Resin-Protected Brake Sensors for High-Load Stress Detection
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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 capability is improved, but sensor structural integrity deteriorates under high compression loads
Solution Approach 1:
A protective element made of resilient material is introduced as an intermediary between the piezoelectric sensor and the external compression forces. This protective element absorbs and distributes the mechanical stress, preventing direct transmission of damaging forces to the sensor while allowing the sensor to detect operational stresses through the protective layer.
Solution Approach 2:
The protective element is pre-installed around the piezoelectric sensor before the sensor is exposed to high compression loads during braking operations. This protective cushioning is in place beforehand to absorb and mitigate the impact of extreme compression forces, preventing structural damage to the sensor during critical braking events.
2Manufacturing precision
If high compression load is applied during production to join friction material to support element, then manufacturing quality is improved, but sensor reliability deteriorates
Solution Approach 1:
The protective element serves as a mediator during the manufacturing process, allowing high compression loads to be applied for joining friction material to the support element while preventing these forces from being transmitted to the piezoelectric sensor. The resilient material absorbs the manufacturing-induced stress, ensuring both manufacturing quality and sensor reliability.
3Temperature
If braking device operates in high temperature conditions, then braking performance is maintained, but sensor performance deteriorates
Solution Approach 1:
The protective element acts as a thermal intermediary, providing thermal insulation between the piezoelectric sensor and the high-temperature environment of braking operations. This protective barrier allows the braking device to operate at high temperatures while maintaining sensor performance stability by reducing thermal exposure to the sensor.
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, such as when an external compression force exceeding 400 kg/cm2 is applied
Implementation Method 3
Certain embodiments provide a reliable production process for the production of a sensorized braking device that is both robust and resistant to high temperatures
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.