Brake Wear Sensor Integrating Planetary Gear for Multi-Parameter Monitoring
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Solution Overview
Problem
Existing brake wear sensors for disc brakes require additional sensors and increased installation space to monitor additional parameters, leading to higher costs and complexity.
Innovation Solution
A brake wear sensor design that utilizes existing components with an additional drive option, such as a spur gear, to detect multiple input variables, eliminating the need for extra sensors by integrating the additional measurement signal through rearrangement and expansion of the transmission system, including a planetary gearing mechanism with a potentiometer and electronic signal processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an additional sensor is installed to monitor additional parameters, then measurement capability is improved, but device complexity and installation space increase
Solution Approach 1:
The brake wear sensor is designed to perform multiple functions by integrating additional measurement capabilities into the existing sensor structure. The sensor can now monitor both brake pad wear and brake disc wear simultaneously, eliminating the need for separate sensors for each parameter. This multi-functionality approach allows one sensor to replace what would traditionally require multiple separate sensing devices, thereby improving measurement capability while avoiding increased device complexity
Solution Approach 2:
The invention merges the measurement functions for brake pad wear and brake disc wear into a single integrated sensor unit. By combining multiple measurement capabilities within one sensor housing and electronic evaluation unit, the system achieves enhanced monitoring functionality without proportionally increasing complexity. The merged design allows both wear parameters to be measured and evaluated through a unified sensing and processing architecture
2Measurement precision
If an additional sensor is installed to monitor additional parameters, then measurement capability is improved, but installation space increases
Solution Approach 1:
The brake wear sensor is designed to perform multiple functions by integrating additional measurement capabilities into the existing sensor structure. The sensor can now monitor both brake pad wear and brake disc wear simultaneously, eliminating the need for separate sensors for each parameter. This multi-functionality approach allows one sensor to replace what would traditionally require multiple separate sensing devices, thereby improving measurement capability while avoiding increased device complexity
Solution Approach 2:
The invention merges the measurement functions for brake pad wear and brake disc wear into a single integrated sensor unit. By combining multiple measurement capabilities within one sensor housing and electronic evaluation unit, the system achieves enhanced monitoring functionality without proportionally increasing complexity. The merged design allows both wear parameters to be measured and evaluated through a unified sensing and processing architecture
3Measurement precision
If traditional contact-based sensors are used, then measurement capability is achieved, but maintenance requirements increase
Solution Approach 1:
The invention replaces traditional contact-based mechanical sensing elements with inductive and capacitive sensing technologies. These non-contact sensors detect wear parameters through electromagnetic fields rather than physical contact, eliminating wear and friction issues associated with mechanical contacts. The inductive sensors detect changes in magnetic fields caused by wear, while capacitive sensors detect changes in capacitance, both providing measurement capability without the maintenance requirements of contact-based systems
Solution Approach 2:
The sensor system utilizes changes in electromagnetic parameters (inductance and capacitance) to detect wear conditions. By monitoring parameter changes in the electromagnetic field rather than relying on mechanical contact, the system achieves measurement capability while avoiding the wear and maintenance issues inherent in contact-based mechanical sensing systems
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 the monitoring of multiple parameters, like brake wear and rotary brake lever stroke, with minimal additional installation space and cost, using existing components, and provides non-contact, maintenance-free operation through inductive and capacitive sensors, allowing for efficient evaluation of measurement signals.
Implementation Method 1
the transmission (10) is a planetary gearing
Implementation Method 2
The sensor unit (3) has a sensor which converts a mechanical variable into an electrical variable. This is a variable electrical resistance in the form of a potentiometer
Implementation Method 3
The sensor unit can also have an inductive and/or capacitive sensor alone or in combination with other sensors
Implementation Method 4
The sensor unit can also have an inductive and/or capacitive sensor alone or in combination with other sensors
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The invention relates to a brake wear sensor of a disk brake, comprising: a. a sensor unit (3); b. a gearbox (10) cooperating with the sensor unit (3); and c. a central drive element (8), which is engaged with the gearbox (10), for an input variable or characteristic variable associated with brake wear; characterized in that d. the brake wear sensor comprises at least one additional input (9) for a further input variable or characteristic variable.