Brake Pad Sensor Retrofit via Spring Release Mechanism
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Solution Overview
Problem
Existing brake pads with preassembled wear end indicators are difficult to replace or retrofit, leading to unnecessary replacement of the entire pad and increased inventory costs due to nonreleasable fastening of the pad-retaining spring to the carrier plate.
Innovation Solution
A brake pad design where the pad-retaining spring can be moved relative to the pad carrier plate, allowing the sensor to be inserted or removed even after the spring is connected, by releasing the pad-retaining clamp and creating sufficient space between the spring and carrier plate to accommodate the sensor's height, enabling easy replacement and retrofitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the pad-retaining spring is connected nonreleasably to the pad carrier plate, then the brake pad structure is simplified and manufacturing is easier, but the sensor cannot be replaced without replacing the entire brake pad
Solution Approach 1:
The brake pad is divided into separable components: the pad-retaining spring can be detached from the pad carrier plate by removing the retaining clamp. This segmentation allows the sensor to be accessed and replaced independently by first removing the retaining clamp, then the spring, then the sensor, without replacing the entire brake pad assembly.
Solution Approach 2:
The connection between the pad-retaining spring and pad carrier plate is made dynamic rather than static. The retaining clamp enables the spring to be fixed during operation but removable when needed for sensor replacement, providing both operational stability and maintenance flexibility.
2Productivity
If the brake pad is preassembled with the wear end indicator, then production efficiency is improved, but inventory costs increase due to inability to replace only defective sensors
Solution Approach 1:
The brake pad system is segmented into replaceable modules: the sensor can be independently replaced from the brake pad body. This allows manufacturers to stock separate sensors rather than entire brake pad assemblies, reducing inventory requirements while maintaining preassembly benefits for components that cannot be easily separated.
Solution Approach 2:
Only the defective sensor is removed and discarded, while the functional brake pad body, friction material, and other components are retained and reused. This selective replacement approach reduces the quantity of materials that need to be inventoried and disposed of.
3Reliability
If the pad-retaining spring is held in a compressed position, then the sensor is securely held captively, but the sensor cannot be inserted or removed
Solution Approach 1:
The pad-retaining spring transitions between two states: compressed and secured when the retaining clamp is engaged (providing reliable sensor retention), and relieved when the clamp is removed (allowing sensor insertion or removal). This dynamic state change enables both secure operation and easy maintenance.
Solution Approach 2:
Before sensor installation or removal, the retaining clamp is preliminarily removed to relieve the spring, creating the necessary space and access. This preliminary action prepares the system for sensor manipulation, and after sensor installation, the clamp is reengaged to restore the compressed, secure state.
Data Source
AI summary
A brake pad of a disc brake is provided, in particular for a commercial vehicle. A pad carrier plate supports a friction lining. A pad-retaining spring, which is movable relative to the pad carrier plate in the clamping direction, is nonreleasably connected by a hood fastened on the pad-retaining spring. An electric final wear indicator is attached with a sensor fitted on the edge of the pad carrier plate. The sensor is retained captively in the fitted position of the brake pad by the pad-retaining spring. The brake pad is designed such that the distance of the fitted pad-retaining spring from the pad carrier plate in the relaxed or substantially relaxed position of the pad-retaining spring in the region of the sensor is the same size as or larger than the associated dimension size of the sensor.