Transverse Brake Force Sensor Arrangement
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Solution Overview
Problem
Existing disc brake measuring arrangements for brake application force measurement are prone to malfunctions due to contamination or incorrect installation, leading to contact between sensors and measurement objects, which results in faulty signals and incomplete displacement measurement.
Innovation Solution
A measuring arrangement where the brake application force sensor is positioned outside the travel path of the measurement object, at a right angle, allowing for contactless interaction and easy attachment/removal, using eddy current or Hall sensors with multiple coils for interference correction, and a hermetically sealed housing to minimize interference from external factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the brake application force sensor is arranged in the extension of the displacement travel of the measurement object, then the measurement arrangement can detect the entire displacement travel, but contamination or particles can accumulate between the sensor and measurement object causing contact and faulty signals
Solution Approach 1:
The sensor is repositioned from a linear arrangement along the displacement path to a transverse arrangement at a right angle to the displacement path. This dimensional change allows the sensor to measure displacement without being in the direct path of contamination, eliminating contact while maintaining measurement capability across the entire travel range.
2Ease of manufacture
If the brake application force sensor and measurement object are in direct contact, then mounting is simple, but contact causes faulty signals and incomplete displacement measurement
Solution Approach 1:
The mechanical contact-based measurement system is replaced with a contactless measurement system. The sensor measures displacement through transverse interaction with the measurement object without physical contact, eliminating signal faults while maintaining ease of mounting through simple attachment to the caliper components.
3Measurement precision
If the sensor is positioned inside the travel path, then measurement coverage is complete, but the sensor is susceptible to contamination and external interference
Solution Approach 1:
The sensor is extracted from the contaminated travel path environment and repositioned in a clean area transverse to the displacement path. This extraction maintains complete measurement coverage through transverse sensing while removing the sensor from exposure to brake dust, particles, and thermal interference.
4Manufacturing precision
If the measuring arrangement is permanently fixed during installation, then alignment is precise, but maintenance and replacement are time-consuming
Solution Approach 1:
The measuring arrangement is segmented into separable components that can be independently attached and detached. The sensor and measurement object are designed with separate mounting interfaces allowing precise alignment during installation while enabling quick removal and replacement during maintenance without affecting the other components.
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 configuration prevents collisions between the measurement object and sensor, ensuring accurate measurement of brake application force with reduced susceptibility to faults, facilitating easy maintenance and calibration, and providing a broader application range including self-energizing disc brakes.
Implementation Method 1
using eddy current or Hall sensors with multiple coils for interference correction
Implementation Method 2
using eddy current or Hall sensors with multiple coils for interference correction
Data Source
AI summary
A measuring arrangement for brake application force measurement of a disc brake, includes two components of the disc brake which can be displaced relative to each other along a travel path when a brake application force is applied, at least one brake application force sensor with a housing; a measurement object which can be permanently connected to one or the other of the two components and having at least one element or at least one target object which has at least one such element for contact-free interaction with the brake application force measurement sensor; and an evaluation unit. The brake application force sensor is designed for the detection of a displacement of the measurement object along the path with the evaluation unit for the conversion of the detected displacement in a measurement variable as a measurement for the brake application force. The brake application force sensor and the measurement object can be mounted with each of the two components in a removable manner. The measuring arrangement is characterized in that the brake application force sensor is arranged outside the path of the measurement object and with the observation direction thereof arranged perpendicular to the path.