Brake Pad Thickness Estimation via Sensor Fusion and Thermal Modeling

The patent replaces mechanical wire-based sensors with a computational model that uses electrical signals from existing vehicle sensors (accelerometer, gyroscope, temperature sensors) to calculate brake pad thickness. The system substitutes physical measurement infrastructure with a mathematical model that processes readily available vehicle operation data to estimate brake pad wear continuously throughout its lifecycle.

The patent creates a virtual model of the brake pad wear process by copying and processing signals from existing vehicle sensors through a computational algorithm. Instead of installing new physical sensors, the system copies data from available sensors (accelerometer, gyroscope, temperature) and uses these copies to generate continuous thickness estimates, eliminating the need for expensive dedicated thickness sensors.

The patent performs preliminary calculation of brake pad thickness continuously throughout the brake pad's service life using a computational model that processes real-time vehicle operation data. By continuously estimating thickness before the pad reaches critical wear levels, the system provides advance warning to operators, allowing them to plan maintenance during convenient downtime rather than being forced to stop operations when the mechanical scraper contacts the rotor.

The patent implements a feedback mechanism where the computational model continuously processes inputs from vehicle sensors (accelerometer, gyroscope, temperature) and updates the brake pad thickness estimate in real-time. This continuous feedback loop provides ongoing information about brake pad condition, enabling operators to monitor wear progression and receive timely warnings before critical wear occurs, rather than relying on the single-point mechanical scraper indication.

The patent makes existing vehicle sensors serve multiple functions: the accelerometer and gyroscope are used not only for their primary vehicle dynamics functions but also as inputs to the brake pad wear estimation model. The temperature sensors serve dual purposes for both thermal management and wear calculation. This multi-functionality allows the system to achieve continuous thickness monitoring without adding dedicated sensors, reducing overall system complexity despite the sophisticated modeling required.

The patent enables the vehicle's existing sensor system to serve itself by using its own operational data (acceleration, rotation, temperature) to monitor the condition of its braking system. The computational model processes data that the vehicle already collects for other purposes, allowing the brake pad thickness estimation to be a byproduct of normal vehicle operation monitoring rather than requiring a separate dedicated measurement infrastructure.