Disc Brake Speed Sensor Mounting for Precise Exciter Alignment
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Solution Overview
Problem
Existing fastening devices for speed sensors in disc brakes require additional components and installation space, increasing costs and susceptibility to heat, while existing solutions position the sensor away from the exciter, affecting measurement precision and reliability.
Innovation Solution
A fastening device with a holding fixture in the brake carrier, such as a bore hole, integrates the speed sensor directly into the brake carrier, eliminating the need for separate mounts and allowing for precise, heat-resistant positioning near the exciter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the speed sensor is arranged on the vehicle axle or axle hub outside the disc brake via an additional fastening device, then the sensor can be positioned at a distance from the exciter, but the device complexity and installation space requirements increase
Solution Approach 1:
The patent integrates the speed sensor arrangement directly into the brake carrier, which is a component already present in the disc brake system. The brake carrier serves dual purposes: it holds the brake pads and now also accommodates the speed sensor through integrated holding fixtures. This merging eliminates the need for separate fastening devices on the vehicle axle or hub, reducing overall device complexity while maintaining reliable sensor positioning at the required distance from the exciter.
2Manufacturing precision
If the speed sensor is arranged on an additional mounting on the vehicle axle, then the sensor can be positioned correctly, but material costs and installation space increase
Solution Approach 1:
The brake carrier is designed as a multi-functional component that simultaneously performs its primary function of holding brake pads and provides integrated holding fixtures for mounting the speed sensor. This universal design eliminates the need for additional dedicated mounting components, thereby reducing material costs while ensuring precise sensor positioning through the purpose-built fixtures that are part of the brake carrier structure.
3Object-affected harmful factors
If the speed sensor is arranged away from the exciter on the vehicle axle, then the sensor is protected from heat, but measurement precision decreases
Solution Approach 1:
The brake carrier is designed with distinct functional zones: one area for the brake pads that handles thermal loads, and separate holding fixtures positioned at an optimized distance from the exciter for the speed sensor. This segmentation allows the sensor to be positioned close enough to the exciter for precise measurement while being thermally isolated through the brake carrier structure, which acts as a thermal barrier between the sensor and the hot brake components.
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 integration reduces material costs, saves installation space, and ensures consistent measurement accuracy by maintaining a fixed distance from the exciter, while protecting the sensor from heat and reducing the need for additional components.
Implementation Method 1
detect the rotational speed of the wheel via an exciter, which is integrated at the wheel axle in the form of a pulse ring or, for example, is integrated in the brake disc. Exciters are ferromagnetic structures, such as gearwheels or shafts, wherein the speed sensor detects the change of the magnetic flux
Data Source
AI summary
A fastening device for a vehicle disc brake having a brake carrier includes holding fixture formed in the brake carrier for receiving a speed sensor. The brake carrier includes fastening members for mounting to a flange of the vehicle. The speed sensor is used for an anti-lock braking system to detect wheel slip. The holding fixture is in the form of a bore. The bore may be formed in the strut facing the axle or in an extension of one of the fastening members of the brake carrier. The speed sensor is aligned in its extension direction axially with an exciter in or on the brake disc or in the axle. The speed sensor is attached to a cable that does not need to be guided past the vehicle flange.