Electric Park Brake Damage Prediction Without Position Sensors
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Solution Overview
Problem
Existing brake systems lack accurate methods to monitor the condition and cumulative damage of components without position or pressure sensors, posing a risk of catastrophic failure due to degradation or wear, which is critical for compliance with vehicle guidelines and safety.
Innovation Solution
A method using control logic to estimate brake forces, determine cycles, and calculate cumulative damage based on parameters such as voltage and current, employing a linear time variant observer to track the condition of brake system components, including motors, spindles, and nuts, and provide warnings before failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If position sensors and pressure sensors are removed to reduce cost, space, and weight, then the brake system meets updated vehicle guidelines and reduces component count, but the ability to accurately monitor brake system condition and cumulative damage deteriorates
Solution Approach 1:
The patent replaces mechanical sensors (position sensors, pressure sensors) with an electrical/control-based monitoring system. The control unit estimates brake forces and determines cumulative damage by evaluating electrical parameters (voltage, current, time intervals) and comparing them against stored threshold values, thereby eliminating the need for physical sensors while maintaining monitoring capability
Solution Approach 2:
The control unit acts as an intermediary that indirectly monitors brake system condition. Instead of directly measuring position or pressure, the control unit evaluates electrical parameters (voltage, current) and time intervals as intermediate indicators to infer brake force magnitude and cumulative damage, bridging the gap between sensor-less operation and condition monitoring
2Ease of manufacture
If control logic is used to estimate brake forces without sensors, then the brake system meets vehicle guidelines and reduces cost, but the accuracy of monitoring brake component wear and degradation deteriorates
Solution Approach 1:
The control unit implements a feedback-based estimation system where it continuously evaluates electrical parameters (voltage, current) and time intervals, compares them against stored threshold values, and uses this feedback to determine brake force magnitude and cumulative damage. This iterative comparison process improves estimation accuracy without requiring additional sensors
Solution Approach 2:
The patent monitors changes in electrical parameters (voltage, current, time intervals) to infer brake system condition. By tracking parameter variations over time and comparing them against threshold values, the system estimates brake forces and cumulative damage with improved accuracy, transforming electrical parameter data into mechanical condition information
3Weight of moving object
If the brake system operates without position sensors, then the system reduces weight and complexity, but the ability to determine actuator assembly and brake piston positions deteriorates
Solution Approach 1:
The patent replaces mechanical position sensing with an electrical control-based position determination system. The control unit determines actuator assembly and brake piston positions by evaluating electrical parameters (voltage, current, time intervals) and comparing them against stored threshold values, eliminating the need for position sensors while maintaining position awareness
Data Source
AI summary
A method of determining the cumulative damage of a brake system, the method comprising: (a) estimating or measuring one or more brake forces based upon one or more parameters; (b) determining a cycle for each of the brake forces and associating each brake force with the determined cycle; and (c) determining a cumulative damage of the brake system based upon the determined cycles and the associated brake forces.