Brake Lining Wear Sensor Using Magnetic Coupling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing brake lining wear detection systems face challenges in precision and maintenance due to mechanical coupling, limited measurement range, and complex analysis logic, making it difficult to detect small wear displacements and complicating maintenance processes.
Innovation Solution
A device that translates linear brake lining displacement into rotary motion using a transmission, enabling precise detection with a contactless magnetic coupling to a sensor, such as a rotary potentiometer or Hall sensor, which generates an analog or pulse-width modulated signal, allowing for easy maintenance and calibration-free operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical coupling is used to communicate wear displacement to the sensor, then the sensor can detect the displacement, but the maintenance becomes very complicated and may require readjustment of the sensor
Solution Approach 1:
The patent replaces the mechanical coupling system with a magnetic coupling system. A magnet is attached to the brake piston, and a Hall sensor mounted on the brake caliper detects the magnetic field changes as the piston moves, enabling wear measurement without mechanical connection between the sensor and moving parts.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the moving brake piston and the stationary Hall sensor. The magnet on the piston modulates the magnetic field, which the Hall sensor detects, allowing information transfer without direct mechanical contact.
2Device complexity
If direct linear displacement measurement is used, then the measurement is simple, but the detection precision is insufficient for small wear displacements
Solution Approach 1:
The patent converts the linear displacement measurement problem into a magnetic field detection problem in a different dimension. Instead of measuring linear position directly, the Hall sensor detects changes in magnetic field strength caused by the piston's linear motion, achieving higher precision through indirect measurement.
3Reliability
If mechanical connection is used between sensor and brake caliper, then the sensor can be securely mounted, but separating the sensor for service or lining replacement is very complicated
Solution Approach 1:
The patent eliminates the mechanical connection between the sensor and the moving brake components by using magnetic coupling. The Hall sensor remains stationary on the caliper housing, while the magnet on the piston provides the coupling, allowing easy sensor removal without affecting brake components.
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
The solution provides a precise, reliable, and economical measurement of brake lining wear with simplified maintenance, as the contactless coupling eliminates mechanical connections and reduces the need for complex calibration, enhancing detection accuracy and ease of use.
Implementation Method 1
a Hall sensor is provided on a brake caliper and a magnet is provided on the brake piston. The relative linear displacement between the piston and brake caliper caused by the wear is determined by means of the resulting change in the magnetic field.
Implementation Method 2
For contactless communication of the rotary motion to the sensor, a contactless coupling, for example a clutch based on magnetic forces, is provided. For example, the coupling can be achieved by an electromagnetic field acting on the sensor whose change based on the lining displacement is detected by the sensor, for example by means of the Hall principle.
Data Source
AI summary
An apparatus is provided for measuring wear-induced displacement of a brake lining with respect to an associated brake caliper, comprising a gear mechanism for converting the wear-induced displacement into a rotary movement, having a sensor for detecting the rotary movement, wherein a contact-free coupling is provided for transmitting the rotary movement to the sensor. The apparatus is designed in such a way that the sensor generates an analogue or pulse-width-modulated detection signal for determining the wear-induced displacement of the brake lining, wherein the detection signal corresponds to the respective displacement caused by the rotary movement. The invention also related to a corresponding method for measuring the wear-induced displacement of a brake lining with respect to an associated brake caliper.