Design and Verification of a Novel Synchronous Force-Increasing Disk Electro-Mechanical Brake Actuator for Pure Electric Trucks

Zhang, Zhenwen; Yang, Kun; Nie, Mengwen; Ma, Chao; Tan, Di; Huang, Zhuangzhuang

doi:2025.26.4.1009

International Journal of Automotive Technology > Volume 26(4); 2025 > Article

Body and Safety, Chassis, Heat Transfer, Fluid and Thermal Engineering, Manufacturing, Noise, Vibration and Harshness, Transmission and Driveline, Vehicle Dynamics and Control

International Journal of Automotive Technology 2025;26(4): 1009-1026.
doi: https://doi.org/10.1007/s12239-025-00208-w

Design and Verification of a Novel Synchronous Force-Increasing Disk Electro-Mechanical Brake Actuator for Pure Electric Trucks

Zhenwen Zhang¹, Kun Yang¹, Mengwen Nie², Chao Ma¹, Di Tan¹, Zhuangzhuang Huang³

¹School of Transportation and Vehicle Engineering, Shandong University of Technology, Zibo 255000, China
²Weichai Power Co., Ltd, Weifang 261043, China
³Shandong Gold Phoenix Co., Ltd, Leling 253600, China

Corresponding Author. Kun Yang , Email. yangkun@sdut.edu.cn

Received: July 8, 2024; Revised: October 21, 2024 Accepted: November 2, 2024. Published online: January 23, 2025.

ABSTRACT

Electro-mechanical brake (EMB) has the characteristics of rapid braking response and precise adjustment for braking torque, it can provide an ideal brake actuator for the uncoupled regenerative braking system of new energy vehicles and active braking system of autonomous driving. Considering the synchronous requirements for braking force variation on both sides of the brake disk and the actuator’s volume for pure electric trucks, a novel scheme of the synchronous force-increasing disk EMB (SFD-EMB) actuator is proposed. The relationship between the force-increasing ratio, push displacement and size parameters of the bidirectional eccentric wheel is analyzed. Meanwhile, considering the requirements for compensating the maximum wear of brake linings and the smooth operation, an optimization based on the particle swarm optimization (PSO) algorithm is studied. The structural strength for the key components is verified based on the statics analysis. Furthermore, the braking response speed and tracking performance of braking torque for the SFD-EMB actuator is verified by performance testing platform. The results show that the braking response and the torque adjustment performance of the SFD-EMB actuator can meet the requirements of GB12676-2014, and the braking response time can be reduced by 68.8% compared with the specified time.

Key Words: Electro-mechanical brake actuator · Synchronous force-increasing · Bidirectional eccentric wheel · PSO algorithm · Structural analysis · Performance verification