Wedge-Brake Sensing Solution


Methode was tasked with creating an accurate and cost-effective way to measure the deformation of the brake caliper in automobiles.



We developed a non-contact Disc Brake Linear Sensor (DBLS) that uses eddy-current technology to continuously measure the linear position of a metal flag that simulates the deformation of a brake caliper.


The automotive industry needed to measure the elastic deformation of the brake caliper, which is used to calculate the normal actuation force of the brake. To accomplish this, a highly accurate sensing device, capable of measuring short linear movement while operating at the high temperatures experienced during severe braking, was required. Additionally, the sensing device had to accommodate any change of the sensing range during its lifetime because of wear-and-tear or permanent deformations. The solution, Methode's Disc Brake Linear Sensor (DBLS), used an eddy-current-based non-contact sensor that continuously measured the linear position of a metal flag, a target located on the brake caliper to represent the deformation of the brake caliper, thereby indicating the applied force. The technical benefits of this breakthrough included:

  • Built-in intelligence (dynamic adaptive learning)
  • Continuous self-diagnostics, monitoring internal failures and self-correct
  • Field-proven technology based on advanced manufacturing
  • SIL 2 (Safety Integrity Level)
  • System lifetime variations for self-compensation
  • ASIC with continuous PWM/LIN outputs of the position, velocity and programmable switching points

These technical benefits translated into reduced system component costs and greater efficiency in data-acquisition for automobile manufacturers.

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