Electric Brake Piston Collision Prevention
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Solution Overview
Problem
In electric brake systems, the repeated collision of a piston during air bleeding can cause damage and degrade system performance due to high speed collisions, especially when the system is not electrically backed up.
Innovation Solution
An air bleeding apparatus and method that uses a piston position sensor, motor drive unit, motor speed detection unit, and control unit to maintain the piston at a predetermined target position during air bleeding mode, adjusting motor control current and proportional gain to prevent collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the electric brake system operates without electrical backup during air bleeding mode, then the system can perform air bleeding operations, but the piston collides repeatedly at high speed causing damage and performance degradation
Solution Approach 1:
The control unit pre-positions the piston to a predetermined position (e.g., center position or retracted position) before air bleeding operations begin. This preliminary positioning prevents the piston from colliding with the master cylinder during subsequent pedal operations, eliminating damage while maintaining air bleeding capability
Solution Approach 2:
The control unit continuously monitors piston position using a position sensor and adjusts motor control in real-time during air bleeding mode. By implementing closed-loop feedback control, the system maintains the piston within a safe position range, preventing high-speed collisions while enabling air bleeding operations
2Ease of operation
If the piston is allowed to move freely during air bleeding mode, then air bleeding operations can be performed, but the piston collides at high speed (1000-1200 rpm) causing accumulated damage
Solution Approach 1:
The control unit applies counteracting force through the motor to prevent the piston from moving to collision positions. By opposing the natural movement tendency of the piston during pedal operations, the system eliminates harmful collisions while preserving the ability to perform air bleeding operations
Solution Approach 2:
The control unit modifies motor control parameters (current, voltage, or duty cycle) to maintain the piston at a predetermined safe position. By dynamically adjusting these parameters during air bleeding mode, the system prevents high-speed piston collisions while enabling normal air bleeding operations
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 piston collisions by maintaining the piston at a target position, reducing wear and tear, and ensuring the electric brake system's performance is not compromised during air bleeding operations.
Implementation Method 1
a motor drive unit configured to drive a motor to move the piston
Data Source
AI summary
An air bleeding apparatus and method for electric brake systems. The air bleeding apparatus includes a piston position sensor configured to detect a position of a piston installed in a main master cylinder, a motor drive unit configured to drive a motor to move the piston, a motor speed detection unit configured to detect a speed of rotation of the motor, a brake pedal position sensor configured to detect a position of a brake pedal, and a control unit configured to, when entering an air bleeding mode, release a normally actuated valve and control the position of the piston by controlling the motor drive unit according to the position of the piston detected by the piston position sensor or the speed of rotation of the motor detected by the motor speed detection unit when it is determined that the brake pedal is pressed.