Disc Brake Wear Monitoring Using Caliper and Adjuster Sensing
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Solution Overview
Problem
Conventional disc brake wear monitoring systems are unreliable and often require disposable sensors that need replacement after a single use, failing to provide continuous and adaptable wear condition monitoring.
Innovation Solution
The development of disc brakes equipped with first and second sensor assemblies that sense linear movement of the caliper housing relative to the carrier and rotational movement of the adjuster, respectively, to determine the wear of inner and outer brake pads and the rotor, using Hall-Effect sensors or similar technology to generate and communicate data to a control system for precise wear estimation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wear monitoring systems are used, then wear detection is provided, but the system reliability deteriorates due to disposable sensors requiring replacement
Solution Approach 1:
The patent applies preliminary action by pre-installing permanent magnets on the caliper housing and carrier that continuously track wear without requiring sensor replacement. The Hall effect sensors are permanently positioned to detect magnetic field changes as components wear, eliminating the need for disposable sensors that must be replaced after single use.
Solution Approach 2:
The patent replaces mechanical contact-based wear sensors with a magnetic field-based detection system using Hall effect sensors. This substitution eliminates mechanical wear of the sensors themselves and allows for continuous monitoring without physical contact between sensing elements and worn surfaces.
2Measurement precision
If disposable sensors are used for wear monitoring, then wear detection is achieved, but device complexity increases due to replacement requirements
Solution Approach 1:
The patent applies self-service by designing a system where the permanent magnets and Hall effect sensors continuously monitor wear without external intervention. The system automatically tracks brake pad, shoe, and rotor wear through magnetic field changes, eliminating the need for manual sensor replacement or system reset that would be required with disposable sensors.
3Measurement precision
If continuous wear monitoring is implemented, then wear estimation accuracy improves, but energy consumption increases
Solution Approach 1:
The patent replaces energy-intensive mechanical or contact-based sensing systems with passive magnetic field detection using Hall effect sensors. The permanent magnets require no power, and the Hall sensors consume minimal energy to detect magnetic field changes, enabling continuous monitoring with low power consumption.
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
Enables continuous, reliable, and adaptable wear monitoring of brake pads and rotor components, providing accurate wear estimation and alerting when maximum allowable wear is reached, without the need for disposable sensors.
Implementation Method 1
using Hall-Effect sensors or similar technology to generate and communicate data to a control system for precise wear estimation
Data Source
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AI summary
A system for braking a vehicle includes a rotor, a disc brake having an inner brake pad and an outer brake pad that are selectively clamped onto the rotor to slow or stop rotation of the rotor, a carrier coupled to the vehicle, a caliper housing movable coupled to the carrier, and an adjuster for moving the inner brake pad and/or the outer brake pad relative to the rotor, a first sensor for sensing linear movement of the caliper housing relative to the carrier housing, a second sensor for sensing rotary movement of the adjuster, and a control system that determines outer brake pad wear based on the linear movement of the caliper housing relative to the carrier and inner brake pad wear based on the rotary movement of the adjuster.