Brake Disc Coating Thickness Sensing Under Disc Wobble
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Solution Overview
Problem
Existing methods for determining the layer thickness of coatings on brake discs, such as laser cladding, face challenges in achieving high precision and speed due to the difficulty in measuring thick and optically non-transparent layers, leading to potential imperfections and increased production time.
Innovation Solution
A sensor device with a first optical sensor system that uses differential measurement between a coated and an uncoated region of the disc, employing multiple optical sensors and a linear guide to achieve high-precision spatial resolution and compensate for disc wobbling, allowing for rapid and accurate layer thickness determination during the coating process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional measurement methods are used for thick and optically non-transparent coating layers, then measurement capability is limited, but measurement precision deteriorates
Solution Approach 1:
The patent uses an uncoated region of the disc as an intermediary reference surface. By comparing the optical path difference between the coated region and the adjacent uncoated region, the system can accurately determine coating thickness without needing to directly penetrate or transmit through the thick, non-transparent coating material itself.
Solution Approach 2:
The patent transitions from attempting to measure through the thickness dimension of the coating to measuring the surface topology in the lateral dimension. By using optical sensors to detect height differences between coated and uncoated regions, the system indirectly determines coating thickness without requiring optical penetration through the coating.
2Productivity
If the disc is rotated at high speed for rapid coating inspection, then productivity improves, but measurement precision deteriorates due to disc wobbling
Solution Approach 1:
The patent employs feedback control where the actual position of the disc surface is continuously measured during rotation, and this information is used to dynamically adjust the reference frame or compensate for deviations. The system monitors the disc's rotational position and wobbling characteristics, then corrects the measurement data accordingly to maintain precision at high rotation speeds.
Solution Approach 2:
The patent transitions from a static measurement approach to a dynamic one that adapts to the rotating disc's motion. By using real-time position-based measurements and continuously updating the reference framework based on the disc's actual rotational state, the system maintains measurement accuracy despite the dynamic conditions of high-speed rotation.
3Manufacturing precision
If multiple measurement points are taken to ensure even coating quality, then manufacturing precision improves, but loss of time increases
Solution Approach 1:
The patent implements continuous measurement during the coating process by rotating the disc and using optical sensors to continuously scan the coating surface. This eliminates the need for separate, discrete measurement steps, as the coating thickness is monitored continuously throughout the entire coating application process, ensuring uniformity without additional time loss.
Solution Approach 2:
The patent performs measurements during the coating process itself rather than after completion. By inspecting the coating in real-time as it is being applied, the system can detect and correct thickness variations immediately, preventing the need for subsequent rework or additional inspection time.
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 efficient and precise monitoring of the coating process, reducing production time and material waste by providing real-time layer thickness data and detecting topographical defects, thus ensuring even and optimal coating quality.
Implementation Method 1
a first optical sensor system (110, 210, 310) for determining the layer thickness of the coating applied to the disc
Data Source
AI summary
The invention relates to a sensor device for examining the coating of a disc as part of a coating process. The sensor device comprises a first optical sensor system for determining the layer thickness of the coating applied to the disc, and comprises a rotation apparatus. The invention is characterized in that the first optical sensor system is designed to simultaneously identify at least one first position-based measured value and one second position-based measured value, the first and the second position-based measured value describing the distance between the sensor systems and the surface of the disc. As a result of this, the sensor system is configured such that the first position-based measured value of a coated region of the disc and the second position-based measured value of an uncoated region of the disc are identified. Furthermore, the first optical sensor system comprises at least one linear guide, which extends from the central region to the edge. In addition, a control and analysis apparatus is provided for calculating the layer thickness of the disc at the position of the first position-based measured value with the aid of the first and the second position-based measured value. Furthermore, the invention relates to a coating for a disc, comprising inspecting the coating for determining the layer thickness of the coating applied to the disc.