Brake Assembly Wear Detection via Shaft Rotation Sensor
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Solution Overview
Problem
Existing brake assemblies lack effective monitoring and control mechanisms for brake pad and rotor wear, leading to potential brake performance issues and safety concerns due to inadequate detection of wear and improper adjustment of brake components.
Innovation Solution
A brake assembly with a sensor assembly that includes sensors to detect the rotation of an operating shaft and provide signals indicative of brake pad and rotor wear, along with a brake overstroke warning system to alert operators when wear thresholds are exceeded, ensuring timely adjustments and maintaining optimal brake performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If brake assemblies use traditional wear monitoring methods, then the structure remains simple, but the measurement precision of brake pad and rotor wear is insufficient
Solution Approach 1:
The patent replaces traditional mechanical wear measurement methods with optical sensors that detect the position of an indicator on the operating shaft. This substitution enables precise wear detection through optical means rather than mechanical contact, resolving the contradiction between measurement precision and device complexity.
Solution Approach 2:
The patent introduces an indicator as an intermediary element that connects the operating shaft position to the sensor assembly. This indicator serves as a mediator that translates mechanical shaft rotation into detectable optical signals, enabling precise wear measurement without direct mechanical contact between the sensor and moving parts.
2Reliability
If brake assemblies lack real-time wear monitoring, then the device complexity is reduced, but the reliability of brake performance deteriorates
Solution Approach 1:
The patent implements a feedback mechanism where the sensor assembly continuously monitors the operating shaft position and provides real-time wear information. This feedback loop enables the system to detect wear conditions and alert operators, maintaining brake performance reliability through continuous monitoring without requiring complex active control systems.
3Loss of time
If brake assemblies use manual wear inspection, then the cost is reduced, but the loss of time for wear detection increases
Solution Approach 1:
The patent enables the brake assembly to self-monitor its own wear condition through the integrated sensor assembly that detects operating shaft position. This self-service capability eliminates the need for manual inspection, reducing detection time while maintaining cost-effectiveness through a relatively simple automated system.
Data Source
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AI summary
A brake assembly that may include a housing assembly, a piston assembly, an operating shaft (50), and a sensor assembly (150). The operating shaft (50) may be configured to rotate about an axis (54) to actuate the piston assembly and translate a brake pad assembly from a retracted position to an extended position. The sensor assembly (150) may be configured to detect rotation of the operating shaft.