Brake Disc Wear Indicator with Self-Referencing Visual Display
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Solution Overview
Problem
Current brake disc wear indicators are complex to produce and require additional tools for monitoring wear, making it difficult to determine the remaining service life without dismantling wheels, especially for commercial vehicles.
Innovation Solution
A brake disc with a visually recognizable wear indicator that changes appearance over decreasing wear levels, allowing for wear progression to be read without additional aids, using geometric designs such as ramps, funnels, or helical shapes in conjunction with a reference indicator for self-referencing and easy visualization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional wear indicators (recesses, pockets, grooves) are used in brake discs, then wear state can be detected, but additional measuring tools (micrometer screws, calipers) are required and direct access to the brake disc is needed, making monitoring complex and time-consuming
Solution Approach 1:
The brake disc wear indicator is designed to automatically display wear state through its own geometric features (conical recesses with varying depths, radial grooves, or annular recesses) that become visible or change appearance as wear progresses, eliminating the need for external measuring tools or complex monitoring systems
Solution Approach 2:
The wear indicator utilizes visual appearance changes through geometric design elements such as conical recesses with different depths, radial grooves, or annular recesses that create distinct visual patterns at different wear stages, allowing intuitive wear assessment without additional equipment
2Measurement precision
If brake disc thickness is measured regularly using micrometer screws to ensure safety, then accurate wear measurement is achieved, but the process requires wheel dismantling and workshop equipment, making it difficult for laypersons to perform independently
Solution Approach 1:
The wear indicator provides a self-explanatory visual display through geometric features (conical recesses, radial grooves, annular recesses) that show wear state directly, enabling any person to assess brake disc condition without specialized training or equipment
Solution Approach 2:
The mechanical measurement process using micrometer screws and calipers is replaced by a purely visual inspection system where the geometric wear indicator features provide direct visual information about brake disc thickness and wear state
3Reliability
If wear features are distributed over the circumference or radially to detect radial or concave oblique wear, then comprehensive wear monitoring is achieved, but the production complexity increases
Solution Approach 1:
The wear indicator is divided into multiple discrete geometric features (multiple conical recesses at different depths, radial grooves, or annular recesses) distributed around the brake disc, each representing different wear stages or wear patterns, allowing comprehensive wear assessment while maintaining manufacturing simplicity
Data Source
Figure 1A~1C
Figure 2A~2C
Figure 3A~3C
AI summary
The brake disc (1) comprises a wear indicator (6) which is incorporated into a braking surface (4) of the brake disc and is designed such that its appearance changes in a top view of the braking surface over a decreasing wear height; and a reference indicator (7A, 7B) which is incorporated into the braking surface of the brake disc and is designed such that its appearance does not change in a top view of the braking surface (4) over the decreasing wear height or changes differently relative to the change of the wear indicator in a predetermined manner, so that a progression of wear can be read from the appearance of the wear indicator in relation to the appearance of the reference indicator (7A, 7B).