Air Disc Brake Sensor with Inspection Port for Seal Integrity
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Solution Overview
Problem
Current brake monitoring systems for air disc brakes in heavy-duty vehicles are unable to effectively detect hanging or dragging brake conditions due to the separation of the pushrod and lever arm, and they cannot verify the integrity of the air-tight seal between the caliper housing and the brake actuator, leading to potential mechanical failures from environmental contamination.
Innovation Solution
A vehicle brake monitor assembly with a telescoping pushrod and integrated sensor that detects movement relative to the lever arm and caliper, allowing for the identification of normal, over-stroke, dragging, or hanging brake conditions, and includes an inspection port for visual and pressure sensors to assess the air-tight enclosure integrity without modifying the conventional brake caliper.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional pushrod monitoring system is used on air disc brakes, then the system structure remains simple, but the system cannot detect hanging or dragging brake conditions due to pushrod-lever arm separation
Solution Approach 1:
The sensor is integrated within the caliper housing structure, with the sensor element positioned to detect pushrod movement through the sealed enclosure. This nesting approach allows the monitoring system to be embedded within existing brake components without adding external complexity.
Solution Approach 2:
A magnetic coupling mechanism serves as an intermediary between the pushrod and the sensor, allowing the sensor to detect pushrod position and movement without direct mechanical contact. This intermediary approach enables accurate detection while maintaining the sealed enclosure integrity.
2Object-affected harmful factors
If the caliper housing is sealed to prevent environmental contamination, then component protection is improved, but the ability to inspect internal components is lost
Solution Approach 1:
The patent incorporates visual indicators that change appearance or become visible under specific conditions, allowing inspection of internal components through the sealed housing without compromising the seal. This enables operators to detect component status while maintaining environmental protection.
3Reliability
If the pushrod is fixedly attached to the lever arm, then the monitoring system can detect hanging brakes, but the system cannot accommodate the telescoping design required for air disc brake adjustment
Solution Approach 1:
The patent replaces direct mechanical attachment with magnetic coupling between the pushrod and lever arm. This substitution allows the pushrod to telescope for adjustment while the magnetic field continuously tracks its position, enabling hanging brake detection without requiring fixed mechanical connection.
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 accurate monitoring of air disc brake conditions and air-tight seal integrity, providing advanced warning of mechanical failures and eliminating the need for caliper modification, thus ensuring proper brake function and preventing contamination-related issues.
Implementation Method 1
The contact member is magnetically coupled to the pushrod shaft such that movement of the pushrod relative to the lever arm and the pushrod shaft moves the contact member relative to the sensor.
Data Source
AI summary
A brake actuator assembly for an air disk brake includes an actuator housing having a pushrod that is extensible from the actuator housing. A lever arm is disposed inside a caliper housing. The lever arm is actuated by the pushrod for transferring motion from the actuator to a brake pad. A sensor element is disposed between the actuator housing and the caliper housing with the sensor element being sealably engaged to the actuator housing providing an air tight enclosure between the caliper housing and the actuator. An inspection port is disposed in the sensor element providing access to receive a visual sensor and a pressure sensor for identifying a condition of the brake actuator and for identifying a condition of the air tight enclosure.