Brake Caliper Control via Non-Linear Transmission and Feedback
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Solution Overview
Problem
In Brake-by-Wire (B-b-W) systems, the linear mechanical transmission between electric motors and actuators absorbs significant power, leading to inefficient performance under extreme conditions, and there is a need for a method to control braking actions that account for non-linear behavior in actuators to prevent incorrect operation or failure.
Innovation Solution
A control system that uses an electronic control unit to manage the braking action of a brake caliper on a mechanical movement member, employing a non-linear transmission mechanism between the electric motor and the actuator, which includes sensors to detect parameters like pressure and position, and adjusts the control signals to compensate for the non-linear transmission effects, ensuring accurate operation across various working conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a linear mechanical transmission is used between the electric motor and the actuator, then the system structure is simple, but the power absorption is large under extreme working conditions
Solution Approach 1:
The patent applies a non-linear mechanical transmission mechanism with variable transmission ratio instead of a fixed linear transmission. The transmission ratio changes dynamically based on the operating conditions, allowing the system to optimize power delivery and reduce power absorption under extreme working conditions while maintaining structural feasibility
2Power
If a non-linear mechanical transmission is used to maximize performance in extreme conditions, then the power efficiency is improved, but the actuator control accuracy deteriorates due to non-linear behavior
Solution Approach 1:
The patent implements a feedback control mechanism where the electronic control unit continuously monitors the actual position and pressure of the actuator and compares them with the desired values. Based on this feedback, the control unit adjusts the motor commands to compensate for the non-linear transmission behavior, thereby maintaining control accuracy while utilizing the benefits of non-linear transmission for extreme condition performance
Solution Approach 2:
The patent employs parameter adaptation strategies where the control system adjusts operational parameters such as transmission ratio, motor torque, and pressure control based on the operating point. This allows the system to optimize performance across different working conditions while compensating for non-linear effects through dynamic parameter modification
3Stress or pressure
If the actuator is designed to handle extreme working conditions with high pressure, then the braking performance is improved, but the risk of actuator failure increases due to non-linear behavior
Solution Approach 1:
The patent implements protective control strategies that anticipate extreme conditions and prepare the actuator accordingly. The electronic control unit monitors operating parameters and adjusts the actuator operation before reaching critical limits, preventing overload conditions that could lead to failure. This includes implementing safety margins and progressive activation of braking force to avoid sudden stress spikes
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system optimizes the operation of the brake caliper by adjusting torque and pressure proportionally, maintaining accurate control in normal conditions and achieving high pressurization in extreme conditions, thereby preventing actuator failure and ensuring reliable braking performance.
Implementation Method 1
Such actuators contain one more electric motors, which, by means of a mechanical transmission, actuate a cylinder
Implementation Method 2
the mechanical transmission between the electric motor and the component to be moved (cylinder or piston) consists of one or more mechanical transmissions with variable transmission ratios
Implementation Method 3
actuate a cylinder, which displaces a braking fluid, whereby generating a pressure which actuates, in turn, the brake caliper
Implementation Method 4
the braking action of a brake caliper on a mechanical movement member
Data Source
AI summary
A method for controlling the braking action applicable by a brake caliper on a mechanical movement member of a vehicle is described. An electronic control unit operatively connected to an actuator assembly receives an input signal representative of a braking request. The unit determines a first reference value of a position of a component in the actuator assembly and a second reference value of a parameter representative of the braking action applicable by a brake caliper via the actuator assembly. The unit determines at least one feedback value of the position of a component in the actuator assembly. The unit also generates at least one control signal for the actuator assembly based on feedback values and the reference values.