Brake Caliper Guide Assembly With Protected Wear Sensor Space
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Solution Overview
Problem
Existing disc brake guide assemblies face challenges in accommodating manufacturing tolerances, thermal effects, and deflections, while also being costly and susceptible to environmental contamination when incorporating wear sensors.
Innovation Solution
A caliper guide assembly with a guide pin and bore that includes a void for a wear sensor, where the sensor is protected from the environment and utilizes non-circular cross-sectional profiles for smooth guidance and space optimization, and optionally features a cover for secure mounting and contamination prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a wear sensor is added to the guide assembly, then wear detection capability is improved, but device complexity and cost increase
Solution Approach 1:
The wear sensor is integrated into the guide assembly by accommodating it within the void space between the guide portion and guide bore, merging the wear detection function with the existing guidance structure. This eliminates the need for separate sensor mounting components and reduces overall device complexity.
Solution Approach 2:
The guide assembly is designed to serve multiple functions: providing mechanical guidance for the caliper and simultaneously housing the wear sensor for brake pad monitoring. The void space that would otherwise be redundant is utilized for sensor accommodation, making the guide assembly a multi-functional component.
2Measurement precision
If a wear sensor is added to the guide assembly, then wear detection capability is improved, but manufacturing cost increases
Solution Approach 1:
The sensor cover is integrated with the guide assembly structure, combining the sensor housing function with the existing guide components. This merger eliminates the need for separate sensor mounting brackets or additional fastening hardware, thereby reducing manufacturing steps and material costs.
Solution Approach 2:
The guide assembly structure itself provides the mounting environment for the wear sensor through its void space, eliminating the need for external mounting components. The structure serves its primary guidance function while simultaneously providing the necessary accommodation for the sensor, reducing overall component count and manufacturing complexity.
3Measurement precision
If the wear sensor is exposed in the guide assembly, then wear detection capability is improved, but reliability decreases due to environmental contamination
Solution Approach 1:
The wear sensor is nested within the guide assembly structure, specifically housed within the void space between the guide portion and guide bore. This nesting arrangement protects the sensor from environmental contamination while maintaining its wear detection functionality through the non-contact measurement approach.
Solution Approach 2:
The sensor cover acts as a protective shell that encloses the wear sensor, shielding it from environmental contaminants such as brake dust and moisture. The cover allows the sensor to function while maintaining a protected environment, similar to how flexible shells protect sensitive components.
4Volume of moving object
If a non-circular guide surface is used, then space for wear sensor is created, but manufacturing complexity increases
Solution Approach 1:
The guide surface is designed with a non-circular, oval cross-section instead of a conventional circular profile. This asymmetric geometry creates the necessary void space for accommodating the wear sensor while maintaining smooth guidance characteristics. The oval shape provides sufficient clearance for the sensor without requiring complex manufacturing processes.
Data Source
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AI summary
A caliper guide assembly comprising a guide pin (11a) having a guide portion; a guide bore (12a) having a guide surface arranged to receive the guide portion and permit relative axial sliding thereof; and a wear sensor (62a) arranged to detect the position of the guide pin in relation to the guide bore; wherein the guide pin and the guide surface have different cross sectional profiles to define at least one void therebetween at long at least part of their length and the wear sensor is at least partially accommodated within the void.