Resin-Embedded Piezoceramic Brake Sensors Under High Compression
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Solution Overview
Problem
Braking devices face challenges in maintaining sensor integrity and performance due to high temperatures and pressures during production and operation, leading to potential damage and malfunction of piezoelectric sensors.
Innovation Solution
A sensorized braking device is designed with a protective element made of resilient materials, such as resin or ceramic, that encases the piezoceramic sensors, directing external compression forces away from the sensors and providing thermal insulation, allowing the device to operate effectively in extreme conditions up to 200°C and beyond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If piezoelectric sensors are embedded in braking devices to detect stresses, then measurement precision is improved, but reliability deteriorates due to high mechanical and thermal stresses during production and operation
Solution Approach 1:
A protective element is provided around the piezoelectric sensor before the high compression load is applied during production. This protective element absorbs and distributes the crushing force, preventing direct transmission to the sensor. The protective element acts as a cushion that protects the sensor from mechanical damage during the braking device assembly process while allowing the sensor to function properly during normal operation.
Solution Approach 2:
The protective element serves as an intermediary between the external compression force and the piezoelectric sensor. It mediates the interaction by distributing the compressive load across a larger area and preventing concentration of stress on the sensitive sensor components. This intermediary structure allows the sensor to detect stresses during braking without being damaged by the much higher compression forces applied during production.
2Manufacturing precision
If high compression load is applied to join friction material to support element, then manufacturing precision is improved, but the piezoelectric sensor structural integrity deteriorates
Solution Approach 1:
The protective element is installed around the piezoelectric sensor before the friction material is joined to the support element using high compression load. This protective cushioning structure prevents the crushing force from damaging the sensor during the manufacturing process, allowing high compression to be applied for precise joining without compromising sensor integrity.
Solution Approach 2:
The protective element is made from a material that combines mechanical strength with stress-distributing properties. This composite approach allows the protective element to withstand the high compression loads applied during manufacturing while distributing these forces in a way that protects the piezoelectric sensor. The material properties are selected to balance protection during manufacturing with appropriate stress transmission during normal sensor operation.
3Difficulty of detecting and measuring
If piezoelectric sensors are used in braking devices, then detection capability is improved, but adaptability to extreme temperatures deteriorates
Solution Approach 1:
The protective element acts as a thermal intermediary between the piezoelectric sensor and the high-temperature environment of the braking device. It provides thermal insulation that protects the temperature-sensitive sensor from direct exposure to extreme temperatures during braking operations, allowing the sensor to maintain its detection capability across a wide temperature range including heavy vehicle applications exceeding 600°C.
Solution Approach 2:
The protective element functions as a protective shell around the piezoelectric sensor, providing both mechanical and thermal protection. This shell structure isolates the sensor from the harsh thermal environment while allowing the sensor to perform its detection function. The protective shell enables the braking device to be adaptable to various temperature conditions, from light vehicle to heavy vehicle applications.
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
The solution ensures the stability and reliability of piezoelectric sensors by reducing mechanical and thermal stresses, maintaining optimal performance and extending the operational lifespan of the braking device across various vehicle types, including heavy vehicles.
Implementation Method 1
Piezoelectric sensors exploit the property of some crystalline materials of polarizing themselves generating a potential difference when they are subjected to mechanical deformation
Implementation Method 2
The protective element can exhibit mechanical properties adapted to maintain said piezoceramic sensor below its maximum load condition
Data Source
AI summary
Various braking devices, systems, and methods are disclosed. In some embodiments, the braking device includes a support element, a block of friction material supported by the support element, at least one piezoceramic sensor supported by the support element and interposed between the block of friction material (and the support element, and a protective element located at the piezoceramic sensor and embedding the latter. The protective element can have one or more layers of resin-based material applied to protect the piezoceramic sensor and direct a predetermined part of the external compression force onto an area of the support element surrounding the piezoceramic sensor. In some embodiments, a signal transduction device is provided and includes at least one piezoceramic sensor supported on a support element and has an integral protective coating having properties of mechanical and temperature resistance.