Wireless Inductive Brake Pad Wear Sensor
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Solution Overview
Problem
Current brake pad wear sensing systems require manual tire removal for wear assessment, are non-reusable, and fail to gather comprehensive vehicle data, with existing solutions being limited to single-purpose functionality and prone to dirt and corrosion issues.
Innovation Solution
A wireless position sensing system for brake pads that measures wear without tire removal, integrates with existing braking systems, and transmits data wirelessly, allowing for continuous monitoring of brake pad wear and other vehicle component conditions using a sensor assembly with a magnet and inductive sensing elements, capable of detecting temperature and frequency changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wire-based brake pad wear sensor is used, then brake pad wear detection is achieved, but the sensor is consumed during operation and must be replaced with the brake pads
Solution Approach 1:
The patent replaces the mechanical wire-based sensing system with a magnetic field-based inductive sensing system. The inductive sensor detects changes in magnetic field caused by rotor movement during braking, eliminating the need for physical contact and wire consumption. This substitution transforms the sensor from a consumable mechanical component to a durable non-contact sensing device.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the sensor and the brake pad wear measurement. Instead of direct mechanical contact, the inductive sensor uses magnetic field changes to indirectly measure rotor position and calculate wear, allowing the sensor to remain stationary while still capturing wear information through field interactions.
2Adaptability or versatility
If a simple wear indicator sensor is used, then brake pad wear indication is provided, but no additional vehicle component data is gathered
Solution Approach 1:
The patent designs the inductive sensing system to serve multiple functions: it measures brake pad wear through rotor position detection, monitors rotor runout, detects wheel bearing issues through vibration analysis, and tracks caliper movement. This multi-functional capability transforms a single-purpose wear indicator into a comprehensive vehicle health monitoring system.
Solution Approach 2:
The system continuously monitors multiple parameters and provides feedback about vehicle component conditions. By analyzing patterns in the sensor data over time, the system can detect developing issues and provide early warning, enabling proactive maintenance before components fail.
3Ease of operation
If a wire harness is integrated into the vehicle architecture for the sensor, then data transmission is enabled, but complicated routing in the moving wheel suspension system is required
Solution Approach 1:
The patent replaces the mechanical wire harness infrastructure with a wireless communication system. The inductive sensor transmits data wirelessly to the vehicle's onboard systems, eliminating the need for physical wiring through the suspension system. This reduces installation complexity and allows greater design flexibility.
4Measurement precision
If manual tire removal is required for brake pad wear assessment, then direct visual inspection is possible, but vehicle downtime and labor costs increase
Solution Approach 1:
The system continuously monitors brake pad wear in real-time during vehicle operation, so the wear assessment is already completed before the vehicle reaches the service bay. This eliminates the need for on-site inspection and allows maintenance scheduling based on actual wear data rather than reactive troubleshooting.
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, accurate monitoring of brake pad wear and other vehicle components, reducing maintenance costs and improving safety by providing timely alerts and diagnostic insights without the need for manual intervention or system replacement.
Implementation Method 1
A sensor assembly measures a distance between the first portion and the second portion. In one embodiment, the sensor assembly includes an inductive sensor assembly and a metallic reference portion
Implementation Method 2
A magnet can be attached to the second portion. The sensor assembly can then measures the distance between the first portion and the second portion by sensing the distance between the magnet and the sensor assembly
Data Source
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AI summary
A position sensing system and method for a braking assembly for a vehicle. The braking assembly includes a rotor (104, 1104), a caliper assembly (102, 1102) disposed around the rotor (104, 1104) and having a fixed mount bracket (106, 1106) and a floating portion (108, 1108) which moves when the brakes are applied. The position sensing system has a sensing element (226, 426) and a reference portion (560). The sensing element (226, 426) is attached to a location of the braking assembly such that the reference portion (560) moves in relation to the sensing element (226, 426) when the floating portion (108, 1108) 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.