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1/23

NIVERSITI TEKNIKAL MALAYSIA MELAKA

UTeM)

EVELOPMENT OF ELECTRONIC WEDGE

RAKE (EWB) SYSTEM 1

DEVELOPMENT OF ELECTRONIC

WEDGE BRAKE (EWB) SYSTEM

MUHAMMAD LUQMAN HAKIM

BIN ABD RAHMANM040910005

860105-43-5829

SUPERVISOR :- DR NOREFFENDY BIN TAMALDIN

AUTOMOTIVE BRAKE SYSTEM

ELECTRONIC WEDGE BRAKE (EWB)

DEVELOPMENT2

SLOW DOWNVEHICLESPEED

STOPVEHICLE

HOLDSTATIONERY(PARKING)

UNIVERSITI TEKNIKAL

MALAYSIA MELAKA (UTeM)


2/23


UTeM)


RAKE (EWB) SYSTEM 2

PROBLEM STATEMENT

UNIVERSITI TEKNIKAL



DEVELOPMENT3

AUTOMOTIVE RESEARCHIS MOVING TOWARDS

DRIVE-BY-WIRETECHNOLOGY

RESPONSE TIMEIMPROVED THROUGH

ELIMINATION OFMECHANICAL LINKAGE

BRAKE-BY-WIRE

ACTIVE SAFETY SYSTEMCAN BE IMPROVED BY

PROVIDING COMPUTERCONTROL

INTERVENTION

ELECTRONIC WEDGEBRAKE

ELIMINATION OFCONVENTIONAL BRAKE

SYSTEM

SPRINGING EFFECT

MAKE THE CONVENTIONAL

BRAKE SYSTEM DIFFICULT

TO CONTROL

OBJECTIVE OF STUDY


DEVELOPMENT4

TO DEVELOP APROTOTYPE OF EWB

CALIPER

TO DEVELOP AMATHEMATICAL MODEL OF

EWB CALIPER BEHAVIOR

TO IMPLEMENT THE

EWB CONTROLSTRATEGY USINGHILS & SILS

UNIVERSITI TEKNIKAL



3/23


UTeM)


RAKE (EWB) SYSTEM 3

SCOPE OF STUDY

DESIGN & FABRICATION OFAN EWB CALIPER

PROTOTYPE

INVESTIGATION &CHARACTERIZATION OF EWB

CALIPER BEHAVIOR

PERFORMANCE EVALUATION OFTHE PROPOSED MATHEMATICAL

MODEL OF EWB CALIPER

PERFORMANCE EVALUATION OFTHE EWB CONTROL STRUCTURE

USING POSITION & TORQUETRACKING CONTROL

UNIVERSITI TEKNIKAL



DEVELOPMENT5

METHODOLOGY

LITERATURE REVIEW

&

PATENT SEARCH

PROTOTYPEDEVELOPMENT

EXPERIMENTAL SETUP

&

CHARACTERIZATIONOF EWB CALIPER

MODELING OF EWBCALIPER

VALIDATION OF EWBCALIPER MODEL

HILS SETUPPOSITION (GAP)

TRACKING CONTROL

TORQUE TRACKINGCONTROL

FUTURE WORKS


DEVELOPMENT6

UNIVERSITI TEKNIKAL


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4/23


UTeM)


RAKE (EWB) SYSTEM 4

BASIC WEDGE MECHANISM


DEVELOPMENT7

THE BRAKING FORCES IS INITIATED FROM THE MOTOR FORCES.

THE WEDGE THEN WILL HAVE A DISPLACEMENT IN X-AXIS AND Y-AXIS (DIAGONALLY)

RESULTING A FRICTION BETWEEN THE BRAKE PAD AND THE DISC.

HEART OF MECHATRONIC WEDGE BRAKE (Hartmanet al. 2002)

Where

F m = Motor Force

F n = Normal Force

F b = Braking Force

R = Action Force

α = Wedge Angle

UNIVERSITI TEKNIKAL


EWB DEVELOPMENT PROCESS

LITERATURE REVIEW

&

PATENT SEARCH


EXPERIMENTAL SETUP

&





TRACKING CONTROL


FUTURE WORKS


DEVELOPMENT8

UNIVERSITI TEKNIKAL


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5/23


UTeM)


RAKE (EWB) SYSTEM 5

LITERATURE REVIEW


DEVELOPMENT9

BRAKE BY WIRE

EHBBY CONTROLLING SOLENOID

VALVE

STILL USING HYDRAUL IC

EMB

PURELY ELECTRONICCONTROL

ELECTRONIC

WEDGEBRAKE

EPBBY CONTROLLING SOLENOID

VALVE

STILL USING PNEUMATIC

•Hartman et al., 2002

•Robert et al., 2003

•Robert et al., 2004

•Ho et al ., 2006

•Kim et al ., 2010

USING 48/24/12 VOLTS

ELECTRIC MOTOR DRIVE

REDUCTION GEAR

COMPLEX STRUCTURE

WEDGE JAMMING

IT IS HARD TO MOUNT IN

THE WHEEL DUE TO

GREATER AXIAL LENGTH

UNIVERSITI TEKNIKAL


PREVIOUS RESEARCHER SIEMENS VDO (TWIN ELECTRIC MOTOR)


DEVELOPMENT10

SIEMENS VDO (SINGLE ELECTRIC MOTOR)

ALPHA PROTOTYPE (Robert et al., 2003)

BETA PROTOTYPE (Robert et al., 2004)

UNIVERSITI TEKNIKAL



6/23


UTeM)


RAKE (EWB) SYSTEM 6

PREVIOUS RESEARCHER


DEVELOPMENT11

MANDO CORPORATION (Kim et al., 2009)

MANDO CORPORATION (CROSS WEDGE)

UNIVERSITI TEKNIKAL



LITERATURE REVIEW

&

PATENT SEARCH


EXPERIMENTAL SETUP

&





TRACKING CONTROL


FUTURE WORKS


DEVELOPMENT12

UNIVERSITI TEKNIKAL


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7/23


UTeM)


RAKE (EWB) SYSTEM 7

EWB DESIGN


DEVELOPMENT13

DC MOTOR

WORM GEAR

WEDGE MECHANISM

PISTON

ROTATIONAL DISPLACEMENT

ROTATIONAL DISPLACEMENT

LINEAR DISPLACEMENT

UNIVERSITI TEKNIKAL


EWB PROTOTYPE


DEVELOPMENT14

UNIVERSITI TEKNIKAL


DC MOTOR

BRACKET

DC MOTOR

BRAKE

PAD

BRAKE

CALIPER

EWB

ACTUATOR


8/23


UTeM)


RAKE (EWB) SYSTEM 8


LITERATURE REVIEW

&

PATENT SEARCH


EXPERIMENTAL SETUP

&





TRACKING CONTROL


FUTURE WORKS


DEVELOPMENT15

UNIVERSITI TEKNIKAL


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EWB CHARACTERIZATION


DEVELOPMENT16

ROTATIONAL

DISPLACEMENT

ON DC MOTOR

LINEAR

DISPLACEMENT

ON PISTON BRAKE

CLAMPING FORCE

ON BRAKE PAD

ROTARY ENCODER

LVDT

LOAD CELL

UNIVERSITI TEKNIKAL


PC DESKTOP

POWER

SUPPLY

IMC DEVICE


9/23


UTeM)


RAKE (EWB) SYSTEM 9

EWB CHARACTERIZATION

UNIVERSITI TEKNIKAL



DEVELOPMENT17

ROTATIONAL INPUT

AT WORM PINION

DISPLACEMENT RESPONSEOF BRAKE PISTON


LITERATURE REVIEW

&

PATENT SEARCH


EXPERIMENTAL SETUP

&





TRACKING CONTROL


FUTURE WORKS


DEVELOPMENT18

UNIVERSITI TEKNIKAL


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10/23


UTeM)


RAKE (EWB) SYSTEM 10

EWB MODELING


DEVELOPMENT19

MATHEMATHICAL MODEL CLAMPING FORCE BEHAVIORUNIVERSITI TEKNIKAL


GAPING INITIAL SET BY FILLER GAUGE

CLAMPING CLAMPING FORCE OCCUR

SATURATION MAX CLAMPING FORCE

EWB MODELING


DEVELOPMENT20

MATHEMATHICAL MODEL FOR BRAKE TORQUE

UNIVERSITI TEKNIKAL


PARAMETERS

d -0.85mm

e -0.6mm

f -0.11mm

µ 0.4

r eff 150mm


11/23


UTeM)




LITERATURE REVIEW

&

PATENT SEARCH


EXPERIMENTAL SETUP

&





TRACKING CONTROL


FUTURE WORKS


DEVELOPMENT21

UNIVERSITI TEKNIKAL


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EWB VALIDATION


DEVELOPMENT22

UNIVERSITI TEKNIKAL


BRAKE FORCE - GAPING

BRAKE TORQUE - GAPING


12/23


UTeM)




LITERATURE REVIEW

&

PATENT SEARCH


EXPERIMENTAL SETUP

&





TRACKING CONTROL


FUTURE WORKS


DEVELOPMENT23

UNIVERSITI TEKNIKAL


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HARDWARE IN THE LOOP

SIMULATION (HILS) SETUP


DEVELOPMENT24

UNIVERSITI TEKNIKAL



13/23


UTeM)



HARDWARE IN THE LOOP

SIMULATION (HILS) SETUP


DEVELOPMENT25

UNIVERSITI TEKNIKAL


TARGET PC

HOST PC

EWB

TEST RIG

POWER

SUPPLY

MICROCONTROLLER

OPTO COUPLER

H-BRIDGE

DAQ (PCI BOARD)

CONNECTOR BLOCK

ECU FOR MOTOR CONTROLLER


DEVELOPMENT26

PROGRAMMABLE CHIP

TO ROTATE DC MOTOR

THROUGH PWM SIGNAL

MCU

ISOLATE ELECTRICAL

CONNECTION BETWEEN

MCU & DRIVER

CONTROL DIRECTION

OF

DC MOTOR ROTATION

UNIVERSITI TEKNIKAL


OPTO COUPLER H-BRIDGE DRIVER


14/23


UTeM)




LITERATURE REVIEW

&

PATENT SEARCH


EXPERIMENTAL SETUP

&





TRACKING CONTROL


FUTURE WORKS


DEVELOPMENT27

UNIVERSITI TEKNIKAL


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POSITION TRACKING CONTROL


DEVELOPMENT28

SOFTWARE IN THE LOOP SIMULATION (SILS)

UNIVERSITI TEKNIKAL



15/23


UTeM)





DEVELOPMENT29

HARDWARE-IN-THE-LOOP-SIMULATION (HILS)

UNIVERSITI TEKNIKAL



UNIVERSITI TEKNIKAL



DEVELOPMENT30

DC MOTOR

LVDT

LOAD

CELL

TEST

RIG

POTENTIOMETER

DC MOTOR

MOUNTING

EWB

ACTUATOR


16/23


UTeM)




PARAMETERS


DEVELOPMENT31

UNIVERSITI TEKNIKAL


TECHNIQUE INPUT P I D

SIL

STEP 5 0 0.02

SINE 4 0 0.1

SQUARE 6.3 0 0.01

HIL

STEP 20 0 2.3

SINE 18 0 5

SQUARE 13 0 8


RESULTS

UNIVERSITI TEKNIKAL



DEVELOPMENT32

STEP INPUT

SINE INPUT

SQUARE-TOOTH INPUT

SOFTWARE IN THE

LOOP

SIMULATION (SILS)


17/23


18/23


UTeM)




LITERATURE REVIEW

&

PATENT SEARCH


EXPERIMENTAL SETUP

&





TRACKING CONTROL


FUTURE WORKS


DEVELOPMENT35

UNIVERSITI TEKNIKAL


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TORQUE TRACKING CONTROL


DEVELOPMENT36

SOFTWARE IN THE LOOP SIMULATION (SILS)

UNIVERSITI TEKNIKAL



19/23


UTeM)





DEVELOPMENT37

HARDWARE IN THE LOOP SIMULATION (HILS)

UNIVERSITI TEKNIKAL


TORQUE TRACKING

CONTROL PARAMETERS


DEVELOPMENT38

UNIVERSITI TEKNIKAL


TECHNIQUE INPUT P I D

SIL

STEP 10 3.2 0.02

SINE 9 2.9 0.02

SQUARE 10 4 0.01

HILSTEP 40 0.1 0.04

SINE 41 0.1 0.02

SQUARE 45 0.15 0.03


20/23


UTeM)




RESULTS


DEVELOPMENT39

STEP INPUT

SOFTWARE INTHE LOOP

SIMULATION (SILS)

UNIVERSITI TEKNIKAL


SINE INPUT

SQUARE-TOOTH INPUT


RESULTS


DEVELOPMENT40

STEP INPUT

UNIVERSITI TEKNIKAL


STEP INPUT

STEP INPUT

HARDWARE IN

THE LOOP

SIMULATION (HILS)


21/23


UTeM)



TECHNIQUE INPUT

TIME

RESPONSE

OBSERVED

RISE TIMESETTLING

TIME

MAXIMUM

PERCENTAGE

OVERSHOOT

(%)

DEAD

TIME10% 90%

SILS

SINE(4TH – 6TH)

SEC4.10 s 4.48 s 6.20 s

NO

OVERSHOOT0.13 s

SQUARE

TOOTH

(2ND – 4TH)

SEC2.00 s 2.10 s 4.03 s 3.15 % -

HILS

SINE(4TH – 6TH)

SEC

4.40 s 4.55 s 6.35 sNO

OVERSHOOT

0.55 s

SQUARE

TOOTH

(2ND – 4TH)

SEC2.35 s 2.45 s 4.65 s 5.00 % 0.40 s

UNIVERSITI TEKNIKAL



DEVELOPMENT41

TRANSIENT RESPONSE FOR TORQUE

TRACKING CONTROL

CONCLUSION

• EWB HAS BEEN SUCCESSFULLY DESIGNED

AND FABRICATED IN THIS STUDY

• A NEW EWB MATHEMATICAL MODEL HAS

BEEN PROPOSED IN THIS STUDY

• EWB HAS BEEN INVESTIGATED IN TERM OF

POSITION (GAPING) AND BRAKE TORQUE

CONTROL

UNIVERSITI TEKNIKAL



DEVELOPMENT42


22/23


UTeM)




LITERATURE REVIEW

&

PATENT SEARCH


EXPERIMENTAL SETUP

&





TRACKING CONTROL


FUTURE WORKS


DEVELOPMENT43

UNIVERSITI TEKNIKAL


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FUTURE WORKS

UNIVERSITI TEKNIKAL



DEVELOPMENT44


23/23


UTeM)

PUBLICATIONS

• Abd. Rahman, M.L.H., Hudha, K., Ahmad, F.

and Jamaluddin, H. (2013) ‘Design and

clamping force modelling of electronic

wedge brake system for automotive

application’, Int. J. Vehicle SystemsModelling

and Test ing, Vol. 8, No. 2, pp.145–156.

• Document Patent – PI 2013003599 (Patent

Pending)

UNIVERSITI TEKNIKAL



DEVELOPMENT45

THANK

YOUUNIVERSITI TEKNIKAL



DEVELOPMENT46

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