Disc Brake Pad Clearance Control With Sensor-Driven Resetting
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Solution Overview
Problem
Conventional disc brake systems face challenges in reliably and accurately setting the clearance between the brake pad and brake disc, particularly due to insufficient restoring forces from pad restoring springs and changes in clearance due to wear and temperature variations.
Innovation Solution
A method involving sensors and drive units to adjust the brake pad position accurately, where sensors determine physical values such as pressure or clearance, and drive units adjust the brake pad based on these values to maintain optimal clearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pad restoring springs are used, then the structure is simple, but the restoring force is insufficient to reliably reset the brake caliper over service life
Solution Approach 1:
The patent replaces the conventional mechanical spring-based restoring mechanism with an electric motor-driven adjusting mechanism. The electric motor (20) provides controlled restoring force through a threaded rod (22) and nut (24) assembly, enabling reliable brake caliper resetting that overcomes friction in the pad guide (14) and compensates for wear and deflection throughout the service life of the disc brake.
Solution Approach 2:
The adjusting mechanism is designed to automatically reset the brake caliper without manual intervention. The control unit (32) monitors the position of the brake pad (18) relative to the brake disc (16) and activates the electric motor (20) when resetting is required, enabling the system to self-correct clearance issues during normal operation.
2Force
If pad restoring springs are used, then the device is simple, but the restoring force is insufficient when soiling increases friction
Solution Approach 1:
The patent replaces the mechanical spring-based restoring mechanism with an electric motor-driven adjusting mechanism. The electric motor (20) provides controlled restoring force through a threaded rod (22) and nut (24) assembly, enabling reliable brake caliper resetting that overcomes friction in the pad guide (14) and compensates for wear and deflection throughout the service life of the disc brake.
3Measurement precision
If manual clearance adjustment is used, then the device is simple, but the clearance setting is imprecise and requires maintenance intervention
Solution Approach 1:
The patent implements a feedback control system where a sensor (34) continuously monitors the position of the brake pad (18) relative to the brake disc (16). The control unit (32) receives this position information and compares it to the desired clearance specification, then activates the electric motor (20) to adjust the brake pad position until the correct clearance is achieved and maintained.
Solution Approach 2:
The patent replaces manual mechanical adjustment with an electric motor-driven system controlled by electronic sensors and a control unit, enabling precise and automated clearance setting that eliminates the need for manual intervention and maintenance.
4Stability of the object's composition
If conventional springs are used, then the structure is simple, but the clearance changes over time due to wear and temperature
Solution Approach 1:
The patent implements a feedback control system where a sensor (34) continuously monitors the position of the brake pad (18) relative to the brake disc (16). The control unit (32) receives this position information and compares it to the desired clearance specification, then activates the electric motor (20) to adjust the brake pad position until the correct clearance is achieved and maintained.
Solution Approach 2:
The patent transitions from a static spring-based system to a dynamic, actively controlled adjusting mechanism. The electric motor (20) can continuously adjust the brake pad position in response to changing conditions such as wear, temperature variations, and deflection, maintaining stable clearance throughout the service life of the disc brake.
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 enables precise and reliable adjustment of the brake pad clearance, ensuring optimal braking performance by preventing unwanted contact and maintaining rapid response behavior.
Implementation Method 1
determining at least one physical value of the brake pad by at least one sensor assigned to the brake pad
Implementation Method 2
at least one drive unit, which is assigned to a brake pad and by which a restoring force can be applied to the assigned brake pad
Data Source
AI summary
Proposed is a method for setting a clearance of a disc brake for a motor vehicle, wherein the disc brake includes a brake caliper, a brake piston, a brake disc, brake pads, at least one drive unit, which is assigned to a brake pad and by which a restoring force can be applied to the assigned brake pad, and at least one sensor, which is assigned to the at least one brake pad coupled to the drive unit, wherein the method comprises determining a physical value of the brake pad, comparing the physical value with an assigned predefined limit value or a predefined limit-value range, and, if necessary the brake pad is adjusted by an assigned drive unit. Also proposed is a brake pad and a service brake for a motor vehicle.