Brake Pad Piezoceramic Sensing for Real-Time Force Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current vehicle braking systems cannot detect forces between brake pads and the disc or drum during braking, leading to issues like abnormal wear, noise, and vibration, due to the incompatibility of existing sensors with high temperatures and pressures.
Innovation Solution
Integration of high-temperature piezoceramic sensors with a metallic support element, embedded within a friction material block, which generates an electrical signal proportional to applied forces without external power, allowing for real-time detection and processing of braking forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If piezoelectric sensors are integrated into brake pads to detect forces during braking, then measurement precision is improved, but the sensors cannot withstand the high temperatures and pressures during production and braking
Solution Approach 1:
The patent changes the material parameters of the piezoelectric sensor by selecting specific piezoceramic materials with high Curie temperatures (above 200°C) and applying thermal treatment during brake pad manufacturing to polarize the sensors in situ. This allows the sensors to withstand the high temperatures and pressures of both production and braking operations while maintaining force detection capability.
Solution Approach 2:
The patent applies preliminary thermal treatment and polarization to the piezoceramic sensors during the brake pad manufacturing process, before the sensors are subjected to operational conditions. This preliminary action ensures the sensors are pre-conditioned to withstand the high temperatures and pressures they will encounter during actual braking, thereby improving their reliability.
2Difficulty of detecting and measuring
If piezoelectric sensors are placed on brake pads to detect forces in real-time, then detection capability is improved, but the system complexity increases due to integration requirements
Solution Approach 1:
The patent merges the piezoelectric sensor integration with the existing brake pad manufacturing process by applying thermal treatment and polarization during standard production steps. This combining of sensor integration with conventional manufacturing reduces overall system complexity while enabling real-time force detection capability.
Solution Approach 2:
The piezoceramic sensors are polarized in situ during the brake pad manufacturing process itself, using the existing thermal treatment equipment and procedures. This self-service approach eliminates the need for separate sensor polarization equipment and processes, thereby reducing system complexity while achieving real-time detection capability.
3Device complexity
If traditional braking systems are used without force detection, then device complexity is reduced, but abnormal wear and vibrations cannot be detected or prevented
Solution Approach 1:
The patent replaces complex mechanical force measurement systems with piezoelectric sensors that generate electrical signals in response to mechanical stress. This substitution maintains relative system simplicity while dramatically improving the ability to detect and prevent abnormal wear and vibrations through real-time electrical signal monitoring.
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 precise, real-time detection of braking forces, preventing abnormal wear and vibrations, and allowing for active or passive control of the braking system to eliminate unwanted noise and indicate abnormal conditions, while avoiding premature brake pad replacement and energy inefficiencies.
Implementation Method 1
at least one piezoceramic sensor (15) capable of emitting an electrical signal when subjected to a mechanical force
Data Source
AI summary
A method in which at least one piezoceramic sensor, which converts every mechanical force to which it is subjected into an electrical signal and having a Curie temperature higher than 200° C., is solidarized directly onto the surface of a metal support element of a vehicle braking element, which during use faces a vehicle element to be braked. While in contact with such a surface, an electrical circuit is implemented that picks up and eventually processes the electrical signal, the electrical circuit being connected with a connector integrated with the metal support element. An electrically insulating layer sandwiches the at least one piezoceramic sensor and the electrical circuit, and a block of friction material with an underlying damping layer is formed upon the electrically insulating layer. After forming the block of friction material, the piezoceramic sensor is polarized by applying a predetermined potential difference thereto by means of the connector.