Brake Pad Wear Sensor Head Layout for Reliable Cable Detection
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Solution Overview
Problem
Existing wear indication devices for vehicle brake pads are susceptible to damage due to the arrangement of signal cables, leading to incorrect information and diagnosis issues when both cables contact the brake disc simultaneously.
Innovation Solution
A wear indication device with a double channel configuration for signal cables, where each cable has a separate section with a distinct axial distance from the fixing section, and protrusions to maintain separation, ensuring that only one cable contacts the brake disc at a time, preventing simultaneous damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two signal cables are arranged in separate channels within the sensor head, then the reliability of wear detection is improved, but the device complexity increases
Solution Approach 1:
The sensor head is segmented into a double channel configuration with a first section and a second section, each accommodating a separate signal cable. This segmentation ensures that the cables are positioned at different axial distances from the brake disc, preventing simultaneous contact and damage, thereby improving wear detection reliability.
Solution Approach 2:
Different regions of the sensor head are assigned different functions: the first section positions one cable at a greater axial distance from the brake disc, while the second section positions the other cable at a smaller axial distance. This local differentiation ensures that only one cable contacts the brake disc at any given time, enhancing the reliability of wear signals.
2Reliability
If the sensor head is made robust and damage-resistant, then the reliability is improved, but the manufacturing complexity increases
Solution Approach 1:
The sensor head is divided into distinct first and second sections with different axial positions for cable accommodation. This segmented design allows for systematic manufacturing processes where each section can be formed and positioned independently, making the robust design more manufacturable.
Solution Approach 2:
The double channel configuration employs asymmetric positioning of the first and second sections relative to the brake disc, with different axial distances. This asymmetric design inherently protects the cables from simultaneous contact damage while maintaining manufacturability through precise but straightforward positioning features.
3Device complexity
If both cables are positioned at the same axial distance from the fixing section, then the device complexity is reduced, but incorrect wear information may be generated
Solution Approach 1:
The patent deliberately positions the first and second signal cables at different axial distances from the fixing section through the asymmetric double channel configuration. This asymmetry ensures that cables contact the brake disc at different wear stages, preventing simultaneous contact that would generate incorrect wear information, while maintaining clear and distinguishable wear signals.
Data Source
AI summary
A wear indication device (10) for a vehicle brake (1), preferably a disc brake of a commercial vehicle, for indicating a wear condition of a brake pad (20) comprising: a fixing section (12) for fixing the wear indication device (10) to a brake pad back plate (30), a sensor head (14) associated to the fixing section (12), and a channel (16) for receiving a signal cable (40) within the sensor head (14). According to the invention, the channel (16) is configured to receive two signal cables (40′, 40″).