A Gear Drive Brake-By-Wire Actuator

The brake-by-wire (BBW) system is considered the future of vehicle brakes, using wires as an energy transmission medium and an electric motor instead of a hydraulic or pneumatic system. Therefore, to meet the demands of commercial vehicle braking systems, it is necessary to design a simple BBW system. This paper introduces a new BBW actuator with a new electromechanical brake (EMB) idea. Firstly, the structure, working principle, the new caliper structure, and the motion-conversion scroll gear mechanism of the new gear drive brake actuator (GDBA) are explained. Secondly, the mathematical modeling of the longitudinal dynamics of a 1000 kg four-seat light vehicle is provided. Thirdly, geometric modeling of a GDBA with a new caliper is designed. Various finite element method (FEM) investigations are conducted to see if the system's essential constituents could resist the forces involved. Such new GDBA analysis shows that it is safe and strong enough to withstand the stresses of its usage and has the capability to replace the conventional hydraulic braking system.