Brake Caliper Wear Sensor Connector With Snap-Fit Elastic Mounting
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Solution Overview
Problem
Existing caliper body connector systems require lengthy machining operations and multiple components, leading to high manufacturing and assembly costs and complexity.
Innovation Solution
An electrical connector with a hook portion and elastic interference portions that directly couple to the caliper body without the need for screws or additional fixing elements, allowing a single-step assembly and reducing components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If threaded screws and machining operations are used to fix the electrical connector to the caliper body, then the connection is secure and reliable, but the manufacturing time and cost increase significantly
Solution Approach 1:
The elastic metal connection plate is pre-formed with bending portions and engagement features during manufacturing, so that during assembly it can be quickly deformed and engaged with the caliper body without requiring on-site machining or threading operations. This preliminary preparation of the connection plate structure enables rapid assembly while maintaining secure connection.
Solution Approach 2:
The connection method transitions from rigid threaded fastening to elastic deformation-based engagement. The metal plate utilizes its elastic properties to deform during assembly and maintain constant contact pressure, changing the connection parameter from static threaded engagement to dynamic elastic engagement that accommodates manufacturing tolerances and thermal expansion.
2Ease of manufacture
If the elastic metal connection plate is sheared and bent to create engagement features, then the connector can be assembled without machining the caliper body, but the number of components and assembly steps increases
Solution Approach 1:
The electrical connector body and the elastic metal connection plate are integrated into a single unit, with the connection plate forming an integral part of the connector housing. This merging eliminates the need for separate fixing components and reduces the number of assembly steps, as the connection plate is directly formed during connector manufacturing rather than being a separate part that requires assembly.
3Reliability
If multiple fixing elements and assembly steps are used to connect the connector to the caliper body, then the connection is secure, but the assembly process becomes more laborious and time-consuming
Solution Approach 1:
The elastic metal connection plate utilizes its own elastic deformation capability to achieve self-fixing to the caliper body. When the connector is positioned on the caliper body, the bending portions of the metal plate automatically deform and engage with the caliper body surfaces, creating a secure connection without requiring external fasteners, clips, or additional fixing elements. The connection plate serves both as the structural support and the fixing mechanism.
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
This solution simplifies the manufacturing and assembly process, reducing costs and time while ensuring a secure, reliable connection to the caliper body.
Implementation Method 1
at least one elastic interference portion (7, 8) which is elastically deformable between a resting configuration and a maximum interference configuration
Data Source
AI summary
An electrical connector for a wear sensor has a connector body made of an electrically insulating material and defining a seat for a plug or a socket for electrically connecting the wear sensor to a wear detection circuit, a hook portion configured to be coupled to a tooth of a caliper body, the hook portion being made in one piece with the connector body, and at least one elastic interference portion overhangingly projecting from the connector body. Each elastic interference portion is elastically bendable between a resting configuration and a maximum interference configuration so as to slide against a caliper body surface opposite to the tooth by bending from the resting configuration until the elastic interference portion blocks by interference against the caliper body surface in the maximum interference configuration by tightening a caliper body wall from opposite sides between the hook portion and each elastic interference portion.