Brake Temperature Feedback for Precise Torque Control
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Solution Overview
Problem
Existing brake systems face challenges in accurately controlling and regulating braking torque due to uncertainties in friction coefficients and contact pressure, making it difficult to achieve a predeterminable braking effect with reasonable measurement effort, especially in safety-critical applications like vehicles.
Innovation Solution
The solution involves determining the temperature in the brake area and using this data to calculate the expected temperature rise based on the specified braking effect, allowing for precise control of the braking process without direct measurement of braking forces or torques, and incorporating sensors like acceleration and speed sensors to account for deviations and system changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If direct measurement of braking force or torque is implemented, then measurement precision is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent uses temperature as an intermediary parameter to indirectly measure braking force. Instead of directly measuring the contact force between brake pad and disc, the system measures the temperature rise of the brake disc, which is caused by the friction during braking. This intermediary measurement approach achieves sufficient precision for control purposes while avoiding the complexity of direct force measurement systems.
Solution Approach 2:
The patent replaces mechanical force measurement systems with a thermal measurement system. By substituting the mechanical sensing approach (force sensors, strain gauges) with temperature sensing, the system achieves the measurement goal with simpler, more reliable, and less expensive components that are easier to implement in mass-produced vehicles.
2Device complexity
If current consumption of the electric motor is used to estimate braking torque, then device complexity is reduced, but measurement precision deteriorates
Solution Approach 1:
The patent changes the measured parameter from electrical (current consumption) to thermal (temperature). While current consumption alone is insufficient for precise braking torque estimation due to varying mechanical conditions, temperature provides a more direct correlation with the actual braking energy dissipation. This parameter change improves measurement precision while maintaining relatively simple system complexity.
3Reliability
If multiple redundant components are added to meet safety requirements, then reliability is improved, but device complexity increases
Solution Approach 1:
By using temperature as an intermediary measurement parameter, the patent inherently improves reliability. Temperature is a stable, easily measurable parameter that provides consistent feedback for control purposes. This approach avoids the need for complex redundant force measurement systems while maintaining high reliability through the robustness of thermal sensing and the direct physical relationship between braking energy and temperature rise.
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 enables precise setting and control of braking effects with minimal measurement effort, compensating for uncertainties in friction and system changes, ensuring reliable and accurate braking performance without the need for complex force measuring systems.
Implementation Method 1
The braking torque is – given known friction coefficients and dimensions of the brake pad and brake disc – directly proportional to the contact force of at least one brake pad on the brake disc
Data Source
Figure 1~2
AI summary
The invention relates to a brake system (1) comprising at least one brake (2) with a frictional surface (3), a pad carrier (4) with a brake pad (5), and a control and monitoring unit (9). According to the invention, the brake system (1) additionally comprises a brake temperature sensor (15) which is connected to the control and monitoring unit (9) that is designed to ascertain brake temperature maintenance values on the basis of the brake effectiveness request, to compare a temperature ascertained by the brake temperature sensor (15) with corresponding brake temperature maintenance values, and to ascertain at least one correction factor on the basis of a deviation. The control and monitoring unit is additionally designed to correct the brake control signal by the at least one correction factor and to actuate the controller (10) using the corrected brake control signal.