Acoustic Brake Component Sensing for Non-Contact Position Detection
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Solution Overview
Problem
Conventional position sensing methods for brake mechanisms in heavy-duty vehicles, such as hall-effect sensors, magnetic sensors, string potentiometers, and optical sensors, face limitations including the need for metal isolation, physical attachment, and sensitivity to optical changes, which affect reliability and cost-effectiveness.
Innovation Solution
The use of an acoustic sensor that emits signals, such as infrasonic, sonic, or ultrasonic, to determine the position of brake actuator components by measuring the time difference between signal emission and reception, allowing for non-contact, reliable, and cost-effective position sensing without the need for metal proximity or physical attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If hall-effect sensors or magnetic sensors are used for position sensing, then position detection capability is improved, but metal isolation requirements and device complexity increase
Solution Approach 1:
The patent replaces magnetic field-based sensing (hall-effect sensors) with acoustic wave-based sensing. The acoustic sensor emits acoustic waves that reflect off the brake component, eliminating the need for metal isolation shields and complex magnetic field management while maintaining position detection capability.
Solution Approach 2:
The patent introduces acoustic waves as an intermediary medium for position sensing. Instead of directly sensing magnetic fields or mechanical position, the sensor uses acoustic wave emission and reflection timing to indirectly determine component position, simplifying the sensing system.
2Measurement precision
If optical sensors are used for position sensing, then measurement precision is improved, but sensitivity to optical reflectivity changes and cost increase
Solution Approach 1:
The patent substitutes optical sensing with acoustic sensing. Acoustic waves are less sensitive to surface reflectivity properties compared to optical signals, eliminating the problem of optical reflectivity changes affecting measurement accuracy while maintaining position sensing precision.
3Measurement precision
If string potentiometers are used for position sensing, then position measurement is achieved, but physical attachment requirements and reliability decrease
Solution Approach 1:
The patent replaces mechanical string potentiometers with contactless acoustic sensing. The acoustic sensor measures position by timing the reflection of acoustic waves from the brake component, eliminating physical attachment requirements and the associated reliability issues with mechanical wear and tear.
4Measurement precision
If conventional sensors are used for position sensing, then position detection is achieved, but cost-effectiveness decreases
Solution Approach 1:
The patent employs acoustic sensors that are generally more cost-effective than hall-effect, magnetic, or optical sensors. The acoustic sensing system eliminates the need for expensive metal isolation shields, complex magnetic shielding, and precision optical components, reducing overall system cost while maintaining position detection functionality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides accurate and reliable position sensing of brake components, enhancing the reliability and cost-effectiveness of brake system monitoring, while eliminating the limitations of conventional methods.
Implementation Method 1
A sensor is configured to emit a signal directed toward the brake actuator component and to receive the signal after the signal bounces off the brake actuator component and is reflected back to the sensor
Implementation Method 2
The sensor may be configured to transmit the data to the controller, the data representative of the time difference between when the sensor emitted the signal and when the sensor received the signal
Data Source
AI summary
A brake actuator with a pushrod configured to actuate a brake of a vehicle. The pushrod is movable between a retracted position and an extended position to actuate the brake. A brake actuator component is operatively coupled to the pushrod. A sensor is configured to emit a signal directed toward the brake actuator component and to receive the signal after the signal bounces off the brake actuator component and is reflected back to the sensor. A disc brake with a disc brake component and a sensor configured to emit a signal directed toward the disc brake component. The sensor is configured to receive the signal after the signal bounces off the disc brake component and is reflected back to the sensor. The sensor may be an acoustic sensor.