Viva Luqman

UNIVERSITI TEKNIKAL MALAYSIA MELAKA
(UTeM)
DEVELOPMENT OF ELECTRONIC
WEDGE BRAKE (EWB) SYSTEM
MUHAMMAD LUQMAN HAKIM
BIN ABD RAHMAN
M040910005
860105-43-5829
SUPERVISOR :- DR NOREFFENDY BIN TAMALDIN
AUTOMOTIVE BRAKE SYSTEM

HOLD
STATIONERY
(PARKING)
STOP
VEHICLE
SLOW DOWN
VEHICLE
SPEED
UNIVERSITI TEKNIKAL
MALAYSIA MELAKA (UTeM)
DEVELOPMENT OF ELECTRONIC WEDGE

BRAKE (EWB) SYSTEM
ELECTRONIC WEDGE BRAKE (EWB)

DEVELOPMENT

(UTeM)
PROBLEM STATEMENT
AUTOMOTIVE RESEARCH
IS MOVING TOWARDS
DRIVE-BY-WIRE
TECHNOLOGY
RESPONSE TIME
IMPROVED THROUGH
ELIMINATION OF
MECHANICAL LINKAGE
BRAKE-BY-WIRE
ACTIVE SAFETY SYSTEM

CAN BE IMPROVED BY
PROVIDING COMPUTER
CONTROL
INTERVENTION
ELECTRONIC WEDGE
BRAKE
UNIVERSITI TEKNIKAL
ELIMINATION OF
CONVENTIONAL BRAKE
SYSTEM
SPRINGING EFFECT
MAKE THE CONVENTIONAL
BRAKE SYSTEM DIFFICULT
TO CONTROL

DEVELOPMENT
OBJECTIVE OF STUDY
TO DEVELOP A
MATHEMATICAL MODEL OF
EWB CALIPER BEHAVIOR
TO IMPLEMENT THE
EWB CONTROL
STRATEGY USING
HILS & SILS
TO DEVELOP A
PROTOTYPE OF EWB
CALIPER
UNIVERSITI TEKNIKAL

BRAKE (EWB) SYSTEM

DEVELOPMENT

(UTeM)
SCOPE OF STUDY
DESIGN & FABRICATION OF
AN EWB CALIPER
PROTOTYPE
PERFORMANCE EVALUATION OF
THE EWB CONTROL STRUCTURE
USING POSITION & TORQUE
TRACKING CONTROL
INVESTIGATION &
CHARACTERIZATION OF EWB
CALIPER BEHAVIOR
PERFORMANCE EVALUATION OF
THE PROPOSED MATHEMATICAL
MODEL OF EWB CALIPER
UNIVERSITI TEKNIKAL

DEVELOPMENT
METHODOLOGY
LITERATURE REVIEW
1
&
HILS SETUP
PATENT SEARCH
PROTOTYPE
DEVELOPMENT
EXPERIMENTAL SETUP
3
&
CHARACTERIZATION
OF EWB CALIPER
UNIVERSITI TEKNIKAL

BRAKE (EWB) SYSTEM
7
POSITION (GAP)
TRACKING CONTROL
VALIDATION OF EWB
CALIPER MODEL
5
TORQUE TRACKING
CONTROL
8
MODELING OF EWB
CALIPER
4
FUTURE WORKS

DEVELOPMENT
9
6

(UTeM)
BASIC WEDGE MECHANISM

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.
Where
Fm = Motor Force
Fn
= Normal Force
Fb
= Braking Force
= Action Force
= Wedge Angle
HEART OF MECHATRONIC WEDGE BRAKE (Hartman et al. 2002)

UNIVERSITI TEKNIKAL

DEVELOPMENT
EWB DEVELOPMENT PROCESS

LITERATURE REVIEW
1
&
HILS SETUP
PATENT SEARCH
PROTOTYPE
DEVELOPMENT
EXPERIMENTAL SETUP
3
&
CHARACTERIZATION
OF EWB CALIPER
UNIVERSITI TEKNIKAL

BRAKE (EWB) SYSTEM
7
POSITION (GAP)
TRACKING CONTROL
VALIDATION OF EWB
CALIPER MODEL
5
TORQUE TRACKING
CONTROL
8
MODELING OF EWB
CALIPER
4
FUTURE WORKS

DEVELOPMENT
9
8

(UTeM)
LITERATURE REVIEW
Hartman et al., 2002
Robert et al., 2003
Robert et al., 2004
Ho et al ., 2006
Kim et al., 2010
BRAKE BY WIRE
EHB
BY CONTROLLING SOLENOID
VALVE
EMB
PURELY ELECTRONIC
CONTROL
STILL USING HYDRAULIC
USING 48/24/12 VOLTS

ELECTRIC MOTOR DRIVE
REDUCTION GEAR
ELECTRONIC
WEDGE
BRAKE
EPB
BY CONTROLLING SOLENOID
VALVE
STILL USING PNEUMATIC
COMPLEX STRUCTURE
WEDGE JAMMING
IT IS HARD TO MOUNT IN
THE WHEEL DUE TO
GREATER AXIAL LENGTH
UNIVERSITI TEKNIKAL

DEVELOPMENT
PREVIOUS RESEARCHER
SIEMENS VDO (TWIN ELECTRIC MOTOR)
ALPHA PROTOTYPE (Robert et al., 2003)
SIEMENS VDO (SINGLE ELECTRIC MOTOR)
BETA PROTOTYPE (Robert et al., 2004)
UNIVERSITI TEKNIKAL

BRAKE (EWB) SYSTEM

DEVELOPMENT
10

(UTeM)
PREVIOUS RESEARCHER
MANDO CORPORATION (CROSS WEDGE)
MANDO CORPORATION (Kim et al., 2009)

UNIVERSITI TEKNIKAL

DEVELOPMENT
11

LITERATURE REVIEW
1
&
HILS SETUP
PATENT SEARCH
PROTOTYPE
DEVELOPMENT
EXPERIMENTAL SETUP
3
&
CHARACTERIZATION
OF EWB CALIPER
UNIVERSITI TEKNIKAL

BRAKE (EWB) SYSTEM
7
POSITION (GAP)
TRACKING CONTROL
VALIDATION OF EWB
CALIPER MODEL
5
TORQUE TRACKING
CONTROL
8
MODELING OF EWB
CALIPER
4
FUTURE WORKS

DEVELOPMENT
9
12

(UTeM)
EWB DESIGN
DC MOTOR
ROTATIONAL DISPLACEMENT
WORM GEAR
ROTATIONAL DISPLACEMENT
WEDGE MECHANISM
LINEAR DISPLACEMENT
PISTON
UNIVERSITI TEKNIKAL
DC MOTOR

DEVELOPMENT
EWB PROTOTYPE
DC MOTOR
BRACKET
BRAKE
PAD
EWB
ACTUATOR
BRAKE
CALIPER
UNIVERSITI TEKNIKAL

BRAKE (EWB) SYSTEM
13

DEVELOPMENT
14

(UTeM)

LITERATURE REVIEW
&
HILS SETUP
PATENT SEARCH
PROTOTYPE
DEVELOPMENT
7
POSITION (GAP)
TRACKING CONTROL
VALIDATION OF EWB
CALIPER MODEL
5
TORQUE TRACKING
CONTROL
8
MODELING OF EWB
CALIPER
4
FUTURE WORKS
EXPERIMENTAL SETUP
3
&
CHARACTERIZATION
OF EWB CALIPER
UNIVERSITI TEKNIKAL

DEVELOPMENT
EWB CHARACTERIZATION
9
15
PC DESKTOP
IMC DEVICE
POWER
SUPPLY
LINEAR
DISPLACEMENT
ON PISTON BRAKE
LVDT
ROTATIONAL
DISPLACEMENT
ON DC MOTOR
ROTARY ENCODER
CLAMPING FORCE
ON BRAKE PAD
LOAD CELL
UNIVERSITI TEKNIKAL

BRAKE (EWB) SYSTEM

DEVELOPMENT
16

(UTeM)
EWB CHARACTERIZATION
ROTATIONAL INPUT
AT WORM PINION
DISPLACEMENT RESPONSE
OF BRAKE PISTON
UNIVERSITI TEKNIKAL

DEVELOPMENT
17

LITERATURE REVIEW
1
&
HILS SETUP
PATENT SEARCH
PROTOTYPE
DEVELOPMENT
EXPERIMENTAL SETUP
3
&
CHARACTERIZATION
OF EWB CALIPER
UNIVERSITI TEKNIKAL

BRAKE (EWB) SYSTEM
7
POSITION (GAP)
TRACKING CONTROL
VALIDATION OF EWB
CALIPER MODEL
5
TORQUE TRACKING
CONTROL
8
MODELING OF EWB
CALIPER
4
FUTURE WORKS

DEVELOPMENT
9
18

(UTeM)
EWB MODELING
GAPING
INITIAL SET BY FILLER GAUGE
CLAMPING
SATURATION
CLAMPING FORCE OCCUR

MAX CLAMPING FORCE
MATHEMATHICAL MODEL CLAMPING FORCE BEHAVIOR

UNIVERSITI TEKNIKAL

DEVELOPMENT
19
EWB MODELING
PARAMETERS
d
-0.85mm
-0.6mm
-0.11mm
0.4
reff
150mm
MATHEMATHICAL MODEL FOR BRAKE TORQUE

UNIVERSITI TEKNIKAL

BRAKE (EWB) SYSTEM

DEVELOPMENT
20
10

(UTeM)

7
POSITION (GAP)
TRACKING CONTROL
LITERATURE REVIEW
&
HILS SETUP
PATENT SEARCH
PROTOTYPE
DEVELOPMENT
VALIDATION OF EWB
CALIPER MODEL
5
TORQUE TRACKING
CONTROL
8
MODELING OF EWB
CALIPER
4
FUTURE WORKS
EXPERIMENTAL SETUP
3
&
CHARACTERIZATION
OF EWB CALIPER
UNIVERSITI TEKNIKAL

DEVELOPMENT
21
EWB VALIDATION
BRAKE FORCE - GAPING
BRAKE TORQUE - GAPING
UNIVERSITI TEKNIKAL

BRAKE (EWB) SYSTEM

DEVELOPMENT
22
11

(UTeM)

LITERATURE REVIEW
&
HILS SETUP
PATENT SEARCH
PROTOTYPE
DEVELOPMENT
7
POSITION (GAP)
TRACKING CONTROL
VALIDATION OF EWB
CALIPER MODEL
5
TORQUE TRACKING
CONTROL
8
MODELING OF EWB
CALIPER
4
FUTURE WORKS
EXPERIMENTAL SETUP
3
&
CHARACTERIZATION
OF EWB CALIPER
UNIVERSITI TEKNIKAL

DEVELOPMENT
9
23
HARDWARE IN THE LOOP

SIMULATION (HILS) SETUP
UNIVERSITI TEKNIKAL

BRAKE (EWB) SYSTEM

DEVELOPMENT
24
12

(UTeM)
TARGET PC
HARDWARE IN THE LOOP

SIMULATION (HILS) SETUP
MICROCONTROLLER
OPTO COUPLER
H-BRIDGE
EWB
TEST RIG
DAQ (PCI BOARD)

CONNECTOR BLOCK
POWER
SUPPLY
UNIVERSITI TEKNIKAL

DEVELOPMENT
HOST PC
25
ECU FOR MOTOR CONTROLLER
MCU
PROGRAMMABLE CHIP
TO ROTATE DC MOTOR
THROUGH PWM SIGNAL
UNIVERSITI TEKNIKAL

BRAKE (EWB) SYSTEM
OPTO COUPLER
ISOLATE ELECTRICAL
CONNECTION BETWEEN
MCU & DRIVER
DEVELOPMENT
H-BRIDGE DRIVER
CONTROL DIRECTION
OF
DC MOTOR ROTATION
26
13

(UTeM)

LITERATURE REVIEW
&
HILS SETUP
PATENT SEARCH
PROTOTYPE
DEVELOPMENT
7
POSITION (GAP)
TRACKING CONTROL
VALIDATION OF EWB
CALIPER MODEL
5
TORQUE TRACKING
CONTROL
8
MODELING OF EWB
CALIPER
4
FUTURE WORKS
EXPERIMENTAL SETUP
3
&
CHARACTERIZATION
OF EWB CALIPER
UNIVERSITI TEKNIKAL

DEVELOPMENT
9
27
POSITION TRACKING CONTROL

SOFTWARE IN THE LOOP SIMULATION (SILS)
UNIVERSITI TEKNIKAL

BRAKE (EWB) SYSTEM

DEVELOPMENT
28
14

(UTeM)

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

DEVELOPMENT
29

POTENTIOMETER
DC MOTOR
LVDT
DC MOTOR
MOUNTING
LOAD
CELL
UNIVERSITI TEKNIKAL
TEST
RIG

BRAKE (EWB) SYSTEM

DEVELOPMENT
EWB
ACTUATOR
30
15

(UTeM)

PARAMETERS
TECHNIQUE
SIL
HIL
UNIVERSITI TEKNIKAL
INPUT
STEP
0.02
SINE
0.1
SQUARE
6.3
0.01
STEP
20
2.3
SINE
18
SQUARE
13

DEVELOPMENT
31

RESULTS
SQUARE-TOOTH INPUT
STEP INPUT
SOFTWARE IN THE
LOOP
SIMULATION (SILS)
UNIVERSITI TEKNIKAL

BRAKE (EWB) SYSTEM

DEVELOPMENT
SINE INPUT
32
16

(UTeM)

RESULTS
SQUARE-TOOTH INPUT
STEP INPUT
HARDWARE IN THE
LOOP
SIMULATION (HILS)
SINE INPUT
UNIVERSITI TEKNIKAL

DEVELOPMENT
33
TRANSIENT RESPONSE FOR POSITION

TRACKING CONTROL
TECHNIQUE
SILS
HILS
INPUT
TIME
RESPONSE
OBSERVED
SETTLING
TIME
MAXIMUM
PERCENTAGE
OVERSHOOT
(%)
DEAD
TIME
RISE TIME
10%
90%
SINE
(4TH 6TH)
SEC
4.15 s
4.70 s
6.05 s
NO
OVERSHOOT
SQUARE
TOOTH
(2ND 4TH)
SEC
2.00 s
2.10 s
4.05 s
3.75 %
SINE
(4TH 6TH)
SEC
4.40 s
4.75 s
6.26 s
NO
OVERSHOOT
0.30 s
SQUARE
TOOTH
(2ND 4TH)
SEC
2.45 s
2.82 s
5.10 s
7.50 %
0.25 s
UNIVERSITI TEKNIKAL

BRAKE (EWB) SYSTEM

DEVELOPMENT
34
17

(UTeM)

LITERATURE REVIEW
&
HILS SETUP
PATENT SEARCH
PROTOTYPE
DEVELOPMENT
7
POSITION (GAP)
TRACKING CONTROL
VALIDATION OF EWB
CALIPER MODEL
5
TORQUE TRACKING
CONTROL
8
MODELING OF EWB
CALIPER
4
FUTURE WORKS
EXPERIMENTAL SETUP
3
&
CHARACTERIZATION
OF EWB CALIPER
UNIVERSITI TEKNIKAL

DEVELOPMENT
9
35
TORQUE TRACKING CONTROL

SOFTWARE IN THE LOOP SIMULATION (SILS)
UNIVERSITI TEKNIKAL

BRAKE (EWB) SYSTEM

DEVELOPMENT
36
18

(UTeM)

HARDWARE IN THE LOOP SIMULATION (HILS)
UNIVERSITI TEKNIKAL

DEVELOPMENT
37
TORQUE TRACKING
CONTROL PARAMETERS
TECHNIQUE
INPUT
STEP
10
3.2
0.02
SINE
2.9
0.02
SQUARE
10
0.01
STEP
40
0.1
0.04
SINE
41
0.1
0.02
SQUARE
45
0.15
0.03
SIL
HIL
UNIVERSITI TEKNIKAL

BRAKE (EWB) SYSTEM

DEVELOPMENT
38
19

(UTeM)

SQUARE-TOOTH INPUT
RESULTS
STEP INPUT
SOFTWARE IN
THE LOOP
SIMULATION (SILS)
SINE INPUT
UNIVERSITI TEKNIKAL

DEVELOPMENT
39

STEP INPUT
RESULTS
STEP INPUT
HARDWARE IN
THE LOOP
SIMULATION (HILS)
UNIVERSITI TEKNIKAL

BRAKE (EWB) SYSTEM

DEVELOPMENT
STEP INPUT
40
20

(UTeM)
TRANSIENT RESPONSE FOR TORQUE

TRACKING CONTROL
TECHNIQUE
SILS
HILS
INPUT
TIME
RESPONSE
OBSERVED
SETTLING
TIME
MAXIMUM
PERCENTAGE
OVERSHOOT
(%)
DEAD
TIME
RISE TIME
10%
90%
SINE
(4TH 6TH)
SEC
4.10 s
4.48 s
6.20 s
NO
OVERSHOOT
0.13 s
SQUARE
TOOTH
(2ND 4TH)
SEC
2.00 s
2.10 s
4.03 s
3.15 %
SINE
(4TH 6TH)
SEC
4.40 s
4.55 s
6.35 s
NO
OVERSHOOT
0.55 s
SQUARE
TOOTH
(2ND 4TH)
SEC
2.35 s
2.45 s
4.65 s
5.00 %
0.40 s
UNIVERSITI TEKNIKAL

DEVELOPMENT
41
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

BRAKE (EWB) SYSTEM

DEVELOPMENT
42
21

(UTeM)

LITERATURE REVIEW
&
HILS SETUP
PATENT SEARCH
PROTOTYPE
DEVELOPMENT
7
POSITION (GAP)
TRACKING CONTROL
VALIDATION OF EWB
CALIPER MODEL
5
TORQUE TRACKING
CONTROL
8
MODELING OF EWB
CALIPER
4
FUTURE WORKS
EXPERIMENTAL SETUP
3
&
CHARACTERIZATION
OF EWB CALIPER
UNIVERSITI TEKNIKAL

DEVELOPMENT
9
43
FUTURE WORKS
UNIVERSITI TEKNIKAL

BRAKE (EWB) SYSTEM

DEVELOPMENT
44
22

(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 Systems Modelling
and Testing, Vol. 8, No. 2, pp.145156.
Document Patent PI 2013003599 (Patent
Pending)
UNIVERSITI TEKNIKAL

DEVELOPMENT
45
THANK
YOU
UNIVERSITI TEKNIKAL

BRAKE (EWB) SYSTEM

DEVELOPMENT
46
23

Viva Luqman

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

AUTOMOTIVE BRAKE SYSTEM

DEVELOPMENT OF ELECTRONIC WEDGE

ELECTRONIC WEDGE BRAKE (EWB)

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

ACTIVE SAFETY SYSTEM

ELECTRONIC WEDGE BRAKE (EWB)

DEVELOPMENT OF ELECTRONIC WEDGE

ELECTRONIC WEDGE BRAKE (EWB)

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

ELECTRONIC WEDGE BRAKE (EWB)

DEVELOPMENT OF ELECTRONIC WEDGE

ELECTRONIC WEDGE BRAKE (EWB)

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BASIC WEDGE MECHANISM

HEART OF MECHATRONIC WEDGE BRAKE (Hartman et al. 2002)

ELECTRONIC WEDGE BRAKE (EWB)

EWB DEVELOPMENT PROCESS

DEVELOPMENT OF ELECTRONIC WEDGE

ELECTRONIC WEDGE BRAKE (EWB)

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

STILL USING HYDRAULIC

USING 48/24/12 VOLTS

ELECTRONIC WEDGE BRAKE (EWB)

ALPHA PROTOTYPE (Robert et al., 2003)

SIEMENS VDO (SINGLE ELECTRIC MOTOR)

BETA PROTOTYPE (Robert et al., 2004)

DEVELOPMENT OF ELECTRONIC WEDGE

ELECTRONIC WEDGE BRAKE (EWB)

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

MANDO CORPORATION (Kim et al., 2009)

ELECTRONIC WEDGE BRAKE (EWB)

EWB DEVELOPMENT PROCESS

DEVELOPMENT OF ELECTRONIC WEDGE

ELECTRONIC WEDGE BRAKE (EWB)

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

ELECTRONIC WEDGE BRAKE (EWB)

DEVELOPMENT OF ELECTRONIC WEDGE

ELECTRONIC WEDGE BRAKE (EWB)

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

EWB DEVELOPMENT PROCESS

ELECTRONIC WEDGE BRAKE (EWB)

DEVELOPMENT OF ELECTRONIC WEDGE

ELECTRONIC WEDGE BRAKE (EWB)

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

ELECTRONIC WEDGE BRAKE (EWB)

EWB DEVELOPMENT PROCESS

DEVELOPMENT OF ELECTRONIC WEDGE

ELECTRONIC WEDGE BRAKE (EWB)

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

INITIAL SET BY FILLER GAUGE

CLAMPING FORCE OCCUR

MATHEMATHICAL MODEL CLAMPING FORCE BEHAVIOR

ELECTRONIC WEDGE BRAKE (EWB)

MATHEMATHICAL MODEL FOR BRAKE TORQUE

DEVELOPMENT OF ELECTRONIC WEDGE

ELECTRONIC WEDGE BRAKE (EWB)

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

EWB DEVELOPMENT PROCESS

ELECTRONIC WEDGE BRAKE (EWB)

BRAKE TORQUE - GAPING

DEVELOPMENT OF ELECTRONIC WEDGE

ELECTRONIC WEDGE BRAKE (EWB)

UNIVERSITI TEKNIKAL MALAYSIA MELAKA