Caliper Guide Assembly With Integrated Wear Sensor Void
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Solution Overview
Problem
Conventional disc brake guide assemblies face challenges in accommodating manufacturing tolerances, thermal effects, and deflections, while existing wear sensing arrangements are costly, environmentally susceptible, and restrictive in design.
Innovation Solution
A caliper guide assembly with a guide pin and bore that includes a void for a wear sensor, protected from the environment, allowing for efficient wear detection using Hall Effect or optical sensors, and a non-circular guide surface for smooth guidance and compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a wear sensor is added to the guide assembly, then wear detection capability is improved, but device complexity and cost increase
Solution Approach 1:
The wear sensor is integrated into the guide assembly structure, merging the sensing function with the existing guide pin and guide bore components. This eliminates the need for separate mounting structures and reduces overall device complexity despite adding sensing capability.
Solution Approach 2:
The guide assembly is designed to serve multiple functions: mechanical guidance of the caliper, accommodation of thermal expansion, and wear sensing. The guide bore simultaneously provides structural support and houses the wear sensor, making the assembly multi-functional.
2Ease of manufacture
If the wear sensor is exposed to the environment, then wear detection is simplified, but sensor reliability decreases due to contamination
Solution Approach 1:
The wear sensor is nested within the guide bore structure, which provides protection from environmental contamination. The sensor is housed inside the bore cavity, shielded from dust, moisture, and other contaminants while remaining functional.
Solution Approach 2:
The guide bore acts as an intermediary structure that protects the wear sensor from the external environment. It provides a controlled, protected environment for the sensor while still allowing it to detect the position of the guide pin accurately.
3Volume of moving object
If the guide surface has a non-circular cross section, then space for wear sensor is created and guidance is improved, but manufacturing complexity increases
Solution Approach 1:
The guide surface is designed with an asymmetric, non-circular cross-section that creates void space for accommodating the wear sensor. This asymmetric geometry provides both the necessary clearance for the sensor and optimized guidance characteristics for the caliper movement.
Solution Approach 2:
The guide surface transitions from a conventional circular cross-section to a non-circular cross-section, utilizing the radial dimension more effectively. This dimensional change creates additional space in the radial direction for housing the wear sensor while maintaining the axial guidance function.
4Reliability
If the guide assembly accommodates manufacturing tolerances and thermal effects, then operational reliability is improved, but design complexity increases
Solution Approach 1:
The guide assembly is designed with dynamic characteristics that allow it to adapt to varying operating conditions. The non-rigid connection and clearance-fit design enable the assembly to accommodate thermal expansion and manufacturing tolerances dynamically without compromising reliability.
Solution Approach 2:
The design accounts for parameter changes in temperature and dimensional tolerances by incorporating clearance fits and flexible mounting arrangements. These design features allow the guide assembly to maintain proper function across a range of operating parameters without requiring complex compensation mechanisms.
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 effective wear sensing without additional components, protects the sensor from contamination, and simplifies manufacturing and mounting, while accommodating thermal and mechanical deflections for reliable disc brake operation.
Implementation Method 1
allowing for efficient wear detection using Hall Effect or optical sensors
Data Source
AI summary
A caliper guide assembly for a heavy vehicle disc brake. The caliper guide assembly may include a wear sensor arranged to detect the position of a guide pin in relation to a guide bore. The guide pin and a guide surface may have different cross sectional profiles to define at least one void therebetween. The wear sensor may be at least partially accommodated within the void.