Snap-Fit Anti-Lock Sensor Ring for Thermal Expansion Stability
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Solution Overview
Problem
Current disc brake systems face challenges with corrosion susceptibility, especially in anti-lock braking systems, where the exciter ring's fit with the rotor is affected by thermal expansion and vibrations, leading to inaccurate rotational speed detection and potential disconnection, and existing solutions require additional components or tools for assembly.
Innovation Solution
An anti-lock sensor ring with a retention mechanism using elastic cantilever spring clips that snap onto the disc brake band, eliminating the need for dedicated hardware or tools, and allowing for easy compensation of material expansion differences, while maintaining a secure attachment that avoids interfering with ventilation channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an exciter ring is pressed onto a disc rotor, then the ring can be made from corrosion-resistant material, but the ring may lose its tight fit and angular position due to thermal expansion and vibrations
Solution Approach 1:
The retention mechanism uses elastic cantilever springs that can dynamically adjust to thermal expansion and vibrations, maintaining continuous contact pressure between the sensor ring and brake band while accommodating dimensional changes without losing fit stability
Solution Approach 2:
The retention mechanism is divided into multiple independent cantilever spring elements distributed around the sensor ring, allowing localized adjustment and maintaining overall fit stability even when individual springs experience varying thermal and vibrational stresses
2Reliability
If dedicated hardware and tools are used for assembly, then secure attachment is achieved, but assembly complexity and time increase
Solution Approach 1:
The retention mechanism integrates the attachment function directly into the sensor ring structure by incorporating cantilever springs as part of the ring itself, eliminating the need for separate fasteners, clips, or dedicated assembly tools while maintaining secure attachment
Solution Approach 2:
The cantilever springs are pre-formed as integral parts of the sensor ring, allowing the ring to self-retain onto the brake band through its own elastic deformation without requiring external hardware or specialized assembly tools
3Reliability
If the sensor ring is positioned to ensure secure attachment, then retention is improved, but ventilation channel access may be blocked
Solution Approach 1:
The retention mechanism applies localized attachment forces at specific circumferential positions where cantilever springs engage with the brake band, while leaving other areas open for ventilation channel access, thus achieving both secure retention and adequate cooling
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
This solution provides a tool-less, secure, and reliable attachment of the anti-lock sensor ring to the disc brake band, maintaining accurate rotational speed detection and preventing disconnection due to thermal expansion and vibrations, without altering air flow or increasing temperature risks.
Implementation Method 1
The retention mechanism comprises a plurality of elastic cantilever spring retention clips (8)
Implementation Method 2
One type of sensor used is a variable reluctance sensor that generates a train of electrical pulses as a function of the dispersion of the variable magnetic flux between the sensor head and the exciter ring
Data Source
AI summary
An anti-lock sensor ring may have a flattened exciting portion having a retention mechanism projecting from a ring radial edge. The retention mechanism may have cantilever spring retention clips elastically deformable to snap on a disc brake band retention seat. The mechanism may also have a cantilever support portion disposed side by side to and spaced apart from the cantilever spring retention clips. Each of the cantilever spring retention clips may have a retention surface and the cantilever support portion with a support surface. When the anti-lock sensor ring is dismounted from a disc brake band, the plane defined by the retention surface and the plane defined by the support surface are facing each other in order to create opposing gripping elements.