Brake Pad Wear Sensor Using 3D Resistor Element
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Solution Overview
Problem
Existing wear distance sensors for brake pads in friction brakes either require regular maintenance for marking recognition or summate wear between pads and discs, lacking direct and continuous measurement of pad thickness.
Innovation Solution
A wear distance sensor with a three-dimensional electrical resistor element that changes resistance based on pad wear, allowing for direct and continuous measurement of pad thickness independently of disc wear, using a housing with a probe and two conductor elements to measure resistance changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a marking is applied to the brake pad for wear detection, then the wear state can be recognized, but regular checking and cleaning work are required
Solution Approach 1:
The patent replaces mechanical/optical wear detection methods (marking recognition) with an electrical sensing system. A sensor element with electrical conductors and resistor elements detects wear through electrical resistance changes, eliminating the need for visual marking inspection and cleaning operations.
Solution Approach 2:
The wear detection system continuously monitors pad thickness automatically without requiring external intervention. The sensor element integrated into the brake pad structure provides ongoing self-diagnosis of wear state, removing the burden of regular manual checking from users.
2Productivity
If wear is measured via rotational angle measurement on a wear adjuster, then continuous wear display is provided, but wear of the brake disc is also incorporated resulting in summation wear detection
Solution Approach 1:
The patent segments the wear measurement function from the overall brake system by integrating a dedicated sensor element directly into the brake pad structure. This separate measurement system independently monitors only pad thickness through electrical resistance changes, excluding brake disc wear from the measurement and providing accurate isolated pad wear data.
3Measurement precision
If a three-dimensional resistor element is used with changing dimensions, then direct pad thickness measurement is achieved, but device complexity increases
Solution Approach 1:
The patent merges the wear sensing function with the brake pad structure itself by integrating the sensor element directly into the pad. The resistor elements are positioned to extend through the pad thickness, combining the measurement function with the structural component, thereby reducing overall system complexity despite the three-dimensional measurement capability.
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 direct, continuous, and independent measurement of brake pad wear, reducing mechanical complexity and material usage, allowing for optimized pad usage and potential temperature detection.
Implementation Method 1
a three-dimensional electrical resistor element (4) having a spatial formation, of which three dimensions are changeable in dependence on the wear distance of a brake pad (26, 26'). It is thus advantageously achieved that a resistance of the resistor element (4) is changed in dependence on the wear distance
Data Source
AI summary
A wear distance sensor detects wear distance of a brake pad, in particular of a friction brake, and includes a housing having a friction side and a connecting side and a probe having two electrical conductor elements in combination with at least one electrical resistance element. Two dimensions of the resistance element are not constant depending on the wear distance. A third dimension of the resistance element, which has a three-dimensional design, is not constant depending on the wear distance.