Brake Pad Wear Sensor with Visual Collar
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Solution Overview
Problem
Existing wear sensors for brake pads often experience signal delays or failure due to the terminal section of electrical wiring becoming partially extracted from the friction material block, compromising the detection of wear limit conditions and posing safety risks.
Innovation Solution
A wear sensor design featuring insulated electrical wiring with a collar member made of plastically deformable metal, such as a brass or aluminum alloy, that is permanently connected to the wiring and allows for visual detection of the terminal section's correct insertion status, ensuring it remains in a fixed position within the blind hole.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal section of electrical wiring is inserted into the blind hole of the friction material block, then the wear sensor can detect the wear limit condition, but the terminal section may become partially extracted due to stresses, causing signal delays or failure
Solution Approach 1:
The collar member is pre-installed on the electrical wiring before insertion into the blind hole. This preliminary action ensures that when the wiring is inserted, the collar member is already positioned to engage with the friction material block, preventing any backward movement or extraction of the terminal section during subsequent stress events.
Solution Approach 2:
The collar member acts as an intermediary element between the electrical wiring and the friction material block. It mediates the interaction by providing a positive mechanical engagement feature that prevents direct contact and potential extraction between the wiring and the block, while still allowing the wiring to be retained in the correct position.
2Ease of operation
If a collar member is added to the wear sensor, then visual detection of terminal section position is enabled, but the device complexity increases
Solution Approach 1:
The collar member incorporates a visual indication feature through color coding or visual contrast. This allows operators to quickly determine the position status of the terminal section by simply observing the color or visual appearance of the collar member, eliminating the need for complex detection systems while maintaining ease of operation.
Solution Approach 2:
The collar member extends radially outward from the electrical wiring, adding a dimensional element that protrudes from the brake pad surface. This radial extension provides a visible indicator of the terminal section's position without requiring complex internal mechanisms, as the position information is presented in a new spatial dimension that is easily observable.
3Object-affected harmful factors
If the collar member is made of plastically deformable metal, then resistance to temperature and contaminants is improved, but manufacturing precision requirements increase
Solution Approach 1:
The collar member is designed with specific material properties (plastically deformable metal) and geometric parameters (radial extension distance, engagement feature dimensions) that allow it to function effectively across a range of operating conditions. The plastic deformability provides a tolerance mechanism that accommodates manufacturing variations while maintaining functional performance.
Solution Approach 2:
The wear sensor employs a composite construction combining different materials with complementary properties: the electrical wiring provides electrical conductivity, the collar member provides mechanical retention and visual indication, and the gluing material provides additional retention. This composite approach allows each component to be optimized for its specific function while collectively achieving the desired performance.
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 solution enables immediate and reliable detection of the terminal section's position, preventing signal delays and ensuring proper functioning of the braking system, while being cost-effective and resistant to temperature and contaminants.
Implementation Method 1
said collar member enables a technician to visibly detect from the outside and in an extremely simple and immediate manner... the possible irregular position of the terminal section
Implementation Method 2
the collar member 20 consists of an open ring... made of plastically deformable material, conveniently metal and preferably a brass or aluminum alloy
Implementation Method 3
the collar member 20... is made of metal, is practically insensitive to temperature, unlike other materials, and therefore its physical and mechanical properties remain unchanged even when it operates at high temperatures and in the presence of water and/or external contaminants
Data Source
Figure 1~3
Figure 4~5
AI summary
A wear sensor (1) suitable to be joined to a block (4) of friction material of a braking member (2) for a vehicle comprises insulated electrical wiring (13), a terminal section (18) of which is inserted into a blind hole (8) of the block (4) of friction material and placed in a fixed operating position of reference for the detection of a wear limit state of the block (4) of friction material; a collar member (20) is fitted on the electrical wiring (13) and is distinct from the electrical wiring (13) and from the braking member (2) to enable the visual detection from the outside of when the terminal section (18) is in a position other than the fixed operating position of reference.