Caliper Guide Assembly Wear Sensor Nesting
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Solution Overview
Problem
Existing disc brake systems face challenges in accommodating manufacturing tolerances, thermal variations, and deflections due to braking torque, while also requiring effective wear sensing without increasing size or susceptibility to environmental damage.
Innovation Solution
A caliper guide assembly with a sensor arrangement integrated within the guide bore, comprising a guide pin with a cavity and a cap, featuring a first sensor component secured to the guide pin and a second sensor component secured to the cap, which provides relative axial displacement feedback, protected by a housing to prevent damage and contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a wear sensor arrangement is provided external to the guide bore, then it is easier to install and access, but it increases the size of the caliper guide assembly and exposes the sensor to environmental contamination
Solution Approach 1:
The sensor arrangement is nested within the guide bore structure. The first sensor component is positioned inside the guide pin cavity, while the second sensor component is positioned inside the guide bore, creating a compact integrated design that eliminates the need for external sensor mounting while protecting the sensors from environmental exposure
2Ease of repair
If the sensor arrangement is exposed to the environment, then it is easier to access for maintenance, but it becomes susceptible to environmental contamination and damage
Solution Approach 1:
The sensor components are nested within the protected cavity of the guide pin and guide bore, shielding them from environmental contaminants such as water, dust, and brake dust while maintaining their functional accessibility through the sealed internal structure
Solution Approach 2:
The guide pin cavity and guide bore structure act as an intermediary protective barrier between the sensor components and the harsh external environment, allowing the sensors to function reliably without direct exposure to contaminants
3Ease of operation
If additional sensor components are provided external to the guide bore, then the sensor arrangement can be more accessible, but it restricts the design freedom of other brake parts
Solution Approach 1:
The sensor arrangement is merged with the guide bore structure, combining the sensor housing function with the existing guide bore and guide pin components. This integration eliminates the need for separate external sensor housings and mounting structures, thereby maintaining design flexibility for other brake components
4Measurement precision
If the sensor components are positioned to maximize displacement sensing, then wear monitoring accuracy is improved, but the sensor arrangement becomes more vulnerable to damage
Solution Approach 1:
The sensor components are nested within the protective cavity of the guide pin and guide bore, allowing them to be positioned optimally for measuring the full range of axial displacement between the guide pin and guide bore while simultaneously being protected from environmental damage and mechanical interference
Data Source
AI summary
A caliper guide assembly having a guide pin, a guide bore, a cap, and a sensor arrangement. The guide bore is arranged to receive the guide pin. The cap may be secured to an open end of the guide bore proximate a free end of the guide pin. The sensor arrangement may include a first sensor component that is configured to provide an output indicative of relative axial displacement between a first sensor component and a second sensor component.