Disk Brake Wear Sensor Integrated in Adjusting Element Recess
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Solution Overview
Problem
The complexity and cost associated with integrating a wear sensor and reset device into a disk brake, particularly in commercial vehicles, are high due to the need for complex recess formation in the caliper, which increases manufacturing expenses and reduces precision in wear detection.
Innovation Solution
Incorporating a wear sensor and reset device with a pressure screw or pressure sleeve, where the reset element is rotationally coupled and housed within a recess in the adjusting element, allowing for axial movement detection and eliminating the need for precise caliper mounting, thus simplifying the structure and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wear sensor is integrated into the caliper with a recess formed in the caliper, then the wear sensor can be accommodated, but the manufacturing complexity and cost increase
Solution Approach 1:
The wear sensor is extracted from the caliper structure and integrated into the adjusting element instead. The adjusting element already contains a recess for the reset device, and the wear sensor is positioned in this same recess, eliminating the need for additional caliper modifications.
Solution Approach 2:
The wear sensor and reset device are merged into the same spatial location (the recess of the adjusting element). This consolidation allows both components to share the same housing space, reducing overall structural complexity.
2Reliability
If a recess is formed in the caliper to accommodate the wear sensor, then the sensor can be mounted, but manufacturing cost increases
Solution Approach 1:
The recess in the adjusting element serves multiple functions: it houses the reset device and simultaneously accommodates the wear sensor. This multi-functional design eliminates the need for separate mounting structures in the caliper.
Solution Approach 2:
The wear sensor mounting function is extracted from the caliper and relocated to the adjusting element, where it utilizes the existing recess space, thereby avoiding additional manufacturing operations on the caliper.
3Measurement precision
If the wear sensor is positioned in the caliper recess, then wear detection is possible, but manufacturing precision requirements increase
Solution Approach 1:
The wear sensor is relocated from the caliper to the adjusting element, transferring the mounting precision requirements from the caliper to the adjusting element. This allows the sensor to be positioned relative to the brake pad through the adjusting element's structure, which may provide more favorable positioning characteristics.
Data Source
AI summary
A disk brake includes a wear sensor and an adjusting device having an adjusting element in the form of a pressure screw and/or a pressure sleeve. The adjusting element has a recess in which a reset device extends which is rotationally coupled to the adjusting element for resetting the adjusting device. The wear sensor lies at least partially in the recess.