Brake Assembly Thermal Monitoring for Dragging Brake Detection

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Solution Overview

Problem

The unintentional dragging of brakes in vehicle brake systems can lead to inefficient operation and excessive heat generation, making it difficult for operators to detect and address the issue.

Innovation Solution

A monitoring system that includes a temperature sensor to measure the actual temperature of the brake assembly, a controller with a thermal model to predict the temperature based on brake torque and other factors, and a user interface to notify the operator when the actual temperature exceeds the predicted temperature by a threshold amount.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a temperature sensor and thermal model are used to detect dragging brakes, then the detection accuracy and reliability are improved, but the device complexity increases

Engineering Contradiction:
Improvedragging brake detection reliabilityVSAvoidmonitoring system complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical monitoring systems with a thermal-based detection system. By using a temperature sensor to measure brake temperature and comparing it against a thermal model that predicts normal operating temperatures, the system detects dragging brakes through thermal anomalies rather than mechanical measurements, simplifying the overall system architecture while improving reliability

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The thermal model acts as an intermediary between the temperature sensor and the detection logic. Instead of directly comparing raw temperature readings to fixed thresholds, the system uses the thermal model to predict expected temperatures under various operating conditions, then compares actual readings against these dynamic predictions, enabling more accurate detection while keeping the system manageable in complexity

Inventive Principle:
Principle #24Intermediary (Mediator)

2Measurement precision

If the monitoring system continuously compares actual temperature to predicted temperature, then the detection precision is improved, but the energy consumption increases

Engineering Contradiction:
Improvetemperature measurement precisionVSAvoidcontroller energy consumption
Core Design Contradiction:
Measurement precisionVSUse of energy by moving object

Solution Approach 1:

The system performs temperature comparisons at periodic intervals rather than continuously. The controller monitors temperature readings from the sensor and compares them to thermal model predictions at defined time intervals or under specific triggering conditions, maintaining detection precision while reducing the energy consumption associated with constant processing

Inventive Principle:
Principle #19Periodic action

Solution Approach 2:

The system applies enhanced monitoring precision only when necessary - such as when temperature readings deviate from expected ranges or when specific operating conditions are detected. During normal operation, the system uses standard monitoring intervals, and only increases measurement and comparison frequency when anomalies are detected, balancing precision with energy efficiency

Inventive Principle:
Principle #16Partial or excessive action

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

The system effectively detects and notifies operators of dragging brakes, preventing inefficiencies and potential damage from excessive heat, thereby enhancing vehicle performance and safety.

Implementation Method 1

a temperature sensor disposed proximate to the brake assembly to measure an actual temperature of the brake assembly

Methodology Applied
Scientific EffectTemperature sensing: Thermocouple

Implementation Method 2

The unintentional dragging of brakes in vehicle brake systems can lead to inefficient operation and excessive heat generation

Methodology Applied
Scientific EffectFriction heating: Friction

Implementation Method 3

a controller with a thermal model to predict the temperature based on brake torque and other factors

Methodology Applied
Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12344215B2System and method for automatically detecting a dragging brake
Publication Date: 2025.07.01 FORD GLOBAL TECH LLC
  • US12344215B2 patent drawing
  • US12344215B2 patent drawing
  • US12344215B2 patent drawing

AI summary

A monitoring system for a brake assembly of a vehicle may include a temperature sensor disposed proximate to the brake assembly to measure an actual temperature of the brake assembly, a controller operably coupled to the temperature sensor and comprising a thermal model, the controller being configured to determine a predicted temperature of the brake assembly using the thermal model, and a user interface operably coupled to the controller to provide a notification to an operator of the vehicle. The controller may compare the actual temperature to the predicted temperature and may automatically generate the notification responsive to the actual temperature exceeding the predicted temperature by a threshold amount.