Insulating Body Peg and Spigot for Wear Sensor Signal Line
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Solution Overview
Problem
Existing wear indicators for vehicle brake linings are prone to false triggering and mechanical damage during assembly due to inadequate protection of the signal line, leading to incorrect wear detection.
Innovation Solution
An insulating body with a peg that securely holds a loop of the signal line, featuring a mushroom-shaped head and angled spigot, combined with snap-in points and a protective socket, provides enhanced fixation and protection against mechanical influences, and a closed channel that covers a significant portion of the signal line to prevent premature triggering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the signal line is wound around a known insulator with grooves, then the signal line is insulated from the pad backing plate, but the signal line is only protected to a limited extent against mechanical influences and can be destroyed during assembly
Solution Approach 1:
The insulating body is pre-formed with integrated features including a recess for receiving the signal line, a peg protruding into the recess to hold a loop of the signal line, and a spigot for routing the signal line. These features are built into the insulating body during manufacturing, providing mechanical protection and secure fixation before the signal line is installed, thereby preventing damage during assembly while maintaining ease of installation.
2Reliability
If the signal line is securely fixed to prevent premature damage, then false triggering is avoided, but the assembly process becomes more complex
Solution Approach 1:
The insulating body integrates multiple functions into a single component: it provides electrical insulation, mechanical protection through an enclosing recess, secure fixation via a peg with loop-holding capability, and signal line routing through a spigot. This merging of functions into one piece eliminates the need for separate protection elements and complex assembly steps, achieving reliable signal line fixation without significantly increasing device complexity.
3Measurement precision
If the signal line is protected against mechanical influences, then wear detection accuracy is improved, but the insulating body requires additional structural features
Solution Approach 1:
The signal line is nested within a recess of the insulating body, which encloses and protects it from mechanical influences. The peg and spigot features are integrated within the same insulating body structure, creating a compact nested arrangement that provides comprehensive protection without requiring separate external protection components, thereby maintaining measurement precision while limiting structural complexity.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The insulating body (1) has a support for a signal line, and a tap (3) arranged around a loop of a signal line. The tap is aligned in such a manner that a signal line provided around the tap and in the support is bent between the support and the tap around angle of sixty degrees. An independent claim is also included for a wear indicator of brake lining.