Disc Brake Wear Sensor Segmentation for Automated Assembly
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Solution Overview
Problem
Existing disc brake systems for commercial vehicles face challenges in efficient assembly and cost-effective maintenance, particularly in accurately positioning wear sensors and replacing defective pad wear sensors, which complicates production and increases operational costs.
Innovation Solution
The structural separation of the lining wear sensor and reduction gear allows for automated assembly and easy replacement of the wear sensor, with the reduction gear and chain assembled as a unit, and the wear sensor attached to the closure cap, enabling non-contact detection using a magnetic or inductive sensor system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a rotation angle sensor (rotary potentiometer) is connected to the adjusting spindle via a reduction gear to detect brake pad wear, then wear detection capability is improved, but assembly complexity and production cost increase due to precise positioning requirements
Solution Approach 1:
The patent divides the wear detection system into two independent parts: a non-contact sensor mounted on the closure cap and a transmitter integrated into the reduction gear. This segmentation eliminates the need for precise relative positioning between sensor and transmitter, as the non-contact arrangement allows for tolerance compensation through the spring-loaded mechanism.
Solution Approach 2:
The patent introduces a spring-loaded compression spring as an intermediary element between the reduction gear and the closure cap. This spring compensates for manufacturing tolerances and assembly variations, ensuring reliable non-contact coupling between the transmitter and sensor without requiring precise positioning.
2Measurement precision
If a reduction gear is connected to the adjusting spindle for wear detection, then wear stroke measurement is improved, but replacement of defective sensors becomes difficult and costly
Solution Approach 1:
The patent separates the sensor assembly from the reduction gear assembly. The sensor is mounted on the closure cap while the transmitter is integrated into the reduction gear, allowing independent replacement of either component without affecting the other, thereby simplifying maintenance and repair operations.
Solution Approach 2:
The patent extracts the sensor from the reduction gear assembly and mounts it separately on the closure cap. This extraction allows the sensor to be replaced independently without disassembling the reduction gear, significantly easing repair procedures and reducing maintenance costs.
3Measurement precision
If the encoder rotates through multiple revolutions to cover the entire wear stroke, then wear detection range is improved, but the overall height of the reduction gear increases
Solution Approach 1:
The patent employs a spring-loaded compression spring that dynamically adjusts the position of the closure cap relative to the reduction gear. This dynamic adjustment allows the encoder to achieve the required rotation range through the spring's compression and extension, rather than requiring a fixed, height-consuming mechanical arrangement.
Solution Approach 2:
The patent transitions from a mechanical multi-revolution coupling to a non-contact magnetic or inductive coupling arrangement. This dimensional change allows the encoder to cover the entire wear stroke through angular rotation combined with spring-loaded axial adjustment, eliminating the need for excessive height while maintaining full measurement range.
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 design facilitates easier assembly, reduces production costs, and allows for automated installation and removal of wear sensors, ensuring precise wear detection without interfering with the reduction gear, while maintaining a compact design and low overall height.
Implementation Method 1
The encoder is preferably pressed against the wall of the closure cover in a spring-loaded manner, for which purpose a compression spring is arranged in a ring gear of the planetary gear
Implementation Method 2
As a non-contact sensor, the lining wear sensor can be of different designs or functional principles. For example, the contactless sensor/transmitter functional unit can function on a magnetic basis or inductively.
Implementation Method 3
the contactless sensor/transmitter functional unit can function on a magnetic basis or inductively
Data Source
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AI summary
A disc brake, in particular for a utility vehicle, having a brake calliper (1) which engages over a brake disc (24), having brake linings (25) which make contact with the brake disc (24) in the functional position, a brake application device (23) with which one of the brake linings (25) can be pressed, via at least one actuation spindle (3, 4), against the brake disc (24), an adjustment device (2) which is connected in a rotationally fixed fashion to the actuation spindle (3, 4) and with which wear-induced change in the running clearance between the brake lining (25) and the brake disc (24) can essentially be compensated, a closure lid (18) which covers the adjustment device (2) and is attached to the brake calliper (1), and a lining wear sensor (19) which corresponds to a step-down gear mechanism which is connected to the actuation spindle (3), is embodied in such a way that a sensor (17) which rotates on a concentric path and which corresponds to the lining wear sensor (19) which is embodied as a contactless sensor and by means of which a change in the angular position of the sensor (17) can be detected and transmitted to an evaluation device is connected to the step-down gear mechanism.