Electric Brake Device Resolution Interpolation
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Solution Overview
Problem
Conventional electric brake devices face challenges in achieving high control accuracy without increasing costs, particularly in ABS control, where insufficient response speed or control accuracy can lead to wheel slipping or increased braking distance, and existing solutions may compromise rigidity, durability, and cost due to the need for precise sensors and noise insulation.
Innovation Solution
An electric brake device with a motor rotation angle detector of higher resolution than the braking force estimation section, coupled with a controller that includes a resolution interpolation section to interpolate the minimum braking force resolution, allowing for improved control accuracy without additional cost by using existing detectors and reducing the need for dedicated sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the sampling time is shortened to improve control speed and accuracy, then the control responsiveness is improved, but the required resolution of the braking force estimation section increases, which may impair responsiveness and decrease control accuracy if insufficient
Solution Approach 1:
The patent replaces direct mechanical measurement of braking force with a computational estimation system. The braking force estimation section calculates braking force based on motor current and rotation angle, substituting physical force sensors with electrical measurements and mathematical models, thereby achieving high resolution without mechanical complexity
Solution Approach 2:
The patent changes the measurement parameters from direct braking force measurement to motor current and rotation angle measurements. By measuring electrical parameters (current, voltage, rotation angle) that are easier to measure with high precision, the system achieves high braking force estimation resolution without the complexity of high-resolution force sensors
2Measurement precision
If precision sensors are used to detect deformation or strain for braking force estimation, then the measurement accuracy is improved, but the rigidity or durability may be reduced and noise insulation requirements increase cost and mounting space
Solution Approach 1:
The patent replaces mechanical strain sensors that require large deformations with an electrical measurement system. By measuring motor current and rotation angle, the system estimates braking force without requiring physical deformation of structural components, thereby maintaining rigidity and durability while achieving precise measurement
Solution Approach 2:
The patent introduces motor current and rotation angle as intermediary measurement parameters. Instead of directly measuring braking force or strain on structural components, the system measures electrical parameters (current, voltage, angle) that correlate with braking force, using these as mediators to infer the actual braking force without compromising structural integrity
3Reliability
If highly effective shield or insulation is provided as anti-noise measure for precision sensors, then the measurement reliability is improved, but the cost and mounting space are increased
Solution Approach 1:
The patent replaces precision mechanical sensors requiring noise insulation with electrical sensors (current detectors, rotation angle detectors) that are inherently more resistant to environmental noise. Electrical measurements are less susceptible to mechanical vibrations and external interference, reducing the need for complex shielding and insulation structures
Data Source
Figure 1
Figure 2
Figure 3(a)~3(b)
AI summary
Provided is an electric brake device that can achieve improved control accuracy without involving a cost increase. The electric brake device includes an electric motor (2), a brake rotor (5), a friction pad (6), a transmission mechanism (4), a braking force command section (26a), a braking force estimation section (30), a motor rotation angle detector (28), and a controller (7). The motor rotation angle detector (28), which is used in a partial region of a braking force from a minimum braking force to a maximum braking force, has a higher resolution than a motor rotation angle that causes a braking force fluctuation equivalent to a minimum braking force resolution of the braking force estimation section (30). The controller (7) includes a resolution interpolation section (37) configured to interpolate, by using a motor rotation angle detected by the motor rotation angle detector (28), a minimum resolution of the braking force obtained by the braking force estimation section (30).