Electro-Mechanical Brake Gap Control to Prevent Pad Drag
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Solution Overview
Problem
The electro-mechanical brake system experiences a drag phenomenon due to friction between the disc and brake pad during non-braking, leading to issues like engine output loss, judder, reduced brake pad life, and degraded braking response performance.
Innovation Solution
An electro-mechanical brake system with sensors and a controller that adjusts the distance between the brake pad and disc based on contact points, using motors to move the brake pad by preset strokes to prevent drag and optimize braking response.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a sufficient gap between the brake pad and disc is secured to prevent the drag phenomenon, then the drag phenomenon is prevented, but braking response performance is degraded because a dead stroke increases during braking
Solution Approach 1:
The brake system dynamically adjusts the gap distance between the brake pad and disc based on operating conditions. During non-braking, a larger gap is maintained to prevent drag phenomenon. During active braking, the gap is reduced or eliminated to improve braking response performance. This dynamic adjustment resolves the contradiction by allowing the system to optimize for drag prevention during idle and for response speed during braking.
Solution Approach 2:
The system changes the gap parameter between brake pad and disc based on braking status. When braking is not active, the gap is set to a sufficient distance to prevent contact and drag. When braking is detected, the gap parameter is adjusted to a smaller value or zero to enable immediate braking response. This parameter change allows the system to eliminate the trade-off between drag prevention and response performance.
2Speed
If the brake pad is moved closer to the disc to improve braking response, then braking response performance is improved, but the drag phenomenon occurs due to friction during non-braking
Solution Approach 1:
The brake system uses dynamic gap adjustment where the distance between brake pad and disc is not fixed but changes based on braking demand. During normal operation, the pad is positioned farther from the disc to eliminate friction and drag. Upon braking detection, the actuator rapidly moves the pad closer to the disc surface, minimizing the dead stroke and improving response time. This dynamic positioning eliminates the need to choose between drag prevention and response performance.
3Object-affected harmful factors
If a large distance is maintained between the brake pad and disc during non-braking, then the drag phenomenon is prevented, but the life of the brake pad is reduced due to repeated contact and friction during braking
Solution Approach 1:
The system performs preliminary positioning of the brake pad to an optimal distance from the disc during non-braking periods. This preliminary action prevents unnecessary contact and drag that would otherwise occur with a fixed small gap. By maintaining the pad at this optimized distance during idle, the system reduces cumulative friction and wear, thereby extending brake pad life while still enabling rapid response when braking is activated.
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
Prevents drag phenomenon and maintains optimal braking performance by minimizing friction and adjusting distances to counter abrasion and active brake conditions, enhancing fuel efficiency and ride comfort.
Implementation Method 1
a motor configured to generate a driving force
Implementation Method 2
a braking force of a vehicle by operating an electrical device such as a motor based on the electric signal... friction occurs between a disc and a brake pad... friction force generated by contact between the disc and the brake pad
Data Source
AI summary
Disclosed herein are an electro-mechanical brake system and a controlling method thereof. The electro-mechanical brake system according to the present embodiment includes a driving part including a motor configured to generate a driving force and a brake pad configured to brake a vehicle or release braking by moving forward and backward with respect to a disc by the motor, a sensor part including a first sensor configured to output a signal corresponding to a stroke of the motor, a second sensor configured to output a signal corresponding to a force applied from the disc to the brake pad, and a third sensor configured to output a signal corresponding to an active brake condition of the vehicle, a controller configured to estimate and update a contact point between the disc and the brake pad, whenever a braking input of the brake pad or release thereof occurs.