Disc Brake Adjuster Assembly With Integrated Wear Sensor
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Solution Overview
Problem
Conventional disc brake adjuster mechanisms with continuous wear sensors occupy excessive space, are susceptible to corrosion, and risk jamming due to excessive torque application, leading to reduced brake performance and potential overheating.
Innovation Solution
Integration of a continuous wear sensor and manual rewind apparatus into a single assembly within the disc brake housing, featuring a clutch mechanism that slips at a predetermined torque to prevent jamming and a compact design that reduces component count and improves packaging efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the continuous wear sensor is mounted as a standalone unit away from the manual adjuster, then the sensor can be easily accessed and replaced, but it occupies excessive space in the brake housing and is susceptible to corrosion and damage
Solution Approach 1:
The patent combines the continuous wear sensor with the manual rewind apparatus into a single integrated assembly. The sensor is mounted on the same bracket as the adjuster shaft, allowing both components to share the same mounting location and protection structure. This merging eliminates the need for separate mounting space while maintaining operational accessibility through the exterior access feature.
2Productivity
If excessive torque is used when manually re-winding the adjuster, then the brake pads can be quickly repositioned, but the adjuster becomes locked or jammed in the fully rewound end position
Solution Approach 1:
The patent incorporates a fuse component on the adjuster shaft that is designed to shear off when excessive torque is applied. This fuse acts as a protective mechanism that prevents the adjuster mechanism from being locked or jammed by absorbing the excessive force through controlled failure of the fuse, thereby protecting the main adjuster mechanism while allowing quick repositioning under normal conditions.
3Manufacturing precision
If excessive torque is used to wind the mechanism forward to take up excess running clearance, then the brake pad clearance is reduced, but the adjuster can be locked in an advanced position leading to overheating
Solution Approach 1:
The fuse component provides protective cushioning against excessive torque in both directions of operation. When adjusting forward to take up running clearance, if excessive torque is applied that would lock the adjuster in an advanced position, the fuse shears off to prevent this condition, thereby preventing the brake pads from being forced into a position that would cause overheating of the friction material.
4Manufacturing precision
If the housing has apertures or recesses for each component on three separate planes, then each component can be properly positioned, but three separate machining operations are required after casting
Solution Approach 1:
The patent consolidates multiple components (manual rewind apparatus, continuous wear sensor, and related mounting features) into a single integrated assembly that mounts to the housing from one location. This integration reduces the number of separate apertures and recesses needed in the housing, thereby reducing the number of separate machining operations required after casting, while maintaining proper positioning accuracy through the integrated mounting design.
Data Source
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AI summary
An adjuster assembly (150) for manually adjusting the position of a brake pad (18) relative to a brake rotor (16) of a disc brake, the assembly comprising: a continuous wear sensor (424); and a manual rewind apparatus (226, 326, 426) to manually reset the position of the brake pad (18) when replacement thereof is required; the manual rewind apparatus (226, 326, 426) comprising a shaft (132, 232) arranged to extend into a housing (120) of the disc brake; wherein the continuous wear sensor (424) is arranged to be located within the housing (120) of the disc brake and is located proximate to the shaft.