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Technical Paper

Accuracy of Sensor-Less Control of an Electro-Mechanical Brake

2015-09-27
2015-01-2704
At first glance a friction brake should be controlled by normal force to produce predictable brake force. Controlling an actuator (and hence brake pad) position basically seems to introduce uncertainties to normal force and brake force, because at first view the position tells little about actual normal force. The electro-mechanical brake (EMB) of Vienna Engineering (VE) can be operated by position-control, either without force sensor (saving costs) or even with a true brake torque sensor. For position control a relation between actuator position and normal force is used. When pad wear is correctly adjusted a certain actuator position produces a given deformation and at known elasticity the deformation produces a defined normal force. In the VE-EMB this relation uses a three-dimensional curve and includes temperature influence of the coefficient of friction, thermal expansion and thermal elasticity change.
Technical Paper

Test Results of A Sensor-Less, Highly Nonlinear Electro-Mechanical Brake

2014-09-28
2014-01-2541
The electro-mechanical brake (EMB) of Vienna Engineering (VE) uses a highly non-linear mechanism to create the high pressing force of the pad. The advantage is that the pad moves very fast when the pad pressing force is low and moves slower with increasing pressing force. The normal force in EMBs is often controlled by observing mechanical deformation to conclude to stress or force, commonly using strain gauges. It causes costs of the gauge itself and attaching them to e.g. the caliper and a sensitive amplifier. The full gauge equipment goes into the safety-related brake control system. The faintest damage (e.g. stone impacts, heat) gets the vehicle to the repair shop making expensive replacement necessary. To avoid the costs of the force measurement in the safety related system VE took the electrical motor measurements from the very beginning of the brake development for EMB control.
Technical Paper

Energy and Timing Advantages of Highly Non-Linear EMB Actuation

2013-09-30
2013-01-2067
With linear actuated brakes the actuation force (or torque) rises linearly from 0 to the full actuation force at full braking. This means that the actuation must be designed for the rare case of full-braking. The parts must be designed for this peak load (e.g. motor, gear) and the transmission ratio is determined by the full-braking actuation torque, which causes the highest transmission ratio and hence determines slow actuation dynamic. Ideally the actuation should make the fastest travel at low normal force and turn to slow movement and high force at the highest pad force. Mathematically the torque transmission ratio should optimally be an exact representation of the actuation characteristics (actuation torque over actuation movement), creating the highest torque-transmission ratio at highest force and the fastest movement at low pad force.
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