Brake Disc Wear Detection via Contact Sensor
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Solution Overview
Problem
Current brake systems lack sensors that can electronically measure the wear of brake discs and brake linings simultaneously and continuously during operation, particularly for motor vehicles, with no known solutions for continuous wear monitoring of brake discs.
Innovation Solution
A sensor arrangement that detects patterns on the brake disc, including grooves and material distribution, in contact with the disc to measure wear, and can be retrofitted, using a single sensor element attached to the brake pad or caliper, which measures wear by changes in electrical resistance or capacitance, and wirelessly transmits data for real-time monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a depth-dependent structure with QR codes is worked into the brake disc for wear detection, then wear information can be read opto-electronically, but the sensor or mobile device must be spaced from the brake disc surface, complicating the measurement setup
Solution Approach 1:
The patent replaces optical/electronic wear detection systems with a mechanical contact-based sensor. The sensor element directly contacts the brake disc surface through the brake lining, mechanically detecting wear patterns without requiring complex optical spacing or QR code reading mechanisms.
Solution Approach 2:
The brake lining serves as an intermediary medium that transmits wear information from the brake disc to the sensor element. As the brake lining wears against the disc, it carries the disc's wear patterns, allowing the sensor to indirectly measure disc wear through contact with the lining material.
2Loss of information
If separate sensors are used to measure brake disc wear and brake lining wear, then individual wear data can be obtained, but the system complexity and cost increase
Solution Approach 1:
The patent merges the detection of brake disc wear and brake lining wear into a single sensor element. The sensor simultaneously measures both the lining thickness (through its own wear) and the disc wear patterns (through contact with the disc), consolidating multiple measurement functions into one device.
Solution Approach 2:
The single sensor element is designed with universal functionality to detect multiple wear parameters. It can identify both the brake lining wear state and the brake disc wear patterns, making one sensor perform the work of multiple specialized sensors.
3Measurement precision
If wear indicators are based on visual inspection of markings on the brake disc, then the degree of wear can be estimated, but continuous electronic monitoring during operation is not achieved
Solution Approach 1:
The patent enables continuous wear monitoring throughout the brake lining's service life. The sensor element remains in constant contact with the brake disc via the brake lining, continuously detecting wear patterns during normal braking operations rather than requiring periodic visual inspections.
Solution Approach 2:
The wear detection system utilizes the natural braking process itself for measurement. During normal braking operations, the sensor automatically detects wear patterns without requiring separate inspection procedures, making the system self-monitoring during its operational cycle.
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 continuous, secure, and cost-effective monitoring of brake disc and lining wear, improving safety by providing accurate wear data for timely replacements and adapting braking strategies, and can be integrated with existing vehicle systems for enhanced driving safety.
Implementation Method 1
measures wear by changes in electrical resistance or capacitance
Implementation Method 2
measures wear by changes in electrical resistance or capacitance
Data Source
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AI summary
Sensor arrangement for detecting wear of components of a brake system. A brake system for a motor vehicle is imagined in particular here. In this case, the brake system has at least one brake disc and one brake pad. The sensor arrangement detects a pattern (303) of the brake disc (202), wherein the state of wear of the brake disc is detected by the sensor arrangement and can be displayed; it is no longer necessary to look at the brake disc.