A Mechatronic Brake Booster for Electric Vehicles: Design, Control, and Experiment

The electro-mechanical brake booster (EMBB) is a kind of mechatronic actuator, which is developed to suit the brake assist requirement of electric vehicles. In this paper, we report on the design of an EMBB system consisting of a dc motor, a two-state reduction of a gear and ball screw, a servo body, and a reaction disk. Considering the inconvenience of installation and high price of the pedal force sensor, we translate the control problem of brake power assist control to position tracking control. Meanwhile, a nonlinear control method for position tracking is presented to solve the problem of power assist braking, which is formalized as three parts: the steady-state control, feed-forward control based on reference dynamics, and state-dependent feedback control. The benefit of the nonlinear control method is that it offers a concise control law and performs well in engineering implementations. In addition, a second-order filter was designed to do the signal processing and obtain a higher-order derivative. Finally, the bench tests based on rapid control prototyping environment were designed and implemented to verify the performance of the controller. Test results show that both the position tracking performance and response time of the EMBB system performed well.