Brake Actuator Retraction Detection via Motor Characteristic Feedback
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Solution Overview
Problem
Existing brake systems lack accurate methods to determine when actuators or brake components have reached specific positions, leading to potential over-stroking and damage, especially when the nut contacts the spindle stop and continued rotation occurs.
Innovation Solution
A control method and system that monitors motor characteristics to determine when the actuator or brake components are in extended or retracted positions, preventing over-stroking by discontinuing torque supply when the nut contacts the spindle stop, thus preventing damage to the actuator, motor, and brake system components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the actuator continues to rotate after the nut contacts the spindle stop, then the actuator reaches the retracted position, but damage occurs to the actuator and motor components
Solution Approach 1:
The system continuously monitors motor characteristics (current, voltage, speed) during actuator operation and compares them against expected values. When the nut contacts the spindle stop, the motor characteristics change (increased current, decreased speed), providing feedback that triggers the controller to immediately discontinue torque supply, preventing over-stroking damage
Solution Approach 2:
The patent replaces mechanical position detection methods (such as mechanical switches or limit switches) with electrical monitoring of motor characteristics. By analyzing electrical parameters during motor operation, the system determines actuator position and prevents over-stroking without additional mechanical components
2Device complexity
If the brake system lacks accurate position detection, then the system is simpler, but over-stroking and component damage occur
Solution Approach 1:
The motor itself serves dual purposes: it both actuates the brake system and provides the sensing function for position detection. The motor's inherent electrical characteristics are monitored to determine actuator position, eliminating the need for separate sensing mechanisms and keeping the system relatively simple while maintaining high reliability
Solution Approach 2:
The motor is designed to perform multiple functions: it provides the driving torque for actuator operation and simultaneously serves as the sensing element for position detection. By monitoring the motor's electrical characteristics during operation, the same component that drives the system also provides feedback on system state
3Productivity
If the motor torque is not discontinued when the nut contacts the spindle stop, then the actuator completes its full rotation, but damage occurs to the brake system components
Solution Approach 1:
The controller continuously monitors motor characteristics during actuator operation and immediately discontinues torque supply when the nut contacts the spindle stop, as detected by changes in motor current, voltage, or speed. This feedback mechanism prevents over-stroking damage while maintaining efficient actuator operation throughout the valid range of motion
Data Source
AI summary
A method that includes monitoring a motor characteristic; and determining an actuator of a brake system has reached a retracted position after the motor characteristic has reached or exceeded a predetermined threshold.