Disc Brake Wear Detection via Comparison Element
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Solution Overview
Problem
Existing disc brake wear indicators are complex, costly to manufacture, and unreliable, often requiring structural modifications that compromise brake strength and cannot be easily accessed for inspection without removing the vehicle wheel, leading to suboptimal wear detection and potential safety issues.
Innovation Solution
A disc brake design featuring a comparison element with a step on the brake carrier that runs parallel to the guide bar and opposite to the brake disc, allowing for visual wear detection without modifying the brake carrier or caliper, and is simple to manufacture and assemble, enabling cost-effective and reliable wear monitoring without the need to remove the vehicle wheel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wear indicator with a current-conducting cable or rotary potentiometer is used, then wear detection capability is provided, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent extracts the wear detection function from complex electrical systems (cables, potentiometers) and implements it through a simple mechanical reference element (comparison element with step) that can be visually inspected. This removes unnecessary complexity while maintaining wear detection capability.
Solution Approach 2:
The comparison element serves itself as a visual reference without requiring external power sources, sensors, or complex signaling systems. The step on the comparison element automatically provides the reference level for wear assessment, eliminating the need for electrical wear indicators.
2Reliability
If recesses or notches are added to the brake carrier for wear detection markings, then wear detection is enabled, but fatigue fracture strength is reduced
Solution Approach 1:
The patent separates the wear detection reference (comparison element with step) from the brake carrier structure. Instead of modifying the carrier with weakening recesses, the reference function is segmented into a separate element that can be added without compromising the carrier's structural integrity.
Solution Approach 2:
The comparison element acts as an intermediary between the brake carrier and the wear detection function. It provides the necessary visual reference without requiring direct modification of the brake carrier, thus avoiding stress concentration and fatigue fracture risks.
3Reliability
If existing wear indicators are used, then wear state can be detected, but inspection requires vehicle wheel removal which reduces operational efficiency
Solution Approach 1:
The comparison element with its step is pre-positioned on the brake carrier at a location that allows visual inspection without wheel removal. This preliminary arrangement of the reference element enables ongoing wear monitoring during normal vehicle operation, improving productivity.
Data Source
AI summary
A disc brake has a brake caliper which straddled a brake disc and is mounted on a stationary brake carrier so as to be axially movable in relation to the brake disc. Brake pads which are placed in the brake caliper can be pressed against the brake disc by a brake application mechanism during a braking operation. In order to be axially movable, the brake caliper is mounted on at least one guide bar that is connected to the brake carrier. A device is provided for optically detecting wear of a brake disc and/or a brake pad. In order for wear to be detectable, a comparative element which runs parallel to the guide bar, extends away from brake disc, and includes at least one step, is mounted on the brake carrier.