Wheel end brake pad wear sensor

1. A sensor assembly for determining an amount of wear on a brake pad in a disc brake, comprising:

a shaft extender including a first end configured for coupling to one end of a shaft of an adjustment mechanism of a caliper of the disc brake for rotation with the shaft about a rotational axis, a second end of the shaft extender defining a shaft extension;

a sensor configured to generate a signal indicative of a degree of rotation of the shaft extension, the signal indicative of the amount of wear on the brake pad, the sensor including

a body coupled to the shaft extension and configured for rotation about an offset axis offset from the rotational axis in response to rotation of the shaft extension about the rotational axis; and,

a measurement device configured to generate the signal responsive to rotation of the body about the offset axis; and,

a housing configured to enclose the sensor

further comprising a shear adapter supported on the shaft extension and configured to be grasped by a tool to impart rotation to the shaft extender and shaft.

2. A sensor assembly for determining an amount of wear on a brake pad in a disc brake, comprising:

a shaft extender including a first end configured for coupling to one end of a shaft of an adjustment mechanism of a caliper of the disc brake for rotation with the shaft about a rotational axis, a second end of the shaft extender defining a shaft extension;

a sensor configured to generate a signal indicative of a degree of rotation of the shaft extension, the signal indicative of the amount of wear on the brake pad, the sensor including

a body coupled to the shaft extension and configured for rotation about an offset axis offset from the rotational axis in response to rotation of the shaft extension about the rotational axis; and,

a measurement device configured to generate the signal responsive to rotation of the body about the offset axis; and,

a housing configured to enclose the sensor

wherein the sensor comprises a potentiometer including a pin extending from the body and contacting a resistive element of the measurement device supported within the housing.

3. The sensor assembly of claim 2 wherein the shaft comprises an adjuster shaft of the adjustment mechanism.

4. The sensor assembly of claim 2 wherein the offset axis is parallel to the rotational axis.

5. The sensor assembly of claim 2 wherein the measurement device includes a printed circuit board on which the resistive element is disposed, the printed circuit board centered about the offset axis and defining a tab configured to be received by the housing to inhibit rotation of the printed circuit board about the offset axis.

6. The sensor assembly of claim 2 wherein the body comprises a ring gear driven by a gear train including a pinion gear coupled to the shaft extension for rotation with the shaft extension.

7. The sensor assembly of claim 2 wherein the housing includes

a first member including a radially extending wall disposed about the rotational axis and through which the shaft extender extends, the radially extending wall having an inboard side configured to face the caliper and an outboard side configured to face away from the caliper; and,

a second member configured to engage the first member of the housing and enclose the sensor on the outboard side of the radially extending wall of the first member of the housing.

8. The sensor assembly of claim 7 wherein the housing includes a third member configured for coupling to the first member of the housing on the inboard side of the radially extending wall of the first member of the housing and for mounting on the caliper such that the third member surrounds the end of the shaft and the first end of the of the shaft extender.

9. The sensor assembly of claim 7 wherein the housing includes a third member configured for coupling to the second member of the housing to enclose the shaft extension of the shaft extender.

10. The sensor assembly of claim 7 wherein the first member of the housing includes a radially extending flange having a bore configured for alignment with a bore in the caliper and configured to receive a fastener extending through the bore in the caliper.

11. The sensor assembly of claim 10 wherein the fastener is inserted through the bore in the flange of the first member of the housing and the bore in the caliper in a direction parallel to the rotational axis.

12. A method of assembling a sensor assembly for determining an amount of wear on a brake pad in a disc brake to the disc brake, comprising the steps of:

rotating a shaft of an adjustment mechanism of a caliper of the disc brake about a rotational axis to position the shaft at a predetermined position;

aligning the sensor assembly with the disc brake, the sensor assembly including a shaft extender including a first end configured for coupling to one end of the shaft of the adjustment mechanism for rotation with the shaft about the rotational axis and a second end defining a shaft extension, a sensor configured to generate a signal indicative of a degree of rotation of the shaft extension, the signal indicative of the amount of wear on the brake pad, the sensor including a body coupled to the shaft extension and configured for rotation about an offset axis offset from the rotational axis in response to rotation of the shaft extension about the rotational axis and a measurement device configured to generate the signal responsive to rotation of the body about the offset axis, the sensor assembly further including a housing configured to enclose the sensor;

moving the sensor assembly along the rotational axis relative to the caliper such that the shaft extender of the sensor assembly is coupled to the one end of the shaft of the adjustment mechanism; and

installing a shear adapter onto the shaft extension of the shaft extender of the sensor assembly.

13. The method of claim 12 wherein, during the alignment step, a bore in the housing is aligned with a bore in the caliper and further comprising the step of installing a fastener through the bore in the housing and the bore in the caliper.

14. The method of claim 13 , further comprising the step of inserting an alignment tool into the bore in the caliper prior to the aligning step and wherein the moving step includes inserting the alignment tool through the bore in the housing.

15. The method of claim 14 , further comprising the step of removing the alignment tool from the bore in the caliper and the bore in the housing of the sensor assembly after the moving step and before the installing step.

16. The method of claim 12 , further comprising the step of enclosing the shear adapter within the housing after the installing step.

17. The method of claim 12 wherein the moving step includes the substep of seating the housing of the sensor assembly on the caliper such that the housing surrounds the end of the shaft.

18. The method of claim 12 wherein the shaft comprises an adjuster shaft of the adjustment mechanism.

19. The method of claim 12 wherein the offset axis is parallel to the rotational axis.