Disc Brake Assembly With Integrated Visual Wear Indicator

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Solution Overview

Problem

Existing air actuated disc brake systems face challenges in monitoring wear of friction elements, as visual indicators are often obscured by wheel installations and require additional components, increasing costs and complexity.

Innovation Solution

A disc brake assembly with integrally cast formations on the carrier and caliper that protrude in a perpendicular direction, enhancing visibility of wear without additional components or machining, allowing easier inspection of friction element wear.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a spring loaded pin visual wear indicator is provided on the disc brake assembly, then wear monitoring capability is improved, but device complexity and manufacturing cost increase due to additional components and machining requirements

Engineering Contradiction:

Improvewear monitoring capabilityVSAvoidnumber of components

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The wear indicator function is merged with the existing caliper and carrier structures. The first formation on the carrier and second formation on the caliper are integrally cast with these components, eliminating the need for separate wear indicator parts while maintaining the wear monitoring capability through their relative movement.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The carrier and caliper components serve dual functions: their primary braking function and a secondary wear indication function. The formations on these components provide wear monitoring information without requiring dedicated wear indicator mechanisms, thus achieving multi-functionality.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Measurement precision

If a spring loaded pin visual wear indicator is provided on the disc brake assembly, then wear monitoring capability is improved, but manufacturing cost increases due to additional components and machining

Engineering Contradiction:

Improvewear monitoring capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

3Loss of information

If a spring loaded pin protrudes from the caliper for visual inspection, then wear information is visible, but visibility is reduced when wheels are fitted to the brake

Engineering Contradiction:

Improvevisual accessibility of wear indicatorVSAvoidconvenience of visual inspection

Core Design Contradiction:

Loss of informationVSEase of operation

Solution Approach 1:

The wear indicator formations are positioned to extend in a radial direction perpendicular to the braking surface, creating a new dimension for visibility. This radial protrusion allows the formations to be viewed from the side when wheels are installed, rather than requiring viewing from the braking surface direction.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentEP3121477B1A disc brake assembly

Publication Date: 2022.10.05 MERITOR HEAVY VEHICLE BRAKING SYSTEMS (UK) LIMITED

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AI summary

A disc brake assembly, comprising: a carrier (12) having a first formation (130) on an inboard surface thereof; a caliper (14) slideably mounted to the carrier having a second formation (132) that is proximate to the first formation (130) in use, wherein the relative positions of the first formation (130) and the second formation (132) are indicative of an amount of wear of a brake friction element and/or a rotor of the assembly in use.