Disc Brake Sensor on Retainer Strap for Pad Position Monitoring
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Solution Overview
Problem
Existing disc brake assemblies lack an efficient method to monitor the position of brake pad assemblies, which can lead to issues such as brake pad wear and potential dragging, requiring complex internal sensor installations that complicate maintenance and increase the risk of environmental leaks.
Innovation Solution
A disc brake assembly with a sensor assembly mounted to a retainer strap, which extends across the brake pad assembly and generates a signal indicative of the brake pad position, allowing for external monitoring and easy access, eliminating the need for internal sensor placement and reducing potential leak paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If internal sensor installation is used to monitor brake pad position, then measurement precision is improved, but device complexity increases and reliability decreases due to potential leaks
Solution Approach 1:
The sensor assembly is extracted from the internal brake caliper environment and mounted externally on the retainer strap. This removes the sensor from the sealed internal environment, eliminating the risk of leaks while maintaining position monitoring capability through external detection of the locator feature.
Solution Approach 2:
A magnetic locator feature is introduced as an intermediary between the brake pad assembly and the sensor assembly. The magnetic field serves as a non-contact mediator that transmits position information from the moving brake pad to the external sensor without requiring physical penetration or internal mounting.
2Measurement precision
If internal sensor installation is used to monitor brake pad position, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The sensor assembly is extracted from the complex internal brake caliper structure and relocated to the external retainer strap. This simplifies installation by utilizing an accessible external mounting location rather than requiring disassembly and integration within the sealed caliper housing.
Solution Approach 2:
The monitoring function is segmented from the brake caliper assembly and placed on the retainer strap. This modular approach allows the sensor to be independently mounted and maintained without affecting the brake caliper's internal sealing or structural integrity.
3Measurement precision
If internal sensor installation is used, then measurement precision is improved, but ease of repair worsens due to reduced accessibility
Solution Approach 1:
The sensor assembly is extracted from the internal brake caliper environment and mounted externally on the retainer strap, making it easily accessible for inspection, testing, and replacement without requiring disassembly of the brake caliper or removal of seals.
Solution Approach 2:
The retainer strap serves multiple functions: it secures the brake pad assembly and simultaneously provides a mounting platform for the sensor assembly. This multi-functional use of the retainer strap simplifies the overall structure and improves sensor accessibility.
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 configuration enables effective monitoring of brake pad position and travel, facilitating early detection of wear or operational issues, simplifying maintenance, and preventing environmental leaks by positioning the sensor externally, thus enhancing brake performance and reliability.
Implementation Method 1
The sensor assembly includes a sensor that detects a position of the brake pad assembly
Data Source
AI summary
A disc brake assembly that includes a brake caliper, a retainer strap, and a sensor assembly. The retainer strap is mounted to the brake caliper and extends across a brake pad assembly. The sensor assembly is mounted to the retainer strap and generates a signal indicative of a position of the brake pad assembly.