Caliper Guide Sleeve Wear Sensing With Protected Hall Sensor
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Solution Overview
Problem
Existing disc brake guide assemblies face issues with free sliding due to manufacturing tolerances, thermal expansion, and deflection, and existing wear sensing arrangements are costly, prone to contamination, and restrict design flexibility.
Innovation Solution
A caliper guide assembly with a wear sensor mounted on a cap closing the bore, using a guide pin and bush with a non-circular inner profile and a Hall Effect sensor to detect brake pad wear, while minimizing contamination and accommodating thermal expansion and deflection through a void in the guide assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a wear sensor is integrated into the guide assembly, then wear status can be monitored accurately, but the device complexity increases
Solution Approach 1:
The wear sensor is integrated directly into the guide pin or guide bushing, merging the sensing function with the existing guide structure. This eliminates the need for separate sensor mounting components and reduces overall device complexity while maintaining accurate wear detection capability.
Solution Approach 2:
The guide pin or guide bushing serves dual purposes: providing mechanical guidance for the caliper and housing the wear sensor. This multi-functionality reduces the number of separate components needed in the assembly.
2Measurement precision
If the sensor component extends into the guide bore, then wear can be detected, but the sensor is susceptible to environmental contamination and damage
Solution Approach 1:
A protective seal or shield is introduced as an intermediary element between the sensor component and the external environment. This seal allows the sensor to detect wear through the guide bore while preventing direct exposure to contaminants, brake dust, and moisture.
Solution Approach 2:
A flexible protective membrane or coating is applied over the sensor component, allowing mechanical wear detection while providing a barrier against environmental contamination. The flexible nature maintains sensor functionality while protecting against damage.
3Ease of operation
If the guide assembly accommodates manufacturing tolerances and thermal expansion, then free sliding is achieved, but the design flexibility is restricted
Solution Approach 1:
The guide assembly incorporates dynamic clearance or adjustable positioning features that automatically adapt to thermal expansion and manufacturing tolerances. This allows the assembly to maintain free sliding capability without requiring overly restrictive design constraints.
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
Ensures smooth sliding of the caliper and provides accurate wear status indication to the vehicle operator, reducing maintenance costs and design constraints while protecting against contamination.
Implementation Method 1
using a guide pin and bush with a non-circular inner profile and a Hall Effect sensor to detect brake pad wear
Data Source
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AI summary
A caliper guide assembly for a heavy vehicle disc brake. The caliper guide assembly comprises: a guide pin (11a) having a guide portion (15a); a guide bore (12a) having an opening and a guide surface arranged to receive the guide portion and permit relative axial sliding thereof; a wear sensor (62a) arranged to detect the position of the guide pin in relation to the guide bore, the wear sensor comprising a signal processing portion (68); and a cover (60a) arranged to close the opening of the guide bore. The signal processing portion is mounted to the cover.