Electromechanical Brake Force Diagnosis Without Force Sensors

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Solution Overview

Problem

Existing electromechanical brake systems lack the necessary space and incur high costs when equipped with force sensors, necessitating a method to determine adequate braking force without relying on sensors.

Innovation Solution

A force-sensor-less electromechanical brake system uses motor torque, position, temperature, and pad wear to estimate braking force, employing a controller to diagnose system failures and initiate safety protocols.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If force sensors are installed in the EMB system to directly measure braking force, then measurement precision is improved, but device complexity and cost increase

Engineering Contradiction:

Improvebraking force measurementVSAvoidsystem complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent introduces intermediary parameters (motor torque, motor position, temperature, pad wear) that serve as mediators to indirectly estimate braking force. Instead of directly measuring force with sensors, the system uses these intermediate variables that are easier to measure and correlates them with braking force through estimation algorithms, thereby avoiding direct force sensing while maintaining measurement capability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the mechanical/physical force sensing system with an electronic estimation system. Rather than using physical force sensors that convert mechanical force to electrical signals, the system uses electronic processors to calculate braking force from electrical and thermal parameters (torque, position, temperature), substituting a mechanical measurement approach with an electronic computation approach

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If force sensors are installed in the EMB system to directly measure braking force, then measurement precision is improved, but manufacturing cost increases

Engineering Contradiction:

Improvebraking force measurementVSAvoidmanufacturing cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent replaces expensive force sensors with cheaper alternative measurement components (temperature sensors, position sensors, torque measurements) that are less costly and more readily available. The estimation algorithm processes these cheaper inputs to produce the required force measurement, effectively substituting expensive components with inexpensive alternatives

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The system uses intermediary parameters (temperature, position, torque) that are already present in the EMB system or can be measured with existing low-cost sensors. These intermediaries serve as proxies for direct force measurement, eliminating the need for expensive force sensors while maintaining the ability to assess braking force

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the EMB system uses multiple parameters (torque, position, temperature, pad wear) for force estimation, then reliability is improved, but device complexity increases

Engineering Contradiction:

Improvebraking force estimation reliabilityVSAvoiddiagnostic system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent makes existing EMB components serve multiple functions. The motor torque and position sensors, originally designed for basic actuator control, are also utilized for braking force estimation. Temperature sensors, intended for thermal management, contribute to force estimation as well. This multi-functionality allows the system to gather multiple parameters for reliable force estimation without adding dedicated sensors for each measurement

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The EMB system uses its own operational parameters (torque, position, temperature, pad wear) to estimate its own braking force. The system is essentially self-diagnosing by utilizing data already generated during normal operation, eliminating the need for external diagnostic equipment or additional specialized sensors

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20260008441A1Force diagnostic for force-sensor-less electromechanical brake systems

Publication Date: 2026.01.08 HL MANDO CORP

AI summary

An electromechanical brake (EMB) system is provided. The EMB system includes: a brake rotor configured to be rotatable with a wheel of a vehicle; a brake pad assembly configured to be engageable with the brake rotor; an actuator assembly including an electric motor configured to mechanically move the brake pad assembly toward or away from the brake rotor; and an electronic control unit (ECU) including a processor associated with a memory that stores instructions that when executed by the processor causes the ECU to perform operations. The operations include: obtaining a primary path force estimate, a diagnostic path force estimate, and a force command; determining whether the EMB system has failed using the primary path force estimate, the diagnostic path force estimate, and the force command; and generating a force fault flag and initiating brake safety protocol processes in response to failure of the EMB system.