Removable Eddy Current Sensor for Disc Brake Clamping Force
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Solution Overview
Problem
Existing disc brake measuring arrangements face challenges in accurately measuring application force under extreme operating conditions, with issues related to installation tolerances, thermal changes, and maintenance complexity, particularly in self-energizing disc brakes.
Innovation Solution
A measuring arrangement featuring a removable application force sensor and measurement object with an eddy current sensor system, allowing for precise displacement detection and calibration, and a compact design with hermetically sealed housing to minimize interference, enabling accurate force measurement across various disc brake types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a measuring arrangement is installed in a disc brake to measure application force, then measurement capability is improved, but installation complexity and maintenance time increase
Solution Approach 1:
The measuring arrangement is divided into separate components: a sensor unit that can be independently installed and a measurement object that can be separately attached to brake components. This segmentation allows for simpler installation and maintenance while maintaining measurement capability.
Solution Approach 2:
The measuring arrangement is designed to be universally applicable to different disc brake types, including self-energizing brakes. The sensor and measurement object can be attached to various brake components (caliper, bracket, etc.), making the system adaptable without requiring complex custom installations for each brake type.
2Measurement precision
If the measuring arrangement is made permanent for accuracy, then measurement reliability is improved, but maintenance and replacement time increase
Solution Approach 1:
The measuring arrangement transitions from a permanent fixed installation to a dynamic removable configuration. The sensor and measurement object can be easily attached and detached while maintaining measurement accuracy, enabling quick maintenance and replacement without compromising measurement reliability.
3Measurement precision
If the sensor is positioned close to the measurement object for precision, then measurement accuracy is improved, but sensitivity to installation tolerances and environmental factors increases
Solution Approach 1:
The measurement object acts as an intermediary between the sensor and the brake components. It provides a stable reference surface with a defined metal end face that mediates the interaction between the sensor and the moving brake parts, reducing sensitivity to installation tolerances and environmental factors while maintaining close sensor positioning for accuracy.
4Ease of operation
If the measuring arrangement is designed for removable attachment, then ease of installation and maintenance is improved, but potential loss of measurement stability occurs
Solution Approach 1:
The measurement capability is extracted into a separate removable sensor unit that can be independently attached and detached. This extraction allows for easy installation and maintenance while the sensor unit itself remains stable and reliable when properly mounted, separating the stability requirement from the removable attachment requirement.
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 solution provides improved accuracy and reduced maintenance time, with enhanced immunity to environmental factors and installation tolerances, while allowing for easy calibration and integration with existing brake systems.
Implementation Method 1
the application force sensor is designed as an eddy current sensor for detecting a displacement along the path
Data Source
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AI summary
The invention relates to a measuring arrangement (1) for measuring the clamping force of a disc brake, comprising two components of the disc brake that are displaceable relative to each other along a path (S) under application of a clamping force, at least one clamping force sensor (2) having a housing (21); a measuring object (7, 7') that is one of the two components or that can be fixedly connected to one of the two components and comprises at least one metal end face (23) or at least one target object (3) having at least one metal end face (23) for interacting with the clamping force sensor (2) in a contact-free manner; and an analysis unit (4), wherein the clamping force sensor (2) is implemented as an eddy current sensor for capturing a displacement along the path (S) using the analysis unit (4) for converting the captured displacement into a measurement variable as a measure for the clamping force, and wherein the clamping force sensor (2) and the measurement object (7, 7') can be removably mounted on the respective component.