Friction Brake Force Monitoring via Embedded Thin-Film Sensors
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Solution Overview
Problem
Existing braking and/or clamping devices face challenges in reliably and directly monitoring their operating state within a small space, lacking effective sensors to accurately record and reproduce operational forces and wear conditions.
Innovation Solution
Integration of thin-film sensors within the friction blocks or shoes to measure compressive forces, combined with pressure sensors arranged on friction locking parts or gears, allowing for real-time monitoring of operational forces and wear, with evaluation electronics to determine maintenance needs and temperature alerts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If thin-film sensors are integrated within friction blocks to measure compressive forces, then measurement precision and reliability of operating state monitoring are improved, but device complexity increases due to integration requirements
Solution Approach 1:
The thin-film sensor is integrated directly into the friction block structure, merging the sensing function with the existing mechanical component. This eliminates the need for separate sensor housings and mounting mechanisms, thereby improving measurement precision while minimizing the increase in device complexity.
Solution Approach 2:
The thin-film sensor is embedded within the friction block in a nested configuration, where the sensor is positioned inside or within the structure of the friction block itself. This nesting approach allows for precise force measurement while maintaining a compact design that does not significantly increase overall device complexity.
2Loss of information
If pressure sensors are arranged on friction locking parts or gears, then real-time monitoring of operational forces is improved, but manufacturing precision requirements increase for sensor placement
Solution Approach 1:
The pressure sensing function is merged with the friction locking part or gear structure itself. The thin-film sensor is integrated into these components during manufacturing, ensuring precise and consistent sensor placement without requiring additional post-manufacturing alignment steps, thereby reducing manufacturing precision requirements while enabling real-time operational force monitoring.
3Reliability
If multiple sensors are integrated into a small space within the braking device, then monitoring reliability is improved, but available space for sensor installation is reduced
Solution Approach 1:
Thin-film sensors are used instead of bulkier traditional sensors, allowing multiple sensing elements to be integrated into the limited space within the braking device. The thin-film technology enables high-density sensor placement while maintaining the compact dimensions of the original device, thereby improving monitoring reliability without significantly increasing the volume required for sensor installation.
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 precise monitoring of braking and clamping forces, wear detection, and temperature management, ensuring timely maintenance and optimal device performance by providing direct and reliable operational state feedback.
Implementation Method 1
at least one thin-film sensor which records the compressive force is arranged in the device in the area of at least one friction block
Data Source
Figure 1~7
Figure 2
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AI summary
The invention relates to a braking and/or clamping device for a slide guided on at least one guide rail (1), wherein the device comprises at least one friction brake (90) actuated via a gearbox (92, 107, 96), which has at least one friction jaw (100) mounted in a housing (10) and pressed against the guide rail, wherein the gearbox (92, 107, 96), which is moved by means of external energy, is movable for loading and unloading the friction brake, per loading and unloading direction, by means of at least one actuator (55, 70, 80) or by means of a spring system (50) comprising at least one spring element (52). At least one pressure-force-receiving thin-film sensor (125) is arranged in the device, propagating transversely to the direction of the force flow of the braking and/or clamping force to be generated, in the area of at least one friction brake and/or at least one gearbox.The present invention develops a braking and/or clamping device by which the operating state of the device can be reliably and directly detected and reproduced at any time in a small installation space.