Disc Brake Running Clearance Calculation via Piston Axial Displacement
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Solution Overview
Problem
Existing disc brake systems lack precise monitoring of running clearance, which can lead to unsafe operating conditions due to insufficient or excessive clearance, affecting brake performance and wear, and are not effectively detected until a critical event occurs.
Innovation Solution
A method to calculate the total running clearance by detecting the axial movement of a piston assembly component during braking, using sensors to determine the displacement before brake pads contact the rotor, and applying a knee point detection algorithm to analyze input force and pressure changes.
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 the running clearance measurement is imprecise and requires the vehicle to be stationary for manual measurement
Solution Approach 1:
The patent replaces manual mechanical measurement methods with an automated sensor-based system. Sensors detect the position of brake pads and rotor to automatically calculate running clearance, eliminating the need for manual measurement while the vehicle is stationary. This substitution of mechanical measurement with automated sensing directly improves measurement precision while maintaining system simplicity.
2Reliability
If the running clearance is not monitored precisely in real-time, then the system operates with simpler monitoring, but brake performance issues are not detected until critical events occur
Solution Approach 1:
The patent implements a feedback mechanism where sensors continuously monitor brake pad position and rotor position, automatically calculate running clearance, and provide real-time feedback on brake health status. This feedback loop enables early detection of clearance issues before they become critical, improving reliability while using moderate automation through automated calculation algorithms.
Solution Approach 2:
The system performs preliminary detection of running clearance issues before they develop into critical problems. By continuously monitoring and calculating clearance in advance, the system can alert operators to potential issues before they affect brake performance, preventing critical events rather than reacting to them.
3Stability of the object's composition
If the running clearance is too high, then the brake assembly structure allows greater tolerance, but brake performance deteriorates due to insufficient clamping force
Solution Approach 1:
The feedback mechanism continuously monitors running clearance and can alert operators when clearance exceeds acceptable thresholds. This real-time feedback enables maintenance personnel to adjust clearance before it becomes too high, maintaining both structural tolerance stability and brake performance reliability through proactive adjustment rather than reactive repair.
4Reliability
If the running clearance is too low, then the brake pads maintain better contact with the rotor, but excessive wear and overheating occur
Solution Approach 1:
The continuous monitoring system detects when running clearance becomes too low and can alert operators to increase the clearance through manual adjustment. This feedback prevents excessive wear and overheating by maintaining clearance within the optimal range, balancing reliable brake contact with prevention of harmful thermal and mechanical effects.
Data Source
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AI summary
A method and apparatus for calculating the total running clearance of a disc brake having inboard and outboard brake pads arranged to contact a rotor during a braking operation, wherein a piston assembly is configured to actuate the inboard brake pad of the disc brake. The method includes detecting the axial movement of a component of the piston assembly to provide data indicating the displacement of the component of the piston assembly during the braking operation; and determining the amount of displacement of the component of the piston assembly that occurs before the inboard brake pad and outboard brake pad are both contacting the rotor to provide a calculated total running clearance.