Modelling and control of electromechanical disc brake for heavy-duty vehicles

This paper proposes a validated procedure that can be used for development stage of model-based controller for heavy-duty electromechanical disc brakes. Firstly, system dynamics model of a single piston electromechanical disc brake is constructed in Matlab/Simulink environment in consideration of nonlinear friction model. To ensure the accuracy of system dynamics model, open loop measurements (clamping force, motor angle and motor current) are conducted on a prototype of single piston electromechanical disc brake. Experimental data is used for the determination of system variables. The predicted outputs are verified by comparison of experimental measurement results. For the control purpose of electromechanical brake, a multi-stage closed loop architecture is introduced. To regulate clamping force, PID and sliding mode controllers are developed in Matlab/Simulink in consideration of braking performance requirements for heavy-duty vehicles. For management of running clearance between brake disc and pad, PID position controller is developed in simulation environment. Those controller parameters obtained in the simulation process are introduced to the control hardware. After that closed loop clamping force and position measurements are conducted. When the rise time values of both clamping force controllers are compared, it is seen that sliding mode controller can reach to the settling point faster than PID controller. As for the position controller, the rise time requirement has been achieved by the designed PID controller. The switching process of force and position controllers are implemented and functional closed loop measurements are conducted for different reference input signals. It is seen from the results that the rise time requirement for position controller has been achieved. The system response of clamping force parameter is considerably stable.