Electric Brake Abnormality Detection Using Thrust and Motor Angle
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Solution Overview
Problem
Existing electric brake systems cannot specifically detect and identify abnormalities in the brake mechanism, such as idling, pad falling, or pad abrasion, which affects their performance and safety.
Innovation Solution
An electric brake system with a brake mechanism that includes a thrust detecting portion, a rotational position detecting portion, and a control device that analyzes the relationship between the thrust and rotational position of the electric motor to identify abnormalities and alert the driver, improving maintainability and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If motor control adapted to temporal changes in brake pads is implemented based on rotational position and thrust, then braking performance is maintained, but specific abnormality detection capability is lost
Solution Approach 1:
The patent segments the monitoring function into two distinct parts: basic motor control based on rotational position and thrust, and separate abnormality detection also based on rotational position and thrust. This segmentation allows the system to maintain braking performance while simultaneously enabling specific abnormality detection, as each function can be optimized independently without interfering with the other.
2Reliability
If general abnormality detection is implemented, then safety is improved, but specific abnormality identification capability is lost
Solution Approach 1:
Instead of using indirect methods or additional sensors to detect abnormalities, the patent inverts the approach by using the existing rotational position and thrust data in an abnormality detection module. By analyzing deviations from normal operational patterns in this data, the system can identify specific abnormality types (such as brake pad wear, motor issues, or transmission problems) while maintaining safety, thus preventing information loss about abnormality types.
3Measurement precision
If multiple detection parameters are monitored, then abnormality specification accuracy is improved, but system complexity increases
Solution Approach 1:
The patent makes the existing rotational position and thrust detection systems multi-functional by using them for both basic motor control and abnormality detection. This universality allows the system to achieve high abnormality specification accuracy through multiple parameters without increasing device complexity, as the same sensors serve dual purposes: controlling motor operation and detecting specific abnormality types by analyzing deviations from normal operational patterns.
Data Source
AI summary
An electric brake comprises a brake mechanism that transmits a thrust generated by driving an electric motor to a piston that moves brake pads pressed against a disc rotor; a thrust sensor that detects the thrust applied to the piston; a rotation angle sensor that detects a rotational position of the electric motor; and a rear electric brake ECU that controls the driving of the electric motor on the basis of a braking command. The rear electric brake ECU detects an abnormality in the brake mechanism from a detected value of the thrust sensor and a detected value of the rotation angle sensor in response to the braking command which are obtained when the electric motor is driven.