Brake Pad Image Inspection Without Wheel Removal
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Solution Overview
Problem
The current process for inspecting brake linings of vehicle brake pads is labor-intensive and requires removing the vehicle's wheels, making it inefficient and time-consuming.
Innovation Solution
A system using a computerized image analysis system that captures a digital image of the brake pad's side view without removing the wheel, allowing for the measurement of brake lining and backing plate thickness, and calculates a ratio to determine if the brake lining has reached its useful life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the current manual inspection process is used, then the technician can visually assess brake lining thickness, but the process requires wheel removal and is labor-intensive
Solution Approach 1:
The patent replaces the manual mechanical inspection process with an automated optical measurement system. The system uses an image capture device to photograph the brake pad through the inspection hole and automatically measures the brake lining thickness using image processing algorithms, eliminating the need for wheel removal and manual gauge measurements.
Solution Approach 2:
The patent creates a digital copy (image) of the brake pad's side profile through the inspection hole. This digital representation allows for precise measurement of brake lining thickness without physical contact or wheel removal, enabling automated analysis while maintaining inspection accuracy.
2Measurement precision
If the manual inspection method is used, then the technician can determine brake lining thickness, but the process is complex and requires multiple steps
Solution Approach 1:
The patent extracts only the essential measurement information (brake lining thickness) by capturing an image through the existing inspection hole. The system processes only the relevant portion of the image to determine thickness, eliminating the need for complex manual procedures while maintaining measurement precision.
Solution Approach 2:
The patent replaces complex manual measurement procedures with automated image processing. The system uses computer vision algorithms to automatically identify the brake lining edges and calculate thickness, reducing operational complexity while improving measurement consistency and precision.
3Ease of operation
If wheel removal is required for inspection, then the technician can access the brake pad, but the process becomes time-consuming and inefficient
Solution Approach 1:
The patent utilizes the existing inspection hole in the brake caliper as a self-provided access point. The system is designed to work through this pre-existing opening, allowing inspection without wheel removal while maintaining ease of access to the brake pad for measurement purposes.
Data Source
AI summary
A method for inspecting a vehicle brake pad, without removal of a vehicle wheel, includes capturing a digital image a side of a brake pad with the wheel installed on the vehicle, and loading the digital image onto a display screen of an image analysis system. An on-screen thickness of each of the backing plate and brake lining is measured as a pixel count distance between a leading and trailing edge of each of the backing plate and brake lining. The image analysis system calculates a ratio between the measured pixel-count thicknesses of each of the backing plate and the brake lining, compares the ratio to a threshold value, and based on that comparison, generates a message indicative whether the brake lining needs to be replaced. The brake pad is replaced in response to a generated message in the image analysis system indicating the brake pad failed inspection.