Disc Brake Caliper Force Distribution for NVH Control
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Solution Overview
Problem
Existing braking systems in vehicles operating with Brake-by-Wire technology face challenges in efficiently reducing or eliminating noise and vibrations, which are costly and time-consuming to optimize during development.
Innovation Solution
A method for controlling braking force distribution in a vehicle braking system using a combination of passive and active algorithms, activated under critical conditions, to manage braking forces dynamically and reduce noise and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If testing is performed on a prototype braking system during development to optimize noise and vibration reduction, then noise and vibration characteristics are improved, but development time and resource consumption increase significantly
Solution Approach 1:
The patent determines critical frequencies during the design phase using finite element analysis and modal analysis, before physical prototypes are built. This preliminary identification of critical frequencies allows the design to be optimized beforehand, avoiding the need for extensive iterative testing on physical prototypes, thus reducing development time while still achieving noise and vibration reduction goals
Solution Approach 2:
The patent replaces physical testing of mechanical braking systems with computational simulations (finite element analysis, modal analysis) to identify critical frequencies. This substitution of mechanical testing with computational methods enables optimization without the time-consuming iterative prototype testing, resolving the contradiction between achieving good NVH characteristics and reducing development time
2Object-affected harmful factors
If testing is performed on a prototype braking system during development to optimize noise and vibration reduction, then noise and vibration characteristics are improved, but resource consumption increases significantly
Solution Approach 1:
The patent performs critical frequency determination and design optimization during the design phase using computational methods, before physical prototypes are manufactured. This preliminary action prevents the need for multiple costly iterative testing cycles on physical prototypes, thereby reducing resource consumption while still achieving the desired noise and vibration reduction
Solution Approach 2:
The patent replaces resource-intensive physical testing with computational simulations (finite element analysis, modal analysis) to identify and optimize critical frequencies. This substitution dramatically reduces the resources required for development while maintaining the ability to achieve good noise and vibration characteristics
3Power
If braking force is applied to both pistons equally to achieve required braking force, then braking efficiency is maintained, but noise and vibrations are generated in critical frequency ranges
Solution Approach 1:
The patent applies different braking forces to different pistons based on their individual characteristics and the identified critical frequencies. Instead of uniform braking force distribution, the system locally adjusts the braking force on each piston to avoid exciting critical frequencies, thereby reducing noise and vibration while maintaining overall braking efficiency
Solution Approach 2:
The patent dynamically adjusts the distribution of braking forces between pistons based on real-time operating conditions and the identified critical frequencies. The braking force distribution is not static but adapts to changing conditions, allowing the system to maintain braking efficiency while avoiding noise and vibration generation across different operating scenarios
4Object-affected harmful factors
If different braking forces are applied to pistons to reduce noise and vibrations, then noise and vibration are reduced, but precise control complexity increases
Solution Approach 1:
The patent implements a feedback mechanism where the actual braking forces applied to each piston are monitored and compared with the target forces calculated based on critical frequency avoidance. This feedback loop enables precise control of the differential braking forces while providing a systematic method to manage the control complexity, ensuring that noise and vibration reduction goals are achieved
Solution Approach 2:
The patent introduces an intermediate control layer that calculates the optimal distribution of braking forces between pistons based on the identified critical frequencies and current operating conditions. This intermediary calculation step simplifies the control complexity by providing a clear algorithmic approach to determine the differential forces needed, rather than requiring complex real-time adjustments
Data Source
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AI summary
The invention relates to a method (200; 300; 400) for controlling a braking system (1000) of a vehicle (1) for distributing braking forces (F3, F4, F5, F6) on at least one first (P11, P21) and at least one second (P12, P22) pistons of a disc brake caliper (P1, P2) of the vehicle (1). The method is performed by a braking system control system (100) for brake force distribution. The method comprises the steps of: - receiving (201) a request for applying a braking force (X) following a braking action applied on a pedal/button (5, EPB-B) of the braking system; - receiving (202) a first plurality of parameters (V, Temp, F, S, DPTemp) associated with the braking system each representative of a current operating condition of the braking system; - comparing (203) each received parameter of said first plurality of parameters with a respective critical range for the reference parameters (Vc, Tempc, Fc, Sc, DPTempc) of a second plurality of parameters representative of a critical operating condition of the braking system; if at least one of the parameters of the first plurality of parameters equals the respective reference parameter of the second plurality of parameters, the method comprises the steps of: - applying (204) the first braking force (Y) to the at least one first piston of the caliper of disc brake, - applying (205) a second braking force (Z) to the at least one second piston of the caliper of disc brake, wherein the sum of the first and the second braking forces is equal to the requested braking force and a ratio between the first and the second braking forces is different from 1; if each of the parameters of the first plurality of parameters differs from the respective reference parameter of the second plurality of parameters, the method comprises the steps of: - applying (206) a third braking force (X/2) equal to half the requested braking force (X) to both the at least one first and the at least one second pistons of the disc brake caliper.