Electronic Brake Backlash Elimination via Preliminary Piston Positioning
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Solution Overview
Problem
Backlash in the electronic brake system causes operational delays and noise due to gaps between the male and female screws, affecting the braking response speed when the motor rotates.
Innovation Solution
A braking controller calculates the displacement of the main piston based on the motor's rotation distance and adjusts the current supply to minimize backlash by moving the main piston to a preset initial position, reducing the delay in braking response.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a screw mechanism is used to convert rotational motion to straight motion, then the actuator can move the main piston, but backlash is generated due to gaps between screw components
Solution Approach 1:
The braking controller performs preliminary action by moving the main piston to a preset initial position before actual braking operation. This preliminary positioning eliminates backlash in the screw mechanism by pre-tightening the connection, ensuring that when braking force is applied, the full motor torque is immediately transmitted to the piston without delay from gap clearance.
2Speed
If the motor is rotated to move the main piston, then braking force is applied, but dead stroke occurs due to backlash
Solution Approach 1:
The system performs preliminary positioning of the main piston to an initial position that eliminates backlash before the actual braking action. This preliminary action removes the dead stroke by ensuring the screw mechanism is already engaged without gaps, so the full motor rotation is immediately converted to piston movement, reducing both response time and wasted motion.
3Productivity
If the braking controller drives the motor, then the main piston moves, but noise is generated due to backlash
Solution Approach 1:
The braking controller performs preliminary positioning to eliminate backlash before the main braking operation. By pre-positioning the piston so that the screw components are fully engaged without gaps, the system prevents the knocking and rattling noises that occur when backlash is present, resulting in quieter braking operation.
4Ease of manufacture
If gaps are formed in the screw engagement, then the mechanism is easier to manufacture, but braking response is delayed
Solution Approach 1:
Rather than trying to eliminate manufacturing gaps, the system uses preliminary positioning to actively eliminate the functional effect of those gaps. By moving the piston to a preset initial position that pre-tightens the screw engagement, the system nullifies the time delay that would otherwise result from backlash, achieving fast response despite the presence of manufacturing tolerances.
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 solution improves braking response speed and reduces noise by preventing backlash, ensuring faster and quieter operation of the electronic brake system.
Implementation Method 1
a motor position sensor disposed to sense a rotation distance of the motor
Implementation Method 2
a power conversion unit that has one side connected with the motor and another side connected with the main piston, and converts a rotational motion of the motor into a straight motion
Data Source
AI summary
According to at least one embodiment, the present disclosure provides an electronic braking system comprising: a main master cylinder including a main body, a main piston that is accommodated to be movable in the main body, a main chamber that is defined in the main body and connected with at least one wheel brake, a motor that generates a rotation force, and a power conversion unit that has one side connected with the motor and another side connected with the main piston, and converts a rotational motion of the motor into a straight motion, the main master cylinder being configured to generate hydraulic pressure by movement of the main piston; a motor position sensor disposed to sense a rotation distance of the motor; and a braking controller configured to perform control to move the main piston to a preset initial position by calculating displacement of the main piston based on the rotation distance of the motor and adjusting an amount of a current that is supplied to the motor.