Brass electrode embedded aluminum oxide high-temperature-resistant brake wear sensor

Abstract

The invention discloses a brass electrode embedded aluminum oxide high-temperature-resistant brake wear sensor, and belongs to the technical field of sensors. The abrasion sensor comprises an abrasion sensor body, the abrasion sensor body is provided with a ceramic base body and a brass electrode, the brass electrode is composed of a lower electrode body part and an upper electrode body part, an installation groove is formed in the upper electrode body part, the ceramic base body is installed in the installation groove in an embedded mode, and two penetrating holes are formed in the ceramic base body. And signal leads are matched in the two through holes. Through the composite design of the alumina ceramic substrate and the brass electrode, the stability of the sensor under an extreme working condition is ensured by using the high hardness, high temperature resistance and insulation characteristics of alumina ceramic, and meanwhile, the linear change of resistance / capacitance signals is realized by the high conductivity and abradability characteristics of the brass electrode, so that the detection precision is improved; the thermal expansion coefficients of the ceramic substrate and the brass electrode are matched, thermal stress cracking caused by temperature change is avoided, and the service life of the sensor is remarkably prolonged.

Description

Technical Field

[0001] This invention relates to the field of sensor technology, specifically to a high-temperature brake wear sensor with brass electrodes embedded in alumina. Background Technology

[0002] Automobiles are the primary means of transportation for modern people, and with rapid economic development, the number of cars is increasing year by year. Due to the increasing number of cars, people encounter various unexpected situations while driving on the road, requiring them to apply the brakes to slow down the vehicle using brake pads. Brake wear sensors monitor changes in brake pad thickness, therefore, the performance of brake wear sensors directly affects the safety and reliability of the vehicle's braking system. With the widespread application of carbon-ceramic brake discs in high-end automobiles and aerospace, the working environment of braking systems has become more demanding, especially high-temperature (>700℃) and high-friction conditions, which place higher requirements on the heat resistance, conductivity, and mechanical strength of sensors.

[0003] Currently, brake wear sensors are mainly made of metal-based or pure ceramic materials. Metal sensors suffer from signal distortion due to oxidation and mismatch in thermal expansion coefficients, while pure ceramic sensors are brittle, easily broken, and have low electrical response sensitivity. Furthermore, traditional contact sensors are difficult to adapt to the extreme wear environment of carbon ceramic discs, resulting in a high false alarm rate. Traditional plastic alarm sensors are prone to carbonization and melting at high temperatures, losing their alarm function. Therefore, metal-based or pure ceramic wear sensors are prone to failure under high temperature (>700℃) and high friction conditions of carbon ceramic brake discs. Summary of the Invention

[0004] The purpose of this invention is to provide a high-temperature brake wear sensor with brass electrode embedded in alumina. By using a composite structure of alumina ceramic substrate and brass electrode, the problem of easy failure of traditional metal or pure ceramic sensors under high temperature and high friction conditions is solved.

[0005] This invention is achieved through the following technical solution:

[0006] This invention relates to a brass electrode embedded alumina high-temperature resistant brake wear sensor, comprising a wear sensor body, which has a ceramic substrate and a brass electrode. The brass electrode is composed of a lower electrode part and an upper electrode part. An installation groove is formed on the upper electrode part, and the ceramic substrate is embedded in the installation groove. Two through holes are formed on the ceramic substrate, and signal leads are fitted into the two through holes.

[0007] The preferred lower electrode portion is L-shaped, with a positioning groove at the top and the bottom of the ceramic substrate located within the positioning groove.

[0008] The preferred lower electrode portion has a reserved slot, which is connected to the positioning slot, and the two ends of the signal lead pass through the reserved slot.

[0009] The preferred upper electrode and lower electrode have circular holes on their respective sides, with vertical rods fitted into the two circular holes and spring pieces sleeved on the vertical rods.

[0010] The preferred spring has a mounting part, an elastic part, and a groove. The mounting part is located on the outside of the ceramic substrate and has a through hole for engaging the vertical rod. There are two elastic parts, which are respectively mounted on both sides of the mounting part, and each of the two elastic parts has a groove at its end.

[0011] The preferred upper electrode portion is provided with a limiting component, which has a left horizontal bar, a right horizontal bar and a double-ended screw. Two arc-shaped grooves are opened on the corresponding side of the left and right horizontal bars. The two opposing arc-shaped grooves form a limiting hole. The signal lead is located in the limiting hole. A slider is installed at the end of the left and right horizontal bars. A threaded groove is opened in both sliders. The two ends of the double-ended screw are threaded into the corresponding threaded grooves.

[0012] The preferred upper electrode portion is provided with a sliding groove and a relief groove, both sliders are slidably fitted in the sliding groove, and the end of the double-ended screw is located in the relief groove.

[0013] The preferred double-ended screw has two baffles at the middle, and one side of each of the two sliders contacts the corresponding side of the baffle.

[0014] The preferred arc-shaped groove is fitted with a rubber pad.

[0015] A protrusion is preferably installed on one side of the left horizontal bar, and a groove for matching the protrusion is opened on the corresponding side of the right horizontal bar.

[0016] The present invention has the following beneficial effects:

[0017] This invention utilizes a composite design of an alumina ceramic substrate and a brass electrode. The high hardness, high temperature resistance (>700℃), and insulation properties of the alumina ceramic ensure the stability of the sensor under extreme conditions. At the same time, the high conductivity and wear-resistant properties of the brass electrode enable linear changes in the resistance / capacitance signal, improving detection accuracy. The matching thermal expansion coefficients of the ceramic substrate and the brass electrode prevent thermal stress cracking caused by temperature changes, significantly extending the service life of the sensor.

[0018] This invention utilizes a spring-loaded structure with a stainless steel spring's elastic part and groove design to achieve rapid installation and stable fixation of the sensor on the brake pad. The elastic part adapts to changes in brake pad thickness and withstands high-frequency vibration, ensuring continuous contact between the ceramic substrate and the friction surface. It also facilitates maintenance and replacement, can be directly embedded into existing brake pad structures without modifying the braking system, and has strong compatibility.

[0019] This invention uses a limiting component to drive the left and right horizontal bars to merge through a double-headed screw. The signal lead is flexibly clamped by the arc groove and rubber pad. Combined with the interlocking of the protrusion and groove and the limiting of the baffle, it prevents the lead from loosening or wearing due to high temperature vibration, thus ensuring the long-term reliability of signal transmission.

[0020] Of course, any product implementing this invention does not necessarily need to achieve all of the advantages described above at the same time. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the wear sensor body.

[0022] Figure 2 This is a schematic diagram of the structure of the upper electrode part and the ceramic matrix;

[0023] Figure 3 This is a schematic diagram of the lower pole body and the spring sheet.

[0024] Figure 4 This is a schematic diagram of the upper electrode body and the limiting assembly.

[0025] Figure 5 This is a schematic diagram of the internal structure of the upper polar body.

[0026] In the diagram: 1. Wear sensor body; 2. Upper electrode part; 201. Mounting groove; 202. Sliding groove; 203. Relief groove; 3. Lower electrode part; 301. Reserved groove; 302. Circular hole; 4. Ceramic substrate; 401. Through hole; 5. Signal lead; 6. Vertical rod; 7. Spring; 701. Mounting part; 702. Elastic part; 703. Hook groove; 8. Limiting component; 801. Left horizontal bar; 802. Right horizontal bar; 803. Arc groove; 804. Slider; 805. Threaded groove; 806. Double-ended screw; 9. Baffle; 10. Rubber pad; 11. Protrusion; 12. Groove. Detailed Implementation

[0027] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0028] Please see Figure 1-5This invention provides a technical solution: a brass electrode embedded alumina high-temperature resistant brake wear sensor, comprising a wear sensor body 1, the wear sensor body 1 having a ceramic substrate 4 and a brass electrode, the ceramic substrate 4 being made of a high-hardness, high-temperature resistant ceramic material (such as alumina 3), possessing excellent high-temperature resistance and insulation properties, the brass electrode being composed of a lower electrode portion 3 and an upper electrode portion 2, the lower electrode portion 3 being L-shaped, with a positioning groove formed at the top of the lower electrode portion 3, the bottom of the ceramic substrate 4 being located within the positioning groove, a reserved groove 301 formed within the lower electrode portion 3, the reserved groove 301 being connected to the positioning groove, the two ends of a signal lead 5 passing through the reserved groove 301, an installation groove 201 formed on the upper electrode portion 2, the ceramic substrate 4 being embedded and installed within the installation groove 201, and a through-hole forming on the ceramic substrate 4. There are two holes 401, and signal leads 5 are fitted inside the two holes 401. The signal leads 5 are made of mica wire. After the signal leads 5 pass through the holes 401 of the ceramic substrate 4, they extend to the reserved groove 301 and finally connect to the external monitoring circuit for real-time transmission of wear signals. When this device is in use, the wear sensor body 1 is installed at the wear position of the brake pad. The brass electrode and the ceramic substrate 4 form a complete conductive circuit. The thermal expansion coefficient of the brass electrode matches that of the ceramic substrate 4. During the use of the brake pad, friction causes the ceramic substrate 4 to wear gradually, the effective conductive cross-sectional area decreases, and the resistance value increases (or the capacitance / impedance changes). When the resistance value exceeds the set threshold (corresponding to the minimum allowable thickness of the brake pad), the monitoring circuit triggers an alarm signal (such as a dashboard warning light or vehicle system prompt).

[0029] Both the upper electrode portion 2 and the lower electrode portion 3 have circular holes 302 on their corresponding sides. Vertical rods 6 are vertically fitted into the two circular holes 302. Spring pieces 7, made of stainless steel, are fitted onto the vertical rods 6. Each spring piece 7 has a mounting part 701, an elastic part 702, and a groove 703. The mounting part 701 is located on the outside of the ceramic substrate 4 and has a through hole for fitting the vertical rods 6. There are two elastic parts 702, which are respectively installed on both sides of the mounting part 701. Each end of the elastic part 702 is provided with a hook groove 703. When the wear sensor body 1 is installed, the mounting part 701 of the spring piece 7 is sleeved on the vertical rod 6, pushing the wear sensor body 1 toward the brake pad. The edge of the brake pad squeezes the two elastic parts 702, causing them to elastically contract into the wear sensor body 1 until the hook groove 703 is located in the fixing groove or edge of the brake pad. At this time, the elastic part 702 expands outward so that the hook groove 703 is inserted into the fixing groove or edge of the brake pad, thus completing the installation of the wear sensor body 1.

[0030] The upper electrode part 2 is provided with a limiting component 8, which has a left horizontal bar 801, a right horizontal bar 802, and a double-ended screw 806. Two arc-shaped grooves 803 are formed on opposite sides of the left horizontal bar 801 and the right horizontal bar 802. Rubber pads 10 fit inside the arc-shaped grooves 803 to prevent wear on the signal lead 5 during clamping. The two opposing arc-shaped grooves 803 form a limiting hole, in which the signal lead 5 is located. Slider blocks 804 are installed at the ends of the left horizontal bar 801 and the right horizontal bar 802. Threaded grooves 805 are formed in both sliders 804. The two ends of the double-ended screw 806 are threaded into the corresponding threaded grooves 805. The upper electrode part 2 is provided with... There are a sliding groove 202 and a relief groove 203. Both sliders 804 are slidably engaged in the sliding groove 202. The end of the double-ended screw 806 is located in the relief groove 203. The relief groove 203 facilitates the rotation of the double-ended screw 806. When the limiting component 8 is in use, the left horizontal bar 801 and the right horizontal bar 802 are in a separated state, and the signal lead 5 is not clamped, which is convenient for installation and adjustment. Then, the double-ended screw 806 is rotated. Since the threads at both ends are opposite, the left slider 804 and the right slider 804 are driven to move towards each other along the sliding groove 202. The left horizontal bar 801 and the right horizontal bar 802 move closer together, so that the arc groove 803 merges into a complete limiting hole, which wraps around and clamps the signal lead 5.

[0031] Two baffles 9 are fitted at the middle of the double-ended screw 806. One side of each of the two sliders 804 contacts the corresponding side of the baffle 9. The baffle 9 is a limiting structure. When the left horizontal bar 801 and the right horizontal bar 802 are closed, the two sliders 804 move until they contact the baffle 9 to prevent the sliders 804 from moving excessively and causing the threads to strip or the signal lead 5 to be damaged. A protrusion 11 is installed on one side of the left horizontal bar 801, and a groove 12 is opened on the corresponding side of the right horizontal bar 802 to engage with the protrusion 11. When the left horizontal bar 801 and the right horizontal bar 802 are fully closed, the protrusion 11 is embedded in the groove 12 to form a mechanical interlock and prevent the limiting component 8 from loosening.

[0032] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to the specific implementations described. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A brass electrode embedded alumina high-temperature resistant brake wear sensor, comprising a wear sensor body (1), characterized in that: The wear sensor body (1) has a ceramic substrate (4) and a brass electrode. The brass electrode is integrally formed by a lower electrode part (3) and an upper electrode part (2). The upper electrode part (2) has a mounting groove (201). The ceramic substrate (4) is embedded in the mounting groove (201). The ceramic substrate (4) has two through holes (401). Signal leads (5) are fitted into the two through holes (401).

2. The high-temperature resistant brake wear sensor with brass electrode embedded in alumina as described in claim 1, characterized in that, The lower electrode portion (3) is L-shaped, and a positioning groove is provided on the top of the lower electrode portion (3). The bottom of the ceramic substrate (4) is located in the positioning groove.

3. The high-temperature resistant brake wear sensor with brass electrode embedded in alumina as described in claim 2, characterized in that, The lower electrode part (3) has a reserved slot (301) inside, the reserved slot (301) is connected to the positioning slot, and the two ends of the signal lead (5) pass through the reserved slot (301).

4. The high-temperature resistant brake wear sensor with brass electrode embedded in alumina as described in claim 1, characterized in that, The upper electrode part (2) and the lower electrode part (3) are provided with a circular hole (302) on one side, and a vertical rod (6) is vertically fitted in the two circular holes (302), and a spring piece (7) is sleeved on the vertical rod (6).

5. A high-temperature resistant brake wear sensor with brass electrode embedded in alumina as described in claim 4, characterized in that, The spring (7) has a mounting part (701), an elastic part (702) and a groove (703). The mounting part (701) is located on the outside of the ceramic substrate (4). The mounting part (701) has a through hole for cooperating with the vertical rod (6). There are two elastic parts (702). The two elastic parts (702) are respectively installed on both sides of the mounting part (701). The ends of the two elastic parts (702) are provided with grooves (703).

6. A high-temperature resistant brake wear sensor with brass electrode embedded in alumina as described in claim 1, characterized in that, The upper electrode part (2) is provided with a limiting component (8). The limiting component (8) has a left horizontal bar (801), a right horizontal bar (802) and a double-ended screw (806). The left horizontal bar (801) and the right horizontal bar (802) each have two arc-shaped grooves (803) on their corresponding sides. The two opposing arc-shaped grooves (803) form a limiting hole. The signal lead (5) is located in the limiting hole. The ends of the left horizontal bar (801) and the right horizontal bar (802) are each equipped with a slider (804). The two sliders (804) each have a threaded groove (805). The two ends of the double-ended screw (806) are threaded into the corresponding threaded grooves (805).

7. A high-temperature resistant brake wear sensor with brass electrode embedded in alumina as described in claim 6, characterized in that, The upper pole body (2) is provided with a sliding groove (202) and a relief groove (203). The two sliders (804) are slidably engaged in the sliding groove (202), and the end of the double-headed screw (806) is located in the relief groove (203).

8. A high-temperature resistant brake wear sensor with brass electrode embedded in alumina as described in claim 6, characterized in that, The double-ended screw (806) is fitted with a baffle (9) at the middle part. There are two baffles (9), and one side of each of the two sliders (804) is in contact with the corresponding side of the baffle (9).

9. A high-temperature resistant brake wear sensor with brass electrode embedded in alumina as described in claim 6, characterized in that, A rubber pad (10) is fitted inside the arc-shaped groove (803).

10. A high-temperature resistant brake wear sensor with brass electrode embedded in alumina as described in claim 6, characterized in that, A protrusion (11) is installed on one side of the left horizontal bar (801), and a groove (12) that matches the protrusion (11) is opened on the corresponding side of the right horizontal bar (802).

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