spring and the second brake pad retraction spring each have a coil and a first arm and a second arm extending from the coil, wherein the first branch engages the coil of the first brake pad retraction spring and is attached to the first arm of the first brake pad retraction spring, and the second branch engages the coil of the second brake pad retraction spring and is attached to the first arm of the second brake pad retraction spring.

15. A disc brake assembly comprising: a first brake pad assembly and a second brake pad assembly; a first brake pad retraction spring extending between the first brake pad assembly and the second brake pad assembly and biasing the first brake pad assembly and the second brake pad assembly away from each other; as well as A sensor assembly, the sensor assembly comprising: a first sensor disposed on the first brake pad assembly; and a wiring harness electrically connected to the first sensor and attached to the first brake pad retraction spring, wherein the first brake pad retraction spring has a coil defining a coil aperture, and wherein the wiring harness includes a first branch electrically connected to the first sensor and a second branch electrically connected to a second sensor disposed on the second brake pad assembly, wherein the first branch and the second branch engage the coil of the first brake pad retraction spring.

16. A disc brake assembly comprising: a first brake pad assembly and a second brake pad assembly; a first brake pad retraction spring extending between the first brake pad assembly and the second brake pad assembly and biasing the first brake pad assembly and the second brake pad assembly away from each other; as well as A sensor assembly, the sensor assembly comprising: a first sensor disposed on the first brake pad assembly; and a wiring harness electrically connected to the first sensor and attached to the first brake pad retraction spring, wherein the wiring harness includes a first branch electrically connected to the first sensor and a second branch electrically connected to a second sensor disposed on the second brake pad assembly, wherein the first branch and the second branch are wound around the first brake pad retraction spring.

17. The disc brake assembly of claim 16, wherein: The first and second branches engage coils of the first brake pad retraction spring.

18. The disc brake assembly of claim 17, further comprising a second brake pad retraction spring extending between the first brake pad assembly and the second brake pad assembly and biasing the first brake pad assembly and the second brake pad assembly away from each other, wherein The second branch engages the second brake pad retraction spring.

19. The disc brake assembly of claim 18, wherein: The first branch passes through a coil of the first brake pad retraction spring, and the second branch passes through a coil of the second brake pad retraction spring.

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