Abstract
Electromechanical brake (EMB) is characterized by rapid response and high control precision, positioning it as the next-generation braking technology. Brake clearance directly influences the response time, and its accurate estimation is a prerequisite for the practical application of EMB. Existing estimation methods typically use the threshold of EMB motor state signals to judge whether the brake clearance has been eliminated. Due to the high noise of motor state signals in the dynamic process, small stiffness of the EMB at the contact point, and the fact that the brake pad wear is not considered, using only a threshold for judgment readily produces estimation errors. This paper proposes a clearance estimation method based on a model for worn brake pads, introducing the wear modeling into the EMB model and using dynamic data from the clamping process to estimate clearance. To further improve estimation accuracy, this paper establishes an EMB variable control parameter calibration method. By varying the EMB control parameters to generate multiple control curves, the influence of motor state signals’ noise is further reduced, and the estimation accuracy is significantly enhanced. Brake pads of different thicknesses (4–10 mm) had been machined to verify the method’s reliability: the maximum estimation error of the proposed method is 2.57% of the total EMB motor travel, demonstrating high estimation accuracy.
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