Brake Disc Internal Microsystem for Sensor Reliability
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Solution Overview
Problem
Existing brake disc monitoring systems are costly, prone to mechanical damage, and susceptible to moisture and thermal fluctuations, leading to unreliable signal output and potential safety risks in vehicles due to incorrect brake responses.
Innovation Solution
A brake disc with a microsystem containing sensors and transmitters internally integrated within the friction disc or axle fastening device, protected from external influences, allowing for reliable parameter monitoring and wireless data transmission, and using piezo sensors and actuators for active control and identification signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor and transmitter are mounted on the brake disc or in its vicinity, then the brake disc can be monitored, but the mounting becomes complex and costs increase
Solution Approach 1:
The sensor device and transmitter device are merged into a single integrated microsystem that is cast directly into the brake disc as one unit. This eliminates the need for separate mounting of multiple components, simplifying the assembly process while ensuring the sensors remain protected and functional throughout the brake disc's service life.
2Reliability
If the sensor and transmitter are mounted externally, then monitoring is possible, but the components are susceptible to mechanical damage from external objects
Solution Approach 1:
The microsystem containing the sensor and transmitter devices is nested within the brake disc structure itself. The brake disc material encases and protects the sensitive electronic components from external mechanical threats such as falling rocks, snow, and other surfaces, while still allowing the sensors to detect temperature, vibration, and strain parameters.
3Reliability
If the transmitter and sensor are exposed, then monitoring function is available, but moisture causes leakage currents and short circuits
Solution Approach 1:
The microsystem is nested within the brake disc, providing inherent protection against moisture ingress. The brake disc material acts as a barrier that prevents moisture from reaching the electronic components, eliminating the problems of leakage currents and short circuits that would occur with exposed components in humid or wet environments.
4Reliability
If sensors are integrated internally, then protection from external influences is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The manufacturing process merges the production of the brake disc and the microsystem into a single casting operation. The microsystem is positioned in a mold along with the brake disc, and both are cast together as one integrated component. This approach distributes the precision requirements across the entire casting process rather than requiring separate high-precision assembly steps, making the manufacturing more feasible.
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
The solution ensures reliable sensor function over the brake disc's lifespan, enhances safety by providing accurate brake control and real-time adjustments, and reduces manufacturing costs through simplified assembly and protection from environmental damage.
Implementation Method 1
Depending on the type of sensor, thermal and/or mechanical loads present in the brake disc, such as compressive and tensile forces, deformation or vibrations, can be monitored. For example, thermocouples or integrated piezo sensors directly at the point of effect are suitable.
Implementation Method 2
The transmitting device is communicatively connected to the sensor device for the wireless output of a signal relating to the parameters detected by the sensor device.
Data Source
Figure 1
AI summary
The invention therefore relates to a brake disc (1), in particular for vehicles and motor vehicles, with a friction disc (10) arranged on an axle mounting device (20), wherein the brake disc (1) has a microsystem (30) with a sensor device (40) and a transmitter device (50), wherein the sensor device (40) comprises at least one sensor from the group consisting of temperature sensor, vibration sensor, structure-borne sound sensor and strain sensor, and wherein the transmitter device (50) is wirelessly connected to the sensor device (40) for the purpose of wirelessly outputting a signal (S) relating to the parameters detected by the sensor device (40), and wherein the microsystem (30) is arranged internally in the friction disc (10) and/or the axle mounting device (20).Furthermore, the invention relates to a braking system (100) with such a brake disc (1), a vehicle with such a braking system (100), the use of such a braking system (100) in a vehicle, and a method for operating such a braking system (100). Additionally, the invention relates to a method for manufacturing a brake disc (1) according to the invention.