Brake Caliper Electrical Sensing for Engagement Detection
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Solution Overview
Problem
Current brake systems lack effective means to electrically sense engagement status, force applied, and positional information of caliper assemblies, making it difficult to determine the degree of brake engagement and system performance.
Innovation Solution
A caliper-based brake system with integrated electrical sensing devices that measure electrical signals through conductive regions on the brake member, allowing for real-time monitoring of engagement status, force applied, and positional information, using dynamic electrical materials and frequency filtering to prevent cross-talk in multi-caliper systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If electrical sensing devices are integrated into the brake system to measure engagement status and force applied, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The electrical sensing device is integrated directly into the brake caliper assembly, merging the sensing function with the existing mechanical brake structure. This consolidation allows engagement status and force measurement capabilities to be built into the brake system itself, improving measurement precision while minimizing the increase in overall device complexity through functional integration rather than additive components.
Solution Approach 2:
The electrical sensing device performs multiple functions simultaneously: detecting engagement status, measuring force applied, and providing positional information. This multi-functionality approach allows a single integrated device to deliver comprehensive measurement capabilities, improving measurement precision across multiple parameters while avoiding the complexity increase that would result from implementing separate sensing devices for each function.
2Reliability
If multiple caliper assemblies are used in a brake system, then braking performance is improved, but cross-talk between sensing devices increases
Solution Approach 1:
The brake member is divided into distinct conductive regions, with each region associated with a specific caliper assembly. This segmentation of the conductive path allows each caliper's sensing device to measure electrical signals through its own dedicated conductive region, preventing cross-talk between adjacent caliper assemblies while maintaining the braking performance benefits of having multiple calipers.
Solution Approach 2:
Different portions of the brake member are given different electrical properties through the segmentation of conductive regions. Each conductive region is locally optimized to work with its corresponding caliper assembly, creating distinct measurement zones that prevent signal interference. This local differentiation of electrical properties enables accurate measurement from multiple calipers simultaneously without cross-talk.
3Measurement precision
If conductive regions are segmented on the brake member, then measurement precision is improved, but manufacturing precision requirements increase
Solution Approach 1:
The measurement system is designed to accommodate normal manufacturing variations in the positioning of conductive regions. The sensing device and conductive regions are configured to work together in a way that is tolerant of reasonable manufacturing tolerances, allowing the system to self-adjust or self-accommodate within normal production variations without requiring ultra-precise manufacturing. This approach maintains measurement precision while avoiding excessive manufacturing precision requirements.
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
Enables accurate detection of engagement and force applied by caliper assemblies, improving brake system efficiency and maintenance scheduling through real-time data, and providing precise positional information for complex systems like rotating platforms.
Implementation Method 1
an electrical sensing device disposed in the caliper assembly and electrically coupled to the brake blocks. The brake member includes a conductive region... the electrical sensing device measures an electrical current flow through the conductive region
Data Source
Figure 1
Figure 2A~2B
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AI summary
Present embodiments relate generally to brake systems (10), and more specifically, to caliper-based brake systems. In an embodiment, a method includes electrifying at least a portion of a first inner surface (30) of a first brake block (18) with a first potential. The method also includes electrifying at least a portion of a second inner surface (30) of a second brake block (19) with a second potential that is different from the first potential. The method includes performing an electrical measurement between the first brake block (18) and the second brake block (19), wherein the electrical measurement include a voltage measurement, a current measurement, a resistance measurement, a frequency measurement, or a combination thereof. The method further includes determining a position of the first and brake blocks (18, 19) relative to a brake member (14) based on the electrical measurement.