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Gill R&D diagnostic measurement of brake pad wear

May 14, 2014

gill-rd-caterpillar-brakewear-sensor.jpgA world renowned manufacturer of plant machinery contacted Gill for a remote solution to measuring brake pad wear on large rigid dump trucks.

A customised solution was required which would eliminate the costly downtime of removing the wheels and could withstand the pressure of the hydraulic brake circuit internally.

The Challenge

The sensor had to be designed to withstand the pressure of the brake circuit hydraulic fluid without leakage. Built into the axle assembly, the sensor was not accessible once the wheels had been fitted, so robustness and reliability were paramount.

The Result

A novel solution was developed to measure the position of the metallic detector rod attached to the brake pad, through a one-piece, pressure resistant metal housing, which also incorporated the mounting interface.

Project results and benefits

  • Successful delivery and deployment of over 500 customised sensors for use in heavy plant machines
  • Delivered a non-contact inductive sensor device capable of withstanding stringent environmental test and build standards
  • Provided complete concept design and development using on-site facilities
  • Close collaboration throughout the design of the sensor electronics and mechanical packaging.

Phases of working with the customer

  • Receipt of customer requirement
  • Development of sensing concept and proof of operation
  • Integration of sensing principle into mechanical package
  • Presentation of proposal to customer
  • Refinement of proposal to meet engineering and cost requirements
  • Manufacture of prototypes
  • Supply of prototypes to customer for testing and approval
  • Incorporation of prototype testing refinements into final design
  • Submission of final design for approval
  • Supply of sensors to the customer


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