BRAKE SYSTEM
20210197777 · 2021-07-01
Assignee
Inventors
- Kyoshiro ITAKURA (Tokyo, JP)
- Toshiyuki AJIMA (Tokyo, JP)
- Kenichiro MATSUBARA (Hitachinaka-shi, JP)
- Daisuke GOTO (Hitachinaka-shi, JP)
Cpc classification
B60T8/171
PERFORMING OPERATIONS; TRANSPORTING
B60T13/746
PERFORMING OPERATIONS; TRANSPORTING
B60T13/741
PERFORMING OPERATIONS; TRANSPORTING
B60T17/221
PERFORMING OPERATIONS; TRANSPORTING
F16D66/023
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
B60T8/171
PERFORMING OPERATIONS; TRANSPORTING
B60T1/06
PERFORMING OPERATIONS; TRANSPORTING
B60T13/74
PERFORMING OPERATIONS; TRANSPORTING
Abstract
An object of the present invention is to appropriately control a clearance amount by correcting an estimation error of a contact position caused by a delay time difference between output signals of sensors, and to establish both improvement of fuel efficiency due to prevention of drag of a brake pad during non-braking and reduction in response time during braking.
A brake system includes a brake disc, a brake pad, a piston, a drive mechanism, a position sensor that detects a position of the piston, a thrust sensor that detects a thrust by which the brake pad presses the brake disc, and a brake control unit that adjusts a braking force by controlling the drive mechanism. The brake control unit includes a contact position computation unit that computes a contact position at which the brake pad and the brake disc come in contact with each other based on output signals of the position sensor and the thrust sensor, a position error computation unit that computes a position error of the contact position based on a delay time difference between the output signals of the position sensor and the thrust sensor, and a contact position correction unit that corrects the contact position obtained by the contact position computation unit by using the position error.
Claims
1. A brake system, comprising: a brake disc that rotates with a wheel; a brake pad that gives a braking force to the brake disc; a piston that drives the brake pad; a drive mechanism that gives a driving force to the piston; a position sensor that detects a position of the piston; a thrust sensor that detects a thrust by which the brake pad presses the brake disc; and a brake control unit that adjusts the braking force by controlling the drive mechanism, wherein the brake control unit includes a contact position computation unit that computes a contact position at which the brake pad and the brake disc come in contact with each other based on output signals of the position sensor and the thrust sensor, a position error computation unit that computes a position error of the contact position based on a delay time difference between the output signals of the position sensor and the thrust sensor, and a contact position correction unit that corrects the contact position obtained by the contact position computation unit by using the position error.
2. The brake system according to claim 1, wherein the brake control unit further includes an apply and release determination unit that determines whether an operation corresponds to an apply operation of increasing the braking force or a release operation of decreasing the braking force based on any of a sign of the thrust, a sign of the position of the piston, and a sign of a speed of the piston.
3. The brake system according to claim 2, wherein when a signal delay of the thrust sensor is longer than the position sensor, the contact position correction unit corrects the contact position by subtracting the position error from the contact position computed by the contact position computation unit in the apply operation, and corrects the contact position by adding the position error to the contact position computed by the contact position computation unit in the release operation.
4. The brake system according to claim 2, wherein when a signal delay of the thrust sensor is shorter than the position sensor, the contact position correction unit corrects the contact position by adding the position error to the contact position computed by the contact position computation unit in the apply operation, and corrects the contact position by subtracting the position error from the contact position computed by the contact position computation unit in the release operation.
5. The brake system according to claim 1, wherein the position error computation unit outputs the position error substantially proportion to a speed of the piston when the brake pad and the brake disc come in contact with each other.
6. The brake system according to claim 1, wherein the position error computation unit outputs the position error substantially proportion to the delay time difference between the output signals of the position sensor and the thrust sensor.
7. The brake system according to claim 6, wherein the delay time difference is a delay time difference determined by learning a time delay until the thrust starts to be changed when the position of the piston is changed.
8. A brake system, comprising: a brake disc that rotates with a wheel; a brake pad that gives a braking force to the brake disc; a piston that drives the brake pad; a drive mechanism that gives a driving force to the piston; a position sensor that detects a position of the piston; a thrust sensor that detects a thrust by which the brake pad presses the brake disc; and a brake control unit that adjusts the braking force by controlling the drive mechanism, wherein the brake control unit includes a contact position computation unit that computes a contact position at which the brake pad and the brake disc come in contact with each other based on output signals of the position sensor and the thrust sensor, a piston position time-series information retainment unit that retains positions of the piston in time series, and a contact position correction unit that sets, as the corrected contact position, the position of the piston at a time separated from a time corresponding to the contact position computed by the contact position computation unit by only the delay time difference between the output signals of the position sensor and the thrust sensor.
9. A brake system, comprising: a brake disc that rotates with a wheel; a brake pad that gives a braking force to the brake disc; a piston that drives the brake pad; a drive mechanism that gives a driving force to the piston; a position sensor that detects a position of the piston; a thrust sensor that detects a thrust by which the brake pad presses the brake disc; and a brake control unit that adjusts the braking force by controlling the drive mechanism, wherein the brake control unit includes a synchronization modification unit that modifies synchronization of the output signals of the position sensor and the thrust sensor based on a delay time difference between the output signals of the position sensor and the thrust sensor, and a contact position computation unit that computes a contact position at which the brake pad and the brake disc come in contact with each other based on the output signals of the position sensor and the thrust sensor of which the synchronization is corrected.
Description
BRIEF DESCRIPTION OF DRAWINGS
[0018]
[0019]
[0020]
[0021]
[0022]
[0023]
DESCRIPTION OF EMBODIMENTS
[0024] Hereinafter, although embodiments of the present invention will be described in detail with reference to the drawings, the present invention is not limited to the following embodiments, and various modifications and applications can be made within a technical concept of the present invention.
First Embodiment
[0025] A brake system according to a first embodiment of the present invention will be described with reference to
[0026]
[0027] As illustrated in
[0028] In this brake system 1, a braking force is given to the brake disc 11b being rotated by reducing a rotational driving force generated by the electric motor 2a by the speed reducer 2b, converting the reduced rotational driving force into a linear driving force via the feed screw 12b, and pressing the brake pad 11a against the brake disc 11b by a linear motion of the piston 12a. Hereinafter, a direction in which the piston 12a approaches the brake disc 11b is a positive direction, and an opposite direction is a negative direction.
[0029] When the above-described braking operation is performed, the motor control unit 3 in the brake control device 10 controls the rotation of the electric motor 2a, and adjusts a pressing force of the brake pad 11a. The brake control device 10 estimates the braking force of the brake pad 11a based on a thrust detected by a thrust sensor 31 installed at the rotation and linear motion conversion mechanism 12. The brake control device 10 estimates a position of the brake pad 11a based on a rotational position detected by a position sensor 32 installed at the electric motor 2a. The position sensor 32 may be attached to the piston 12a such that the position of the piston 12a can be directly detected.
[0030] A control signal line 21, communication lines 22 and 23, and a main power line 26 are connected to the brake control device 10. The motor control unit 3 and the contact position estimation unit 4 built therein are connected to each other by the communication lines 24 and 25. Of these, the control signal line 21 is used to input a control command from a host control device such as an ECU to the brake control device 10, and the communication lines 22 and 23 are used to communicate information other than the control command with the host control device. Although the host control device and the brake control device 10 are separate devices, these devices may be integrated into an integrated control device.
[0031] Next, details of the contact position estimation unit 4 will be described with reference to
<Contact Position Computation Unit 40>
[0032] The contact position computation unit 40 moves the piston 12a to the brake disc 11b side, and a position of the piston 12a when the brake pad 11a and the brake disc 11b come into contact with each other and a gap therebetween becomes zero, that is, an origin position of the piston 12a is obtained by computation. p There are various methods for computing the origin position of the piston 12a. However, for example, a case where the same computation method as that of PTL 3 is adopted will be described. In this case, in the contact position computation unit 40, a relationship between the thrust of the brake pad 11a and the position of the piston 12a is plotted in a two-dimensional space based on detection signals of the thrust sensor 31 and the position sensor 32 which are input moment by moment at a predetermined sampling cycle, and the origin position of the piston 12a is computed based on a rate of change of any two points on an obtained curve (for example, two points corresponding to predetermined threshold values T.sub.high and T.sub.low in consideration of performance of the thrust sensor 31) (see
[0033] Since a delay time difference Δt between output signals of the sensors is not taken into consideration in the computation, the origin position which is the computation result deviates from the actual origin position. Thus, even though the origin position obtained by the computation is used as it is, appropriate clearance control aimed at by the present invention cannot be realized.
<Delay Time Difference Retainment Unit 41>
[0034] The delay time difference retainment unit 41 outputs the delay time difference Δt between the output signals of the thrust sensor 31 and the position sensor 32 which is generated by performing filter processing, communication processing, or computation processing. This delay time difference is a constant determined by the specifications of the sensors, and delay times of the thrust sensor 31 and the position sensor 32 may be stored individually, and the delay time difference Δt obtained by computation may be output, or the delay time difference Δt stored in advance may be output as it is. The delay time difference Δt output in this manner is transmitted to the position error computation unit 42.
[0035] Since the delay time difference retainment unit 41 is only required to be able to output a relative delay time difference Δt between the thrust sensor 31 and the position sensor 32, it is not always necessary to retain delay time information of both the sensors as constants in advance. Alternatively, the delay time difference Δt of the thrust sensor which is observed when the piston 12a executes any operation may be learned and output.
<Position Error Computation Unit 42>
[0036] The position error computation unit 42 computes a position error ΔXerr of the piston 12a caused by the delay time difference Δt by using the delay time difference Δt output by the delay time difference retainment unit 41 and a speed of the piston 12a obtained by performing time differentiation or the like on the output signal of the position sensor 32. The calculated position error ΔXerr is transmitted to the contact position correction unit 44 to be described later.
[0037] For example, the position error ΔXerr caused by the delay time difference Δt between both the sensors is calculated by multiplying the delay time difference Δt between both the sensors and the piston speed at a point in time when the detection signal of the thrust sensor 31 exceeds a predetermined threshold value (at a point in time when the brake pad 11a and the brake disc 11b are considered to have come into contact). It is assumed that the calculated piston speed is substantially equal to the piston speed at the time of contact, and it is desirable that the aforementioned threshold value is as small as possible to satisfy accuracy of the thrust sensor 31.
<Apply and Release Determination Unit 43>
[0038] The apply and release determination unit 43 determines whether an operation at the time of contact position estimation is an apply (increase) operation or a release (decrease) operation. For example, it is determined to be the apply operation when a thrust command value is increased compared to the previous command value, and conversely, it is determined to be the release operation when the thrust command value is decreased. The determination result of the apply and release determination unit 43 is transmitted to the contact position correction unit 44 as operation information.
<Contact Position Correction Unit 44>
[0039] The contact position correction unit 44 corrects an estimation error caused by the delay time difference Δt between the sensors by using the contact position computation value X.sub.1 from the contact position computation unit 40, the position error ΔXerr from the position error computation unit 42, and the operation information from the apply and release determination unit 43, and outputs a contact position correction value X.sub.2. For example, it is possible to output more accurate contact position correction value X.sub.2 in consideration of the position error ΔXerr caused by the delay time difference Δt between the sensor signals in any operation by subtracting the position error ΔXerr from the contact position computation value X.sub.1 in the apply operation and by adding the position error ΔXerr to the contact position computation value X.sub.1 in the release operation. The contact position correction value X.sub.2 corrected by the contact position correction unit 44 is transmitted to the motor control unit 3 via the communication line 25, and thereafter, the motor control unit 3 executes desired clearance control by regarding the contact position correction value X.sub.2 as the origin position at which the brake pad 11a and the brake disc 11b come in contact with each other.
[0040] Functional blocks of the contact position estimation unit 4 illustrated in
<<Step S10>>
[0041] In step S10, it is determined whether or not the vehicle is currently in a braking state. This determination can be performed based on whether a driver steps on a brake pedal by a predetermined amount or more and the thrust command value is equal to or greater than zero. When it is determined to be a non-braking state, since the processing of the contact position estimation cannot be executed, the processing is ended, and waits for the next start timing. Meanwhile, when it is determined to be the braking state, the processing proceeds to the next step S11.
<<Step S11>>
[0042] In step S11, the thrust of the brake pad 11a is detected from the output of the thrust sensor 31 installed at the rotation and linear motion conversion mechanism 12. A motor rotation position is detected from the output of the position sensor 32 installed at the electric motor 2a, and a motor rotation speed is detected by the time differentiation thereof.
<<Step S12>>
[0043] In step S12, the obtained motor rotation position is converted into a linear motion direction according to a ratio of rotational linear motion as in (Equation 1). The motor speed is similarly converted into a speed of the piston in the linear motion direction.
Xp=θ×(L/ε) [mm] (Equation 1)
[0044] Xp is a piston position [mm], θ is a motor rotation position [rev], L is a lead of the feed screw 12b [mm/rev], and ε is a reduction ratio of the speed reducer 2b.
[0045] Here, these pieces of information are stored in a temporary storage area of a RAM provided in the microcomputer, and are used for the computation executed in the following control steps. It is also possible to detect other information other than these pieces of information in accordance with the brake system 1.
<<Step S13>>
[0046] Step S13 mainly corresponds to the processing in the contact position computation unit 40, and the origin position (contact position computation value X.sub.1) of the piston 12a when the brake pad 11a and the brake disc 11b comes in contact with each other is computed. As described above, there are various methods of computing the origin position. For example, a piston position at which thrust values of any two points in the increase operation or the decrease operation and a thrust value from the amount of change in the piston position (tilt) become zero is determined as the contact position computation value X.sub.1 based on the know-how of PTL 3 (see
<<Step S14>>
[0047] Step S14 mainly corresponds to the processing in the position error computation unit 42, the position error ΔXerr is calculated by (Equation 2) by using a representative piston speed Vp and the delay time difference Δt between the thrust sensor 31 and the position sensor 32 acquired from the delay time difference retainment unit 41.
ΔXerr=Vp×Δt (Equation 2)
[0048] Here, the representative piston speed Vp originally needs to be the speed at a point in time when the brake pad 11a comes in contact with, but it is not possible to know the piston speed at a true contact position before the completion of the contact position estimation in
Vp=(Vp1+Vp2)/2 (Equation 3)
[0049] However, the speed when the thrust values at the two points handed in step S13 and the thrust value from the rate of change in the piston speed become zero may be estimated as the representative piston speed Vp, and the estimated speed may be used as the representative piston speed Vp. When the position error ΔXerr is calculated by (Equation 2) by using any representative piston speed Vp, the processing proceeds to step S15.
<<Step S15>>
[0050] Step S15 mainly corresponds to the processing in the apply and release determination unit 43, and it is determined whether the contact position computation value X.sub.1 in step S13 is computed based on data acquired in an apply period or a release period. For example, it may be determined to be the apply operation when a thrust change rate ΔF at the two points handled in step S13 is positive, and it may be determined to be the release operation when thrust change rate is negative. Alternatively, it may be determined from the piston position or an increase or decrease of the thrust command. When the apply and release determination is completed, the processing proceeds to step S16 or step S17.
<<Step S16 and S17>>
[0051] When the determination result of step S15 is “apply”, the processing proceeds to step S16, and the contact position correction value X.sub.2 is obtained by subtracting the position error ΔXerr from the contact position computation value X.sub.1. Meanwhile, when the determination result of step S15 is “release”, the processing proceeds to step S17, and the contact position correction value X.sub.2 is obtained by adding the position error ΔXerr to the contact position computation value X.sub.1.
[0052] However, the aforementioned steps are performed when the thrust sensor 31 has a large delay with respect to the position sensor 32, and when the position sensor 32 has a large delay with respect to the thrust sensor 31, a sign is reversed. That is, when it is determined to the apply operation, the contact position correction value X.sub.2 is obtained by adding the position error ΔXerr to the contact position computation value X.sub.1, and when it is determined to be the release operation, the position error ΔXerr is subtracted from the contact position computation value X.sub.1. By doing so, the contact position correction value X.sub.2 is obtained.
[0053] Due to the execution of the above-described computation, when there is the delay time difference Δt between the thrust sensor 31 and the position sensor 32, the position error ΔXerr of the contact position estimation caused by the delay time difference is corrected, and the highly accurate contact position correction value X.sub.2 is obtained. The obtained contact position correction value X.sub.2 is used as the origin position of the piston 12a, and thus, it is possible to realize appropriate clearance control.
[0054] Next, a computation procedure illustrated in
[0055] In
[0056] A dashed dotted line curve represents thrust characteristics in the apply operation of a system in which the thrust sensor 31 has a delay with respect to the position sensor 32. In the apply (increase) operation, since an increase in the thrust detected by the thrust sensor 31 is delayed from an increase in the position detected by the position sensor 32, the contact position computation unit 40 recognizes the characteristics represented by the dashed dotted line. A dashed double-dotted line curve represents thrust characteristics in the release operation of a system in which the thrust sensor 31 has a delay with respect to the position sensor 32. In the release (decrease) operation, since a decrease in thrust detected by the thrust sensor 31 is delayed from a decrease in position detected by the position sensor 32, the contact position computation unit 40 recognizes the characteristics represented by the dashed double-dotted line.
[0057] Here, an example (corresponding to PTL 3) of the method of computing the contact position computation value X.sub.1 in the contact position computation unit 40 will be described in detail by using the dashed dotted line curve corresponding to the apply operation as an example. First, an intersection (black circle in
[0058] Next, the contact position computation value X.sub.1 is corrected by using the position error ΔXerr obtained by the position error computation unit 42. That is, the correction in consideration of the delay time difference Δt between the sensors is performed for the characteristics in the apply operation represented by the dashed dotted line by subtracting the position error ΔXerr from the contact position computation value X.sub.1 and for the characteristics in the release operation represented by the dashed double-dotted line by adding the position error ΔXerr to the contact position computation value X.sub.1, and thus, the corrected contact position correction value X.sub.2 (white circle represented by a solid line) closer to the true contact position than the contact position computation value X.sub.1 can be obtained.
[0059] The position error ΔXerr is changed depending on the piston speed when the brake disc comes in contact with the brake pad 11a, and the position error ΔXerr is increased as the piston speed is increased. In the present embodiment, the representative piston speed Vp of (Equation 3) is used in the computation of the position error ΔXerr, and the position error ΔXerr is increased when a contact speed is high, and the position error ΔXerr is decreased when the contact speed is low. That is, since the position error ΔXerr obtained by (Equation 2) takes into consideration the representative piston speed Vp, the contact position correction value X.sub.2 (white circle by a solid line) close to the true contact position can be obtained regardless of the magnitude of the piston speed at the time of contact.
[0060] In the present embodiment, since the contact position computation value X.sub.1 can be corrected to the contact position correction value X.sub.2 closer to the true origin position by the aforementioned computation, the position control of the piston 12a is performed with this contact position correction value X.sub.2.as a reference, and thus, it is possible to realize accurate clearance control higher than in the related art. Thus, according to the present embodiment, the drag of the brake pad 11a can be reduced during non-braking, and responsiveness during braking can be improved.
Second Embodiment
[0061] Next, a brake system according to a second embodiment of the present invention will be described with reference to a functional block diagram of
[0062] The second embodiment includes a contact position estimation unit 4 for obtaining the contact position correction value X.sub.2 by a method different from that of the first embodiment, and includes a piston position time-series information retainment unit 45 in addition to the contact position computation unit 40, the delay time difference retainment unit 41, the apply and release determination unit 43, and the contact position correction unit 44 which are the same as those in the first embodiment as illustrated in
[0063] The piston position time-series information retainment unit 45 added in the present embodiment is used for recording a time-series change of the piston position in the apply operation or the release operation in a RAM region of the microcomputer, and obtains the contact position correction value X.sub.2 close to the true origin position by reading, from the RAM, piston position information at a time returned from a time when the contact position computation value X.sub.1 is computed by the contact position computation unit 40 by only the delay time difference Δt between the sensors and correcting the contact position computation value X.sub.1 by using the read piston position information.
[0064] According to the configuration of the present embodiment, the contact position correction value X.sub.2 close to the true origin position can be obtained based on the actually recorded time-series data without computing the piston speed. As in the first embodiment, it is possible to reduce the drag of the brake pad 11a during non-braking by this contact position correction value X.sub.2, and it is possible to improve the responsiveness during braking.
Third Embodiment
[0065] Next, a brake system according to a third embodiment of the present invention will be described with reference to a functional block diagram of
[0066] The third embodiment includes a contact position estimation unit 4 for obtaining the contact position correction value X.sub.2 by a method different from that of the first embodiment, and includes a synchronization modification unit 46 in addition to the contact position computation unit 40 and the delay time difference retainment unit 41 which are the same as those of the first embodiment as illustrated in
[0067] The synchronization modification unit 46 of the present embodiment synchronizes the signals of the thrust sensor 31 and the position sensor 32 input via the communication line 24 based on the delay time difference Δt input from the delay time difference retainment unit 41. For example, when the detection result of the thrust sensor is delayed from the detection result of the position sensor 32 by 1 [ms], a set of pieces of data obtained by associating the information of the position sensor 32 after 1 [ms] with the current value of the thrust sensor 31 is processed, and thus, it is possible to cancel influence of a time shift present between the output values of the sensors. The output values of the sensors are input to the contact position computation unit 40 as a set of pieces of data in which the time shift is corrected in this manner, and thus, the position correction value X.sub.2 close to the true origin position of the piston 12a can be obtained as in in the above-described embodiment. Due to the use of this contact position correction value X.sub.2, the drag of the brake pad 11a can be reduced during non-braking, and the responsiveness during braking can be improved as in the above-described embodiment.
REFERENCE SIGNS LIST
[0068] 1 brake system, [0069] 2 drive mechanism, [0070] 2a electric motor, [0071] 2b speed reducer, [0072] 3 motor control unit, [0073] 4 contact position estimation unit, [0074] 10 brake control device, [0075] 11 braking mechanism, [0076] 11a brake pad, [0077] 11b brake disc, [0078] 12 rotation and linear motion conversion mechanism, [0079] 12a piston, [0080] 12b feed screw, [0081] 21 control signal line, [0082] 22 to 25 communication line, [0083] 26 main power line, [0084] 31 thrust sensor [0085] 32 position sensor, [0086] 40 contact position computation unit, [0087] 41 delay time difference retainment unit, [0088] 42 position error computation unit, [0089] 43 apply and release determination unit, [0090] 44 contact position correction unit, [0091] 45 piston position time-series information retainment unit, [0092] 46 synchronization modification unit, [0093] X.sub.1 contact position computation value, [0094] X.sub.2 contact position correction value