Brake Pad Wear Sensor Rounded Transition Reduces Cracking
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Solution Overview
Problem
Existing brake pad wear detection devices are prone to cracking under mechanical stress, leading to a loss of clamping force and unreliable operation, particularly in commercial vehicles, which compromises the service life and safety of the brake system.
Innovation Solution
The device features a rounded transition area between the clamping element and contact leg, reducing the likelihood of cracking and ensuring a secure fit, along with a reduced cross-section of the contact leg for added resilience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a sharp-edged transition area is used between the clamping element and contact leg, then the manufacturing is simpler, but the component is prone to cracking under mechanical stress
Solution Approach 1:
The patent applies curvature by rounding the transition area between the clamping element and contact leg. Instead of a sharp-edged transition, a curved fillet radius is introduced. This eliminates stress concentration points that would otherwise lead to crack initiation under mechanical stress and vibrations during brake operation, thereby improving reliability while maintaining manufacturing feasibility through standard fillet radius practices.
2Strength
If the contact leg has a larger cross section, then the structural strength is higher, but the resilience and ability to absorb mechanical stress is reduced
Solution Approach 1:
The patent applies local quality by varying the cross-sectional dimensions of the contact leg along its length. The contact leg features a reduced cross-section in specific areas (narrower web thickness) while maintaining adequate strength in other regions. This localized reduction in cross-section increases resilience and flexibility, allowing the contact leg to better absorb mechanical stress and vibrations without compromising overall structural integrity.
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
This design enhances the robustness and functional reliability of the brake pad wear detection system, preventing slippage and maintaining functionality throughout the service life of the brake lining, thereby improving safety and reducing maintenance costs.
Implementation Method 1
The transition area (11) between the contact leg (8) and clamping element (9) is rounded, in particular in the form of a fillet (15), which reduces the likelihood of cracking, in particular due to the high mechanical stress
Implementation Method 2
the clamping element is equipped with two clamping legs, which can be pressed elastically against one another, for inserting the holder into the pad carrier plate and then, due to the restoring forces inherent in the clamping legs, are pressed against the walls of the recess of the pad carrier plate, whereby a Friction results
Implementation Method 3
whereby a Friction results, which forms a backup in the insertion direction of the bracket
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to a device for recognizing wear of a brake pad (1) of a disk brake, comprising a holder (5) that can be inserted in a pad carrier plate (3) of the brake pad (1) for holding a contact conductor, a contact arm (8) comprising a receptacle for the contact conductor, wherein a clamping element (9) comprising two clamping arms (10) elastically movable relative to one another is connected to said contact arm. The device is designed such that the transition regions (11) between the clamping element (9) and the contact arm (8) are rounded in the spreading direction of the clamping arms (10).