Abstract: A brake lining wear sensor includes a thermoplastic body that is secured to a support plate between adjacent brake lining blocks. The support plate includes an opening formed within a gap between adjacent lining blocks. The thermoplastic body is received within the opening and includes a central bore that extends from a first body end to a second body end. A sensor wire is received within the bore and includes a single looped portion that extends outwardly from an end face of the second body end. The single looped portion is positioned at a predefined maximum lining wear limit. When the single looped portion is broken due to contact with a rotating brake component, a warning signal is communicated to an operator to indicate that the predefined maximum lining wear limit has been reached.

Abstract: A brake lining wear sensor includes a first portion attached to a brake lining support plate, a second portion that engages a rotating brake component after brake lining material wears to a predetermined wear level, and an internal bore that extends through the first and said second portions. A sensor wire is received within the internal bore and includes a looped portion positioned within the second portion such that the looped portion is held at a predetermined brake lining wear level limit. When the looped portion is broken due to contact with a rotating brake component, a warning signal is communicated to an operator to indicate that a wear limit has been reached.