Sensorized Brake Pad Assembly for In-Pad Force Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current vehicle braking systems lack the ability to detect forces between brake pads and the braking element during use, leading to issues like abnormal wear, noise, and vibration, which can result in premature brake pad replacement and malfunctions.
Innovation Solution
Integration of high-temperature piezoceramic sensors into brake pads, embedded within a friction material block, to emit an electric signal proportional to mechanical stress, allowing for efficient detection of forces during braking without the need for external power, combined with an electric circuit and thermally insulating layers for durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If piezoelectric sensors are integrated into brake pads to detect forces during braking, then measurement precision is improved, but device complexity increases due to construction difficulties and integration requirements
Solution Approach 1:
The piezoelectric sensor is embedded within the brake pad structure, specifically integrated into the friction material block. The sensor is nested between the friction material and the metal support plate, allowing force detection while maintaining a compact, integrated design that reduces overall system complexity despite adding sensing capability.
Solution Approach 2:
The sensor integration process combines multiple functions into a single manufacturing sequence. The piezoelectric sensor is bonded directly to the metal support plate during the brake pad manufacturing process, merging the sensor attachment with the existing assembly operations. This eliminates separate sensor installation steps and reduces construction complexity.
2Reliability
If piezoelectric sensors are placed on brake pads to detect forces, then reliability is improved through real-time monitoring, but difficulty of detecting and measuring increases due to high temperatures and pressures during production and use
Solution Approach 1:
A high-temperature adhesive layer is introduced as an intermediary between the piezoelectric sensor and the metal support plate. This adhesive mediator protects the sensor from direct exposure to extreme temperatures and pressures during both manufacturing and operation, enabling reliable force detection while the sensor remains shielded from harsh conditions.
Solution Approach 2:
The adhesive layer's properties are selected to withstand high temperatures, changing the thermal environment experienced by the sensor. By using an adhesive with high-temperature resistance, the sensor operates in a more favorable thermal parameter range, reducing the difficulty of maintaining sensor functionality under extreme braking conditions.
3Measurement precision
If piezoelectric elements are arranged on the backplate to detect deformations, then measurement precision is improved, but ease of manufacture deteriorates due to experimental nature and lack of mass production suitability
Solution Approach 1:
The piezoelectric sensor is pre-bonded to the metal support plate during the brake pad manufacturing process, before the friction material is applied. This preliminary action integrates the sensor into the assembly line workflow, allowing subsequent steps to proceed without interruption and enabling mass production while maintaining measurement precision.
Solution Approach 2:
The sensor integration is designed to continue seamlessly through the manufacturing process. The sensor remains in place and functional throughout subsequent manufacturing steps, including friction material application and curing. This continuous integration ensures measurement precision is maintained while facilitating uninterrupted mass production.
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 reliable and efficient detection of forces between brake pads and the braking element, preventing premature wear and noise, thereby improving braking performance and extending brake pad lifespan.
Implementation Method 1
at least one piezoceramic sensor (15) designed for emitting, without the need for electric power, an electric signal only when subjected to a mechanical stress
Implementation Method 2
a thermally insulating layer (12) formed upon the supporting metal element (11)
Data Source
AI summary
A method in which at least one piezoceramic sensor and an electric circuit to collect an electric signal emitted by the piezoceramic sensor when subjected to a mechanical stress and possibly processing it are made as an electrically insulated unit. The unit is equipped with at least a branching ending with respective electric contacts and having the connected at least one piezoelectric sensor. The electric circuit and the at least one sensor are mechanically fixed integral with a first surface of a supporting metal element of a brake pad. Branching is formed so as to position the at least one piezoelectric sensor at a predetermined point of the first surface.