Disk Brake Wear Monitoring Using Signal-Line Limit Detection
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Solution Overview
Problem
Existing wear monitoring devices for disk brakes in commercial vehicles require additional complexity and resources to monitor individual brake linings for different wear rates, as they only quantify cumulative wear, potentially leading to unnoticed excessive wear of one lining.
Innovation Solution
The use of a signal line connected to both the first sensor unit and evaluating unit, which comes into contact with a stop or is severed when a predetermined wear limit is reached, allowing for simple monitoring of individual brake lining wear without additional sensors, utilizing existing infrastructure to output warning signals for safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a second sensor unit is added to monitor individual brake lining wear, then the reliability of wear monitoring is improved, but the device complexity and cost increase
Solution Approach 1:
The signal line is designed to serve dual functions: transmitting cumulative wear data from the first sensor unit to the evaluating unit, and simultaneously acting as a second sensor unit that detects when the wear limit of individual brake linings is reached through contact with stops or severance. This multi-functionality eliminates the need for separate dedicated wear limit detection sensors.
Solution Approach 2:
The patent merges the function of the signal line used for cumulative wear data transmission with the function of a wear limit detection sensor. By integrating these two functions into a single component, the system achieves reliable individual brake lining monitoring without adding separate sensor units, thus reducing device complexity while maintaining monitoring reliability.
2Loss of information
If a second sensor unit is added to monitor individual brake lining wear, then the completeness of wear information is improved, but the manufacturing cost increases
Solution Approach 1:
The signal line is designed to serve dual functions: transmitting cumulative wear data from the first sensor unit to the evaluating unit, and simultaneously acting as a second sensor unit that detects when the wear limit of individual brake linings is reached through contact with stops or severance. This multi-functionality eliminates the need for separate dedicated wear limit detection sensors.
Solution Approach 2:
The signal line performs self-service by utilizing its own structural configuration to detect wear limits. The signal line's physical arrangement relative to the stops and brake linings allows it to automatically detect wear limit conditions through contact or severance events, eliminating the need for additional dedicated detection components and reducing manufacturing costs.
3Device complexity
If the signal line is arranged to contact a stop at wear limit, then the simplicity of the solution is improved, but the risk of false signals due to vibration or thermal expansion may worsen
Solution Approach 1:
The signal line is segmented into multiple sections, with each section responsible for monitoring a specific brake lining. This segmentation allows the system to independently evaluate wear of each lining through separate contact or severance events, improving signal accuracy by isolating individual wear detection from cumulative wear data transmission.
Solution Approach 2:
The stop acts as an intermediary element between the signal line and the evaluating unit. The stop provides a stable reference point that the signal line contacts to indicate wear limit conditions, while the evaluating unit processes this contact signal to determine actual wear status, filtering out false signals from vibration or thermal expansion.
Data Source
AI summary
A wear monitoring device of a disk brake includes a brake disk, a first brake lining on a first face of the brake disk, and a second brake lining on a second face of the brake disk, in particular for commercial vehicles. The wear monitoring device has a first sensor unit that quantitatively ascertains the cumulative wear of the first and second brake linings. The wear monitoring device outputs, at the output connection of the first sensor unit, a first electrical output signal that is associated with the cumulative wear. A signal line is connected on the one hand to the output connection of the first sensor unit and on the other hand to an evaluating unit. The signal line is arranged in such a manner that, when a predetermined first wear limit of the first or second brake lining is reached, the signal line comes into contact with a stop.