Brake Wear Sensor Assembly With Shared Harness Wiring
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Solution Overview
Problem
Existing brake wear sensing systems for air disc brakes in commercial vehicles require complex wiring and are expensive and less reliable due to the need for separate harnesses for progressive and in-pad wear sensors, leading to installation challenges and increased costs.
Innovation Solution
A brake wear sensing assembly that integrates a progressive wear sensor, lining wear sensor, and control device using a single adapter to share a wire harness, allowing power and signal transmission between both sensors in series, reducing the need for multiple harnesses and simplifying installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If both progressive wear sensor and lining wear sensor are installed on air disc brake assembly, then wear monitoring capability is improved, but wiring complexity increases
Solution Approach 1:
The patent combines both the progressive wear sensor and lining wear sensor into a single integrated sensor assembly that shares common wiring connections to the control device. The adapter module integrates multiple sensor inputs and power connections into a unified interface, eliminating the need for separate wiring harnesses for each sensor type.
Solution Approach 2:
The adapter module serves multiple functions: it provides power to both sensor types, receives signals from both sensors, and interfaces with the control device through a single connection point. This multi-functional component reduces overall system complexity while maintaining full sensor functionality.
2Reliability
If separate wire harnesses are used for progressive wear sensor and lining wear sensor, then sensor reliability is maintained, but installation complexity increases
Solution Approach 1:
The patent merges the installation process by providing a single adapter assembly that accommodates both sensor types. Technicians install one unified component rather than managing separate wiring harnesses, significantly reducing installation steps and potential errors while maintaining electrical reliability through proper internal connections.
3Measurement precision
If multiple sensors are installed with separate wiring, then measurement precision is improved, but cost increases
Solution Approach 1:
The integrated adapter assembly consolidates multiple wiring connections into a single interface with the control device. By sharing common power and ground lines while maintaining separate signal paths internally, the system reduces wiring material requirements while preserving the measurement precision of both sensor types.
Data Source
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AI summary
A brake wear sensing assembly (10) for an air disc brake includes a progressive wear sensor (12), at least one lining wear sensor (16a, 16b), a control device (56), a wire harness (36) connected to the control device (56) and an adapter for joining the progressive wear sensor (12) and the lining wear sensor (16a, 16b) to the wire harness (36). The adapter (20) connects a power line to the progressive wear sensor (12), a ground line to the progressive wear sensor (12) and an input to the output of the at least one lining wear sensor (16a, 16b). An output signal from the progressive wear sensor (12) is connected to the input of the at least one lining wear sensor (16a, 16b). The signal from the progressive wear sensor (12) passes through the at least one lining wear sensor (16A, 16B) to the control device (56) such that the progressive wear sensor (12) and the at least one lining wear sensor (16A, 16B) are in series with each other.