Undercarriage Heat Shield for ABS Sensor Thermal Protection
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Solution Overview
Problem
In commercial vehicles equipped with disc brakes, ABS sensors positioned close to the brake discs are at risk of damage due to high temperatures, leading to potential short circuits and oxidation, compromising their fault-free operation.
Innovation Solution
A chassis component design featuring a heat shield with a collar-shaped section spaced apart from the electrical component's connection section, providing thermal protection and allowing for a more compact configuration without increasing the risk of damage, using a combination of a sleeve-shaped section for the electrical component and a collar-shaped section for the heat shield, with an air gap or thermally insulating material to reduce heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the ABS sensor is positioned close to the brake disc to enable compact chassis design, then the chassis component size is reduced, but the electrical component is exposed to high temperatures causing melting, burning, short circuits, and oxidation
Solution Approach 1:
A heat shield is introduced as an intermediary component between the brake disc and the ABS sensor. The heat shield includes a sleeve-shaped section that surrounds the shaft-shaped section of the ABS sensor and a collar-shaped section that extends toward the brake disc, creating a thermal barrier that protects the electrical component from high temperatures while allowing the sensor to remain positioned close to the brake disc for compact design
2Reliability
If the electrical component is protected from heat by increasing distance from the brake disc, then thermal damage is prevented, but the chassis component size increases and compact design is compromised
Solution Approach 1:
The heat shield is designed with a sleeve-shaped section that nests around the shaft-shaped section of the ABS sensor. This nested configuration allows the heat shield to provide comprehensive thermal protection while maintaining a compact overall structure, as the protective element is integrated within the existing spatial envelope rather than extending outward
3Object-affected harmful factors
If a heat shield is added to protect the electrical component, then thermal protection is improved, but the device complexity increases
Solution Approach 1:
The heat shield is segmented into two distinct functional sections: a sleeve-shaped section that surrounds the ABS sensor shaft and provides direct thermal protection, and a collar-shaped section that extends toward the brake disc to block radiant heat. This segmentation allows each section to be optimized for its specific protective function while keeping the overall structure manageable and manufacturable
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 design effectively protects electrical components from excessive temperatures, enabling a more compact vehicle chassis while maintaining reliable ABS sensor operation by minimizing heat transfer and preventing damage from thermal radiation.
Implementation Method 1
using a combination of a sleeve-shaped section for the electrical component and a collar-shaped section for the heat shield, with an air gap or thermally insulating material to reduce heat transfer
Data Source
Figure 1
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AI summary
The gear component (1) has a shaft, and electrical component which is arranged proximate to a brake disc. The electrical component comprises shaft-shaped portion and a connecting portion for connecting an electrical cable. The shaft-shaped portion is accommodated in a sleeve-shaped portion of a heat shield. The heat shield is provided with a connecting portion of electrical component associated with a collar-shaped portion which is arranged at preset spacing with the connecting portion.