• The Transactions of The Korean Institute of Electrical Engineers
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• v.57 no.12
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• pp.2291-2299
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• 2008

Hall effect force sensors have been used to measure clamping force in conventional Electric Parking Brake(EPB) systems. Estimation of clamping force without the sensors has drawn attentions due to mounting space limitations and cost issues. Removing the sensor requires the estimation of the initial contact point where the clamping force is effectively applied to the brake pads. In this paper, we propose how to estimate the initial contact point finding the relation between the angular velocity of an actuator and the initial contact point. For force estimation a look-up table is used as a function of the displacement of parking cable from the initial contact point. The proposed method is validated by experiments. From the experimental results we observe that the proposed method satisfies the specifications. The designed method is also able to estimate clamping force although parking cables are loosened and brake pads are worn out. Applying the proposed method enables manufacturing of low cost EPB systems.

• Transactions of the Korean Society of Automotive Engineers
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• v.24 no.3
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• pp.365-371
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• 2016

The electromechanical brake (EMB) is one of future brake systems due to its many advantages. For implementation of the EMB, the correct feed back about clamping force is necessary. Keeping commercialization of the EMB in mind, it is strongly demanded that an expensive load cell measuring the clamping force is replaced with an estimation algorithm. In addition, an estimation of the kissing point where the brake pads start to come into contact with a disk wheel is proposed in this paper. With these estimation algorithms, the clamping force can be expressed as a polynomial characteristic curve versus the motor angle. Also, a method for calibration of measured values by the load cell is proposed and used for an actual characteristic curve. Lastly, the performance of the proposed algorithms is evaluated in comparison with the actual curve on a developed EMB test bench.

• Transactions of the Korean Society of Automotive Engineers
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• v.24 no.1
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• pp.16-23
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• 2016

The EWB(electronic wedge brake) is one in which the braking force is developed in a wedge and caliper system and applied to a disk and wedge mechanism. The advantage of the wedge structure is that it produces self-reinforcing effect and hence, utilizes minimal motor power, resulting in reduced gear and current. The extent of use of clamping force sensors and protection from failure of the EWB system directly depends on the level of vehicle mass production. This study investigated the mathematical equations, simulation modeling, and failsafe control algorithm for the clamping force sensor of the EWB and validated the simulations. As this EWB system modeling can be applied to motor inductance, resistance, screw inertia, stiffness, and wedge mass and angle, this study could improve the accuracy of simulation of the EWB. The simulation results demonstrated the braking force, motor speed, and current of the EWB system when the driver desired to the step and pulse the brake force inputs. Moreover, this paper demonstrated that the proposed failsafe control algorithm accurately detects faults in the clamping force sensor, if any.

• Transactions of the Korean Society of Automotive Engineers
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• v.13 no.4
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• pp.190-196
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• 2005

The power steering hose assembly is usually manufactured through the swaging process, which is conducted to connect a hose with metal fittings. In this process the hose is inserted into metal components, the sleeve and the nipple, and compressed in the radial direction by the jaws to clamp the hose with metal components. In case that the clamping force is small, the oil in the hose can leak locally under the severe operating conditions. To confirm the clamping force requirements, the measurement of separation force in longitudinal direction of the hose is usually performed. In this study, the swaging process of a hose is simulated with the finite element method, to investigate the effect of friction coefficient on the separation fDrce. The results interpretations are ffcused on the inner rubber component, and also a formula is proposed to estimate the separation farces with respect to friction coefficients.

• Journal of the Korean Society for Advanced Composite Structures
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• v.6 no.3
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• pp.32-40
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• 2015

The torque shear high strength bolt is clamped normally at the break of pin-tail specified. However, the clamping forces on slip critical connections do not often meet the required tension, as it considerably fluctuates due to torque coefficient dependent on lubricant affected temperature. In this study, the clamping tests of torque shear bolts were conducted independently at indoor conditions and at construction site conditions. During last six years, temperature of candidated site conditions was recorded from $-11^{\circ}C$ to $34^{\circ}C$. The indoor temperature condition was ranged from $-10^{\circ}C$ to $50^{\circ}C$ at each $10^{\circ}C$ interval. As for site conditions, the clamping force was reached in the range from 159 to 210 kN and the torque value was from 405 to $556 N{\cdot}m$. The range of torque coefficient at indoor conditions was analyzed from 0.126 to 0.158 while tensions were indicated from 179 to 192 kN. The torque coefficient at site conditions was ranged from 0.118 to 0.152. Based on this test, the variable trends of torque coefficient, tension subjected temperature can be taken by statistic regressive analysis. The variable of torque coefficient under the indoor conditions is $0.13%/^{\circ}C$ while it reaches $2.73%/^{\circ}C$ at actual site conditions. When the indoor trends and site conditions is combined, the modified variable of torque coefficient can be expected as $0.2%/^{\circ}C$. and the modified variable of tension can be determined as $0.18%/^{\circ}C$.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.21 no.10
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• pp.581-588
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• 2020

This study examined a brake pad wear compensation method for an Electro-Mechanical Brake (EMB) using the braking test device. A three-phase Interior Permanent Magnet Synchronous Motor (IPMSM) was applied to drive the actuator of an EMB. Current control, speed control, and position control were used to control the clamping force of the EMB. The wear compensation method was performed using a software algorithm that updates the motor model equation by comparing the motor output torque current with a reference current. In addition, a simple first-order motor model equation was applied to estimate the output clamping force. The operation time to the maximum clamping force increased within 0.1 seconds compared to the brake pad in its initial condition. The experiment verified that the reference operating time was within 0.5 seconds, and the maximum value of the clamping force was satisfied under the wear condition. The wear compensation method based on the software algorithm in this paper can be performed in the pre-departure test of rolling stock.

• Journal of the Korean Society for Advanced Composite Structures
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• v.3 no.1
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• pp.8-15
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• 2012

The initial clamping forces of high strength bolts depending on different faying surface conditions drop within 1,000 hours regardless of loading, any other external force or loosening of the nut. This study is focused on an expectation model for relaxation of high strength bolt, which is confined to creep on coated faying surfaces after initial clamping. The range of this experiment is limited to estimate the relaxation of bolted joints coated by inorganic zinc primer. The candidate bolts were dacro-coated tension control bolts. The parameters of coated thickness for the faying surface were 96, 168,and $226{\mu}m$ respectively. From experiments, it exhibited that the logarithmic function for creep strain was derived due to the parameter of coating thickness. By using the creep strain, subsequently the quantitative model for estimating long term relaxation of high strength bolt can be taken with the elapsed time. The experimental results showed that the relaxation after the initial clamping of high strength bolt rose to a much higher range from 10% to 18% due to creep of the coating as the coating thickness was increased. This study showed that the clamping force reflecting relaxation after the elapse of constant time can be calculated from the initial clamping force of high strength bolt.

• Journal of Aerospace System Engineering
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• v.11 no.6
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• pp.68-75
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• 2017

In this study, the bolt torque calculation method for space industry was compared and verified experimentally. Currently, NASA, European Aerospace Agency, and US National Defense Standards are proposing standards for bolt torque estimation. However, these standards vary slightly and require a high level of comprehension. To address these challenges, we selected typical equations among the widely-used bolt torque calculation methodologies, and the predicted values were verified via clamping force test. In addition, we examined the changes in clamping force associated with handling and refastening.

• KSCE Journal of Civil and Environmental Engineering Research
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• v.29 no.4A
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• pp.291-297
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• 2009

Relaxation of high strength bolts was investigated. Block type and splice type specimens were fabricated with different types of bolts and different clamping lengths. Bolts were tightened to the specified torque. Clamping forces were measured through strain gauges installed on the shafts of bolts, while specimens were kept in a constant temperature and humidity. In all cases, ratio of clamping force reduction is less than 10%. Test results of different types of specimens and bolts and different clamping lengths were compared each other by using a simple model, which is suggested in this study for the estimation of bolt relaxation. The suggested model shows reasonably good agreements with test results for all cases. No difference is found between F13T and F10T bolts, but Dacro coated bolts shows higher relaxation than black bolts by approx. 30%. And also the comparison of test results shows that ratios of bolt relaxation become larger as clamping lengths of bolt shorter and the number of faying surfaces greater.

• Journal of the Korean Society for Precision Engineering
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• v.23 no.9 s.186
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• pp.76-83
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• 2006

Machining accuracy is closely related with tool deflection induced by cutting forces. In this research, cutting forces and tool deflection in end milling are expressed as a closed form of tool rotational angle and cutting conditions. The discrete cutting fores caused by periodic tool entry and exit are represented as a continuous function using the Fourier series expansion. Tool deflection is predicted by direct integration of the distributed loads on cutting edges. Cutting conditions, tool geometry, run-outs and the stiffness of tool clamping part are considered together far cutting forces and tool deflection estimation. Compared with numerical methods, the presented method has advantages in prediction time reduction and the effects of feeding and run-outs on cutting forces and tool deflection can be analyzed quantitatively. This research can be effectively used in real time machining error estimation and cutting condition selection for error minimization since the form accuracy is easily predicted from tool deflection curve.