Automated Sensor Guiding for Brake Disc Layer Thickness Measurement
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Solution Overview
Problem
Existing devices for detecting layer thickness on coated components, such as brake disks, are limited by their inability to efficiently measure all surfaces without manual rotation and positioning, which increases measurement time and costs.
Innovation Solution
A device with a guiding system that allows the sensor to move along both vertical and horizontal axes, pivot about a horizontal axis of rotation, and have a rotatable bearing surface, enabled by controllable actuators and guide rails, allowing for automated and precise layer thickness measurement across all surfaces with minimal setup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the sensor is mounted to move only along a vertical axis and pivot about a vertical axis of rotation, then the device structure is simpler, but the sensor cannot reach additional positions on the component surface, requiring manual rotation and increasing measurement time
Solution Approach 1:
The patent adds a horizontal axis of movement to the sensor's guiding mechanism, transforming it from a single-vertical-axis system to a two-dimensional movement system. This allows the sensor to reach additional positions on the component surface without manual intervention, directly improving measurement efficiency while the added horizontal guidance capability justifies the increased structural complexity
2Ease of operation
If the axis of rotation is vertically oriented, then the sensor can be positioned vertically, but the upper side, lower side and side walls require separate setups or manual rotation of the component
Solution Approach 1:
By changing the axis of rotation from vertical to horizontal orientation, the patent enables the sensor to pivot and access side walls and lower surfaces of the component without requiring manual rotation. This dimensional change in the rotation axis allows all surfaces to be measured in a single setup, eliminating time losses associated with repositioning
Solution Approach 2:
The patent implements automated guiding devices that dynamically position the sensor along horizontal and vertical axes with programmable control. This dynamic positioning system automatically adjusts the sensor's position and orientation to measure all surfaces sequentially, eliminating the need for manual rotation and reducing measurement time
3Measurement precision
If manual positioning and rotation is used, then the device structure is simpler, but measurement precision and repeatability decrease due to human intervention
Solution Approach 1:
The patent replaces manual mechanical positioning with an automated guiding system that uses controllable actuators (such as electric motors or servo mechanisms) to position the sensor along horizontal and vertical axes. This substitution of manual operation with automated mechanical control significantly improves measurement precision and repeatability, justifying the increased complexity of the guiding system
Solution Approach 2:
The automated guiding device incorporates control systems that can monitor and adjust the sensor's position along the horizontal and vertical axes in real-time. This feedback mechanism ensures precise positioning and consistent measurement quality, maintaining high measurement accuracy while managing the complexity of the automated system through intelligent control
Data Source
AI summary
A device for detecting a layer thickness of a coated component, particularly a brake disc for a disc brake of a motor vehicle, includes at least one holding device and a guiding device. The holding device has a bearing surface for the component. The guiding device is configured to hold and guide a sensor in order to measure the layer thickness. The sensor is configured to be moved by the guiding device along a vertical axis and pivot about a first axis of rotation that is oriented horizontally. The sensor is further configured to be moved by the guiding device along a horizontal axis.