Electromechanical Brake Clearance Detection Without Wear Sensors
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Solution Overview
Problem
Existing electromechanical brakes in commercial vehicles face challenges in maintaining consistent brake actuation times due to progressive wear of brake pads, which requires frequent mechanical adjustments and the use of costly wear sensors to determine clearance.
Innovation Solution
A method that determines clearance without external sensors by using the operating parameters of the electromechanical brake actuator, specifically the rotor position and motor current, to identify the contact position between the brake pad and disc, allowing for accurate determination of pad wear and clearance using existing components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If wear sensors are used to determine pad wear and adjust clearance, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The brake actuator performs self-diagnosis by monitoring its own motor current and rotor position during operation. The control unit analyzes the electrical parameters already present in the actuator system to detect pad wear and determine clearance, eliminating the need for external wear sensors. This self-service approach maintains measurement precision while reducing device complexity and cost.
Solution Approach 2:
The patent replaces mechanical wear sensors with an electrical/electronic detection method. By substituting the mechanical sensing system with analysis of motor current and rotor position data from the existing electromechanical actuator, the system achieves sensorless clearance determination, reducing both complexity and cost while maintaining measurement capability.
2Stability of the object's composition
If mechanical wear readjustments are performed to maintain constant clearance, then clearance stability is improved, but productivity decreases due to frequent adjustments
Solution Approach 1:
The control unit continuously monitors motor current and rotor position during brake actuation and uses this feedback to determine the actual clearance and pad wear status. This real-time feedback enables the system to track clearance changes without mechanical adjustments, maintaining clearance stability information while eliminating time-consuming manual interventions and improving maintenance productivity.
Solution Approach 2:
The system performs preliminary detection of pad wear and clearance changes during normal brake operation through continuous monitoring of electrical parameters. By detecting wear trends in advance, the system can plan maintenance activities proactively rather than performing frequent reactive adjustments, thereby improving productivity while maintaining clearance stability.
3Measurement precision
If external sensors are installed to monitor brake pad wear, then measurement precision is improved, but ease of manufacture and cost are worsened
Solution Approach 1:
The existing brake actuator components (motor, control unit, sensors for position and current) are made multi-functional by using them not only for brake actuation but also for pad wear detection and clearance determination. This universal use of existing components eliminates the need for additional specialized sensors, simplifying manufacturing while maintaining measurement precision.
Solution Approach 2:
The brake actuator system performs self-diagnosis using its own operational parameters (motor current, rotor position) to determine pad wear and clearance. This self-service capability eliminates the need for separate external sensing systems, making the brake system easier to manufacture and more cost-effective while maintaining accurate wear measurement.
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
This approach simplifies the process, reduces complexity and costs by eliminating the need for external sensors, and provides a reliable method for determining clearance and pad wear, enhancing the efficiency of brake actuation.
Implementation Method 1
moving an electromechanical brake actuator (2) by means of a drive motor (A) into a first end position
Implementation Method 2
there is a mechanical frictional effect between the brake disc and the brake pad and thus a braking effect occurs
Data Source
AI summary
A method for determining a clearance of an electromechanical brake involves the following steps: Activating a clearance determination cycle for the brake, moving an electromechanical brake actuator by a drive motor into a first end position, moving the electromechanical brake actuator via the drive motor toward a second end position, continuously determining a rotor position and/or a motor current of the drive motor during the movement of the brake actuator toward the second end position, determining a contact position at which the brake pad comes into contact with the brake disc, on the basis of the rotor position and/or of the motor current, and determining a clearance and/or a degree of pad wear on the basis of the determined contact position. A suitable electomechanical brake and a respective control unit carry out the method.