Friction Lining Wear Sensor Clamping Sleeve Assembly
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Solution Overview
Problem
Existing friction lining wear sensors require a separate sensor body for each geometry, leading to high production costs and complex pre-assembly, especially when multiple sensors are connected, and existing designs either leave the conductors unprotected or require complex support structures.
Innovation Solution
A clamping sleeve is used to indirectly fix the protective conductor sleeve to the pair of conductors at the sensor head, eliminating the need for a separate support base and allowing for greater geometric flexibility and protection of the conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate sensor body with integrated support base is used for each geometry, then the conductors are protected and the sensor structure is stable, but production costs increase and device complexity increases
Solution Approach 1:
The sensor system is divided into separate functional components: the sensor body and the support base are separated. The sensor body remains geometry-independent while the support base provides structural stability and conductor protection. This segmentation allows the sensor body to be standardized across different geometries while the support base adapts to specific installation requirements.
Solution Approach 2:
The sensor body is designed as a universal component that can be used across multiple geometries and configurations. By separating the geometry-specific support base from the universal sensor body, the same sensor body can serve multiple functions in different sensor arrangements without requiring custom manufacturing for each geometry.
2Object-affected harmful factors
If a separate sensor body with integrated support base is used for each geometry, then the conductors are protected, but production costs increase
Solution Approach 1:
The protection function is segmented from the sensor body and assigned to a separate support base component. This allows the sensor body to be mass-produced as a standard part while the support base can be customized or adapted to specific protection requirements, reducing overall manufacturing costs through standardization of the more complex sensor body component.
Solution Approach 2:
The support base acts as an intermediary component between the sensor body and the installation environment. It provides the necessary conductor protection and structural support without requiring the sensor body itself to be customized for each application, thereby reducing production costs through standardization.
3Device complexity
If the protective conductor sleeve is directly fixed to the conductors, then the assembly is simplified, but the conductors are vulnerable to damage
Solution Approach 1:
The support base serves as an intermediary structure between the protective conductor sleeve and the conductors. It provides mechanical support and protection to the conductors while allowing the conductor sleeve to be simply attached to the support base rather than directly to the vulnerable conductors, thus reducing assembly complexity without compromising conductor protection.
Data Source
Figure 1~2c
Figure 3
Figure 4a~4b
AI summary
The friction lining wear sensor has sensor head (100) having a sensor casing (10), and a conductor loop of an electric conductor which wraps around the sensor casing. A conduit unit (30) comprises a pair of conductors (24) having wires (24a,24b) that are enveloped by a conductor sleeve (26). The proximal and distal ends of conductor in conductor sleeve are connected to support bases of respective sensor heads. The conductor sleeve is non-positively fixed to the pair of conductors.