Wireless Brake Pad Wear Sensor Using Magnetic Field Sensing
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Solution Overview
Problem
Current brake pad wear sensing systems require tire removal for wear assessment, are non-reusable, and fail to gather comprehensive vehicle data, leading to additional costs and limited functionality.
Innovation Solution
A wireless position sensing system for braking systems that measures brake pad wear without tire removal, integrates with existing systems, and transmits data wirelessly, allowing for continuous monitoring and providing insights into other vehicle components' conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a wire-based brake pad wear sensor is used, then brake pad wear detection is achieved, but the sensor must be replaced when brake pads are replaced and additional wire harness routing is required
Solution Approach 1:
The patent replaces the mechanical wire-based sensing system with a magnetic field-based sensor assembly. The sensor uses a magnet and magnetic sensor to detect brake pad wear through non-contact measurement, eliminating the need for wire harness routing and connection points while maintaining wear detection capability throughout the brake pad's service life
Solution Approach 2:
The sensor assembly is designed to remain in the vehicle for the life of the vehicle rather than being consumed with the brake pads. It can detect wear on multiple brake pads and potentially other vehicle components, providing multi-functional capability beyond the single-purpose wire sensor that only detects when one specific pad reaches wear limit
2Loss of information
If a simple wire sensor is used, then brake pad wear indication is provided, but no other vehicle component data is gathered
Solution Approach 1:
The sensor assembly incorporates multiple sensors that can detect various vehicle parameters including brake pad wear, rotor runout, caliper position, and potentially other suspension or steering components. This multi-functional design allows a single device to gather comprehensive vehicle health data rather than just brake pad wear information
3Measurement precision
If a wire-based sensor system is implemented, then brake pad wear monitoring is enabled, but tire removal is still required for wear assessment
Solution Approach 1:
The patent employs magnetic sensors and magnets to create a contactless measurement system that can detect brake pad wear through the brake assembly structure. This allows wear measurement to be transmitted wirelessly or through existing vehicle electronics without requiring physical access to the brake pads by removing the wheel
Solution Approach 2:
The sensor assembly acts as an intermediary device that measures brake pad wear indirectly through magnetic field interactions with components attached to or near the brake pads. This indirect measurement method enables wear detection without direct contact with the brake pads, eliminating the need for wheel removal
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 continuous brake pad wear monitoring over the vehicle's life, reduces maintenance costs, and provides comprehensive data on vehicle health, enhancing safety and maintenance efficiency.
Implementation Method 1
A sensor assembly measures a distance between the first portion and the second portion
Implementation Method 2
The sensor assembly can include an inductive sense element for measuring a distance between the inductive sense element and the metallic reference portion
Data Source
AI summary
A position sensing system and method for a braking assembly for a vehicle. The braking assembly includes a rotor, a caliper assembly disposed around the rotor and having a fixed mount bracket and a floating portion which moves when the brakes are applied. The position sensing system has a sensing element and a reference portion. The sensing element is attached to a location of the braking assembly such that the reference portion moves in relation to the sensing element when the floating portion moves. The sensor assembly is configured to generate a signal correlative to the relative positions of the sensing element and reference portion. The position sensing system includes a processor configured to store predetermined signatures and determine a condition of a component of the vehicle based on a match between the signal and one of the predetermined signatures.