Brake Lining Wear Gradient Analysis via Energy Input Monitoring
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Solution Overview
Problem
Existing brake wear monitoring systems are costly and inefficient in detecting wear behavior changes, particularly for brake pads with multiple layers of friction material, as they rely on expensive end contacts and cannot accurately track uneven wear patterns.
Innovation Solution
A method and system that utilize wear sensors to monitor the energy input during braking, analyzing the wear gradient over mileage to detect changes in friction material layers, eliminating the need for expensive end contacts and providing timely warnings for pad replacement by comparing wear gradients at regular intervals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If end contacts are used to determine wear, then wear detection is achieved, but the cost and assembly complexity increase significantly
Solution Approach 1:
The invention extracts the wear detection function from the complex end contact system and implements it through a simplified sensor system that monitors the position of the friction material relative to the backing plate, eliminating the need for complex mechanical end contacts while maintaining detection capability
Solution Approach 2:
The invention replaces the mechanical end contact system with an electrical or electronic sensor system that detects wear through electrical signals or position sensing, thereby reducing mechanical complexity and assembly requirements
2Loss of information
If individual wear sensors are installed on all four disc brakes, then comprehensive wear information is obtained, but the system cost increases
Solution Approach 1:
The invention creates a universal wear monitoring system where a single sensor design can be applied to all disc brakes, and the sensor serves multiple functions including wear detection, position monitoring, and integration with existing vehicle communication systems, thereby reducing overall system cost
Solution Approach 2:
The invention merges the wear sensor system with existing vehicle communication buses and control units, combining multiple functions into a unified system that reduces component count and overall system cost while maintaining comprehensive wear information
3Device complexity
If wear is monitored only at end contact points, then simple detection is achieved, but changes in wear behavior of multi-layer friction material cannot be detected
Solution Approach 1:
The invention segments the wear detection approach by monitoring multiple parameters including position, wear gradient, and energy input rather than relying on a single end contact point, enabling detection of wear behavior changes in multi-layer friction material through analysis of wear patterns across different zones
4Reliability
If expensive end contacts are used, then reliable wear detection is achieved, but cost reduction is not possible
Solution Approach 1:
The invention employs cost-effective sensor elements that can be easily replaced if needed, using inexpensive position sensors and communication bus integration rather than expensive reusable end contacts, thereby achieving reliable wear detection at lower system cost
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
A method for analysing the wear behaviour of brake linings of a brake system has at least the following steps: a) making available a brake system with at least one or more brakes, each with one or more brake linings (6a, 6b) which each have a lining carrier plate (10, 11) and a friction lining composed of at least two or more friction material layers (12, 13) which are composed of different friction materials; and at least one evaluation device (8); b) determining the wear which is brought about per brake during braking operations with at least one wear sensor per brake; c) determining the braking energy which is brought about per brake during braking operations with the evaluation device; d) repeated determination of an instantaneous gradient of a curve which relates the values determined in steps b) and c) and preferably a route information item to one another; and e) outputting a signal at an output device if the gradient changes.