Brake Clearance Monitoring via Displacement Sensor Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for monitoring brake lining wear and clearance in commercial vehicles are inadequate, as they fail to detect malfunctions such as excessive or insufficient clearance, leading to potential brake overheating and system failure, and require manual checks.
Innovation Solution
A method using displacement sensors integrated into the brake actuation chain, connected to an electronic evaluation unit, which detects signal differences between brake actuated and non-actuated states to determine actual clearance and generate warnings for deviations from setpoint values, allowing for early detection of brake malfunctions and increased operational reliability without additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a rotary potentiometer and angle sensor are used to monitor brake clearance, then the clearance can be measured, but the system cannot detect malfunctions such as unintentional brake application or insufficient clearance
Solution Approach 1:
The patent implements feedback by comparing the measured clearance value with a predetermined target clearance value. The evaluation unit continuously monitors the clearance and generates a warning signal when the measured value deviates from the target value by more than a predetermined amount, enabling detection of both excessive and insufficient clearance conditions that indicate malfunctions
Solution Approach 2:
The patent monitors changes in the clearance parameter over time and compares it against target values. By evaluating whether the clearance parameter remains within acceptable deviation limits from the target clearance, the system can detect malfunctions such as unintentional brake application (insufficient clearance) or wear adjustment failures (excessive clearance)
2Device complexity
If manual clearance checks are performed, then the system is simple, but the operational reliability is reduced and time is lost
Solution Approach 1:
The brake clearance monitoring system performs self-service by automatically measuring the clearance between brake components and comparing it with target values. The electronic evaluation unit continuously monitors the clearance parameter and generates warning signals without requiring manual intervention, enabling the system to self-diagnose clearance-related malfunctions and maintain operational reliability
Solution Approach 2:
The patent replaces manual mechanical clearance checking with an electronic sensor-based measurement system. A displacement sensor electronically measures the clearance parameter and transmits the signal to an evaluation unit, substituting the mechanical manual checking process with an automated electronic monitoring system that improves reliability and reduces time loss
3Ease of operation
If clearance is not monitored accurately, then the system is simpler to operate, but brake overheating and system failure can occur
Solution Approach 1:
The system provides automatic feedback by continuously comparing the measured clearance value with the target clearance value. When the clearance deviates from the target by more than a predetermined amount, the evaluation unit generates a warning signal, enabling early detection of conditions that could lead to brake overheating or system failure without requiring complex manual monitoring procedures
Solution Approach 2:
The patent implements preliminary action by continuously monitoring the clearance parameter and generating warning signals before critical failure occurs. By detecting clearance deviations early and alerting the driver before the brake system fails or overheats, the system prevents harmful effects while maintaining ease of operation through automated monitoring
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 enables continuous monitoring of brake clearance, detecting both excessive and insufficient clearance, preventing brake overheating and system failures, and reducing the need for manual checks, thereby enhancing operational reliability and safety.
Implementation Method 1
at least one displacement sensor for each wheel brake, which is switched into the actuation chain of the brake actuation
Data Source
Figure 1
AI summary
The method involves connecting a displacement sensor (18) with an electronic evaluation unit (20). The brake lining wear and air gap of service brake are detected. The electronic evaluation unit is provided to evaluate whether the detected air gap is larger or smaller than the predetermined air gap. A warning indicator is activated, when the detected air gap is larger or smaller than the predetermined air gap. The warning signal with high priority is generated, if smaller air gap is detected. Independent claims are included for the following: (1) device for monitoring brake lining wear and air gap of service brake in motor vehicle; and (2) motor vehicle.