Brake Wear And Temperature Sensing Assembly With Segmented Circuits
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Solution Overview
Problem
Existing sensor assemblies for detecting the wear and temperature of braking members in vehicles are not sufficiently reliable and accurate, prone to failure due to thermistor breakdown, and are bulky, making them difficult to use on various braking devices, especially brake pads.
Innovation Solution
A compact wear and temperature detecting unit featuring a cascaded arrangement of independent electrical detection circuits on a flexible polyimide tape, with platinum RTDs for temperature detection and shearable wear detectors, managed by a microprocessor to provide precise and continuous monitoring with minimal interference between circuits as they wear out.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermistors are arranged in series on common branches to detect wear and temperature, then both parameters can be detected simultaneously, but the system becomes unreliable because breakdown of one thermistor causes entire assembly failure
Solution Approach 1:
The detection system is segmented into multiple independent electrical circuits, each with its own thermistors arranged in series. When one circuit fails due to thermistor breakdown, other circuits remain operational and continue to provide detection data. This segmentation isolates failures to individual circuits rather than causing system-wide failure.
Solution Approach 2:
The system uses multiple thermistors with different temperature coefficients (positive and negative) arranged in series within each circuit. By changing the parameters of individual thermistors (their temperature coefficients), the system achieves both wear detection (through voltage variation as thermistors are eliminated) and temperature detection (through the temperature-dependent resistance characteristics) simultaneously while maintaining reliability.
2Measurement precision
If multiple thermistors are used for simultaneous wear and temperature detection, then detection capability is improved, but measurement accuracy deteriorates due to temperature behavior variations based on relative position to mobile braking members
Solution Approach 1:
The system incorporates an electronic unit that processes signals from multiple thermistors and applies correction algorithms. The electronic unit receives temperature data from thermistors at different positions, compares their readings, and compensates for position-dependent temperature variations through computational feedback, thereby achieving accurate temperature measurement despite the mobile nature of braking members.
Solution Approach 2:
The detection system is designed to be universally applicable to different braking member configurations and positions. By using multiple thermistors with different temperature coefficients and processing their combined signals through the electronic unit, the system achieves accurate temperature detection regardless of the relative position between the braking member and the sensor assembly, making it adaptable to various braking system designs.
3Adaptability or versatility
If a sensor assembly with multiple thermistors and common branches is used, then wear and temperature can be detected, but the assembly becomes large and difficult to use on various braking devices
Solution Approach 1:
The sensor assembly uses flexible printed circuit boards or thin film substrates to mount the thermistors and electrical circuits. This allows the assembly to be made compact and adaptable to different braking device geometries. The flexible substrate enables the sensor to conform to various shapes and sizes of braking members, reducing the overall volume requirement while maintaining adaptability.
Solution Approach 2:
The system merges multiple functions (wear detection, temperature detection, signal processing) into a single integrated sensor assembly. By combining the electrical circuits for detecting both wear and temperature, along with the signal processing electronics, into one compact unit, the overall volume is reduced while maintaining versatility for use on different braking devices.
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 ensures high precision and reliability in detecting wear and temperature, with minimal deviation in temperature readings, and is compact enough to be applied to any braking device without modifying existing components, offering efficient and economical operation across various vehicle types and sizes.
Implementation Method 1
with platinum RTDs for temperature detection
Implementation Method 2
shearable wear detectors
Data Source
AI summary
A braking member of a vehicle is joined to a unit for detecting wear and temperature of the braking member; the unit comprising a sensing assembly, an electrical connector adapted to enable connection of the unit to an electrical circuit of the vehicle, and an electrical wiring for connection of the sensing assembly to the electrical connector; the sensing assembly comprising an attachment body having an axis and configured to be stably connected to the braking member; the attachment body housing wear detection means and temperature sensor means arranged along the axis and embedded in the attachment body, while the electrical connector houses an electronic unit for receiving and processing signals and for sending an output signal through the electrical connector.