Brake Disc Wear Indicator Recess for Tool-Free Wear Assessment
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Solution Overview
Problem
Conventional brake discs with high hardness coatings for friction surfaces are difficult to measure wear levels without specialized tools, making it impossible to determine when they need replacement, and they release harmful fine particles into the atmosphere.
Innovation Solution
A brake disc design with a wear indicator featuring a visible recess on the friction zones and friction-free zones, utilizing a two-layer coating with a hard outer layer and an intermediate layer, where the recess depth indicates wear levels visibly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high hardness coating is applied to the friction surface of the brake disc, then the wear resistance is improved, but the measurability of wear level deteriorates
Solution Approach 1:
The brake disc friction surface is segmented into multiple friction zones separated by friction-free zones. The wear indicator recess is positioned in a friction-free zone, allowing it to remain visible and measurable even as the friction zones wear down. This segmentation enables the wear indicator to function independently from the wear-prone friction surfaces.
Solution Approach 2:
The wear indicator recess acts as an intermediary element between the friction zones and the measurement process. By placing the recess in a friction-free zone, it serves as a reference feature that does not wear away with the friction zones, enabling accurate wear assessment through visual or measurement tool inspection of the recess depth relative to the worn friction zones.
2Duration of action of stationary object
If a high hardness coating is applied to the friction surface, then the service life is extended, but the ease of wear assessment deteriorates
Solution Approach 1:
The brake disc is divided into friction zones that experience wear and friction-free zones that do not. The wear indicator recess is located in a friction-free zone, creating a permanent reference feature that allows easy visual assessment of wear by comparing the recess visibility against the worn friction zones, eliminating the need for complex measurement procedures.
Solution Approach 2:
The wear indicator utilizes visual appearance changes - specifically the visibility or partial visibility of the recess - to indicate wear level. As the friction zones wear away, the recess transitions from being completely visible to partially visible or invisible, providing an intuitive visual cue for wear assessment without requiring specialized tools or procedures.
3Object-generated harmful factors
If the friction surface hardness is increased to reduce particle emissions, then the environmental harm is reduced, but the wear measurability deteriorates
Solution Approach 1:
By segmenting the brake disc surface into friction zones and friction-free zones, the wear indicator recess in the friction-free zone serves as a stable reference feature. This allows wear measurement of the high-hardness friction zones without requiring the recess itself to be measurable with the same tools, as wear assessment is done by visual inspection of recess visibility rather than direct measurement.
Solution Approach 2:
The wear indicator recess serves as an intermediary reference feature that enables wear assessment of the high-hardness friction surface. Since the recess is located in a friction-free zone with different wear characteristics, it provides a stable reference that facilitates wear measurement of the friction zones through visual comparison rather than direct measurement of the worn surface.
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 visual assessment of wear without tools, ensuring timely replacement and reducing particle emissions by providing a clear indication of wear state through a simple, rapid, and economical manufacturing process.
Implementation Method 1
the coating being obtained according to a very high speed laser material deposition technique called EHLA
Implementation Method 2
at least one wear indicator comprising a recess visible to the naked eye and comprising a first portion extending over the friction zone and a second portion extending the first portion and extending over the friction-free zone
Data Source
Figure 1
Figure 2~4
Figure 5
AI summary
Brake disc comprising a first face (2) and a second face (3) opposite the first face (2), each of the first and second faces (2, 3) comprising a substrate and an external surface (2a, 3a) of the substrate (2a, 3a), at least one of the external surfaces (2a, 3a) comprising a friction zone (4) of a brake pad and at least one friction-free zone (5, 6) of the brake pad. In addition, the brake disc (1) comprises at least one wear indicator (10) comprising a recess visible to the naked eye and comprising a first portion (12) extending over the friction zone (4) of said at least one external surface (2a, 3a) and a second portion (13) extending the first portion (12) and extending over the friction-free zone (5, 6).