Disc Brake Running Clearance Calculation from Piston Axial Movement
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Solution Overview
Problem
Existing disc brake systems lack precise real-time monitoring of running clearance, leading to potential safety issues due to inadequate detection of brake performance degradation, as the current methods require the vehicle to be stationary for accurate measurement and provide only estimates of brake pad and rotor wear.
Innovation Solution
A method to calculate the total running clearance by detecting the axial movement of a piston assembly component during braking operations, using input force and pressure data to determine the displacement at which the brake pads contact the rotor, and employing a knee point detection algorithm to identify key contact points, allowing for live monitoring of brake pad wear and clearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional manual adjuster mechanisms with CWS are used to monitor brake wear, then the system can provide an estimate of total wear, but it cannot provide precise real-time measurement of running clearance during vehicle operation
Solution Approach 1:
The patent replaces manual mechanical measurement methods with an automated sensor-based system. A displacement sensor detects the axial movement of the piston assembly component, and a controller calculates running clearance based on this data, eliminating the need for manual measurement while the vehicle is stationary.
Solution Approach 2:
The system enables the brake assembly to self-monitor its own running clearance through integrated sensors and controllers that automatically detect piston movement and calculate clearance values during normal vehicle operation, without requiring external intervention or vehicle shutdown.
2Reliability
If running clearance is not monitored in real-time, then the system structure remains simple, but brake performance degradation cannot be detected early, leading to safety issues
Solution Approach 1:
The patent implements a feedback mechanism where the displacement sensor continuously monitors piston movement, the controller calculates running clearance based on this feedback, and the system can alert operators when clearance exceeds acceptable thresholds, enabling proactive maintenance before safety issues arise.
Solution Approach 2:
The displacement sensor and controller serve multiple functions: they detect piston movement, calculate running clearance, monitor brake wear, and provide early warning of performance degradation. This multi-functionality improves reliability without proportionally increasing system complexity.
3Measurement precision
If the vehicle must be stationary for accurate running clearance measurement, then measurement precision may be improved, but productivity and operational time are reduced
Solution Approach 1:
The patent transitions from static measurement (vehicle stationary) to dynamic measurement (vehicle in motion). The displacement sensor and controller are designed to accurately detect and calculate running clearance during normal braking operations, allowing continuous monitoring without interrupting vehicle productivity.
4Measurement precision
If manual measurement methods are used, then device complexity is low, but measurement precision and real-time monitoring capability are insufficient
Solution Approach 1:
The patent replaces manual mechanical measurement with an automated sensor-based system. The displacement sensor electronically detects piston movement, and the controller algorithmically calculates running clearance, providing superior precision while keeping the added complexity manageable through integrated electronics.
Data Source
AI summary
A method and apparatus for calculating the total running clearance of a disc brake. The method includes detecting axial movement of a component of a piston assembly of the disc brake to provide data indicating the displacement of the component of the piston assembly during a braking operation, and determining an amount of displacement of the component that occurs before inboard and outboard brake pads both contact a rotor to provide a calculated total running clearance.