Disc Brake Pad Wear Detection via Mechanical Sound Generation
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Solution Overview
Problem
Conventional disk brakes that detect pad wear using sensors increase costs due to the need for electric components and components assembly limitations.
Innovation Solution
A disk brake design featuring a warning sound generating mechanism on the mounting member's arm, which produces a sound when the pads wear out, eliminating the need for electric detection and allowing for a wider range of pad types, reducing costs and maintaining the disk's integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is used to detect pad wear, then wear detection accuracy is improved, but cost increases due to electric components
Solution Approach 1:
The patent replaces the electrical sensor-based detection system with a purely mechanical warning sound generating mechanism. The sliding pin physically contacts the warning sound generating member when pad wear reaches a certain level, eliminating the need for sensors, wires, and electronic components, thus reducing cost while maintaining detection functionality
Solution Approach 2:
The warning sound generating mechanism is self-actuating through the mechanical displacement of the sliding pin relative to the arm. The system uses its own operational movement (caliper sliding along the arm) to trigger the warning, requiring no external power source or control system
2Reliability
If electric sensors are used for wear detection, then detection reliability is improved, but ease of manufacture deteriorates due to assembly limitations
Solution Approach 1:
The patent replaces complex electrical sensor assemblies with a simple mechanical linkage involving the sliding pin and warning sound generating member. This mechanical system is easier to manufacture and assemble as it requires no electrical connections, shielding, or precise electronic calibration, while providing reliable wear detection through direct mechanical contact
Solution Approach 2:
The warning sound generating mechanism is designed as a separate, modular component that can be independently manufactured and then assembled to the arm. This segmentation allows for specialized manufacturing of the warning mechanism without complicating the overall brake assembly process
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
The system effectively informs the driver of pad wear without electrical detection, reducing costs and increasing pad selection versatility while protecting the disk from wear-related damage.
Implementation Method 1
a pair of pads movably attached to the mounting member and pressed against the opposite sides, respectively, of the disk by the caliper
Implementation Method 2
at least one arm of the arms of the mounting member is provided with a warning sound generating mechanism generating a warning sound for wear detection according to displacement of the sliding pin relative to the arm
Data Source
AI summary
A disk brake includes a mounting member (2) having a pair of arms (2A) formed to extend over the outer periphery of a disk (1), the mounting member being secured to a non-rotating part of a vehicle, a caliper (3) provided on the mounting member (2) movably in the axial direction of the disk (1), a pair of pin holes (2C) provided in the arms (2A), respectively, of the mounting member (2) to extend in the axial direction of the disk (1), a pair of sliding pins (6) provided at the opposite ends of the caliper (3) to slide in the pin holes (2C), respectively, and a pair of pads (10) movably attached to the mounting member (2) and pressed against the opposite sides, respectively, of the disk (1) by the caliper (3). At least one arm (2A) of the arms (2A) of the mounting member (2) is provided with a warning sound generating mechanism (13) generating a warning sound for wear detection according to displacement of the sliding pin (6) relative to the arm (2A) when the pads (10) have worn by a predetermined amount.