Requirements for Brake Booster Motor Manufacturing Equipment

The brake booster motor, also known as the Electronic Hydraulic Brake (EHB) system, is an essential component in the automotive braking system. It utilizes an electric motor to replace the traditional vacuum booster. Its function is to assist the driver by providing additional braking force when the brake pedal is depressed, thereby enhancing the braking effect and improving the vehicle's safety.

1. Functions of the Brake Booster Motor

Braking Force: With the assistance of the motor, the braking force during braking can be significantly increased, enabling the vehicle to decelerate or stop more quickly in emergencies.

Improved Response Speed: The electric assist can quickly respond to the driver’s braking commands, accelerating the response time of the braking system and thus enhancing vehicle safety.

Reduced Driver Effort: In situations requiring significant braking force, such as emergency braking, the electric assist can reduce the physical effort required from the driver, making it easier to control the brakes.

Optimized Driving Experience: The electric assist system can provide a smoother and more consistent braking feel, improving comfort.

Support for Regenerative Braking: In electric or hybrid vehicles, the brake booster motor can work in conjunction with the regenerative braking system to recover kinetic energy and convert it into electrical energy stored back into the battery.

Intelligent Control: Modern electric assist braking systems can be integrated with the vehicle’s intelligent driving assistance systems, such as automatic emergency braking, adaptive cruise control, and so on, enabling more advanced automatic control functions.

Enhanced System Reliability: The electric assist braking system reduces reliance on traditional hydraulic systems and vacuum power pumps, thereby improving the reliability and durability of the entire braking system.

2. Working Principle of Brake Booster Motor

Conversion of Pedal Displacement to Electric Signal: When the driver presses the brake pedal, the displacement of the pedal is transmitted to the sensor of the brake booster motor through a lever mechanism. The sensor converts the pedal displacement into an electrical signal, which is proportional to the pedal displacement and reflects the magnitude of the braking force the driver intends to apply.

Signal Processing by the Control Unit: The electrical signal is transmitted to the control unit. The control unit calculates the required braking force based on the intensity of the electrical signal and activates the brake booster motor.

Motor Drives Pump Operation: The brake booster motor drives a pump to operate, which can be electronic or mechanical. The pump draws fluid from the reservoir to generate hydraulic pressure.

Hydraulic Pressure Amplification: The generated hydraulic pressure is transmitted to various parts of the braking system through the hydraulic system. The design of valves and pipelines in the hydraulic system can amplify the hydraulic pressure, thereby producing greater braking force than the driver's foot force.

Generation of Braking Force: The amplified hydraulic pressure pushes the brake calipers to clamp the brake discs or drums, generating braking force to decelerate or stop the wheels.

Feedback Control: In some advanced systems, the brake booster motor also includes a feedback mechanism. Sensors monitor the braking pressure in real time and feed the actual braking force back to the control unit. The control unit adjusts the motor's operating state according to the feedback signal to ensure the precision and consistency of the braking force.

Energy Recovery: In some hybrid or electric vehicles, the brake booster motor can also function as a generator to recover energy. When the driver releases the brake pedal, the motor operates as a generator, converting the kinetic energy during braking into electrical energy and storing it in the battery.

System Protection: The brake booster motor system also includes various protective mechanisms, such as overload protection and overheating protection, to ensure the safety and reliability of the system.

Maintenance and Diagnostics: The brake booster motor system can be inspected and maintained through the vehicle's diagnostic interface. Engineers can read various parameters, such as motor current and hydraulic pressure, to assess the working condition of the system. System Integration:The brake booster motor needs to be integrated with other vehicle systems, such as ABS and ESP. Through precise control strategies, various advanced braking functions, such as automatic parking and brake pre-charging, can be realized.

3. Advantages of the Brake Booster Motor

Precise Control: The electronic control unit can precisely adjust the braking force based on the driver's pedal pressure and the vehicle's driving conditions, ensuring the consistency and predictability of the braking force.

Rapid Response: The brake booster motor has a fast response time, providing braking assistance in a short period, reducing braking distance, and enhancing driving safety.

Reduced Driver Effort: By providing additional braking force, the brake booster motor reduces the driver's effort during emergency braking or long-term driving.

Environmentally Friendly: The electric system does not rely on hydraulic fluid, reducing environmental impact.

Compact Structure: The brake booster motor is small in size and light in weight, saving space and reducing weight for the entire vehicle.

Easy Maintenance: Compared to traditional hydraulic systems, the brake booster motor has a simple structure, making maintenance more convenient.

Energy Recovery: In certain hybrid or electric vehicles, the brake booster motor can also serve as a generator to recover braking energy, improving energy efficiency.

4. Disadvantages of the Brake Booster Motor

High Cost: The manufacturing cost of the brake booster motor is higher than that of traditional vacuum boosters.

Maintenance Complexity: The integration of electronic control units and sensors increases system complexity, potentially making repairs and diagnostics more difficult.

Dependence on Electronic Systems: The electric brake booster system relies on electronic signals and control units, which may increase points of failure.

Power Demand: The motor requires electricity to operate, potentially imposing an additional burden on the vehicle's battery system, especially in electric vehicles.

Thermal Management: The motor generates heat during operation, necessitating an effective thermal management system to prevent overheating, which may add to design and manufacturing costs.

Integration Challenges: Integrating the electric brake booster system with other vehicle systems may require more complex software and hardware design.

5. Application Fields of the Brake Booster Motor

Automotive Industry: Brake booster motors are widely used in various types of vehicles, such as passenger cars, commercial vehicles, and heavy trucks.

Electric Vehicles (EV): In EVs, brake booster motors combine with regenerative braking systems to improve energy recovery efficiency.

Hybrid Electric Vehicles (HEV): They utilize brake booster motors to recover energy during braking and provide auxiliary braking force.

Autonomous Vehicles: Autonomous driving technology requires precise and rapid braking force control, and the brake booster motor is a key component in achieving the goal.

Aviation Field: In some aviation applications, brake booster motors recover energy during braking and provide auxiliary braking force.

Industrial Automation: In the field of industrial automation, brake booster motors can be used to control and regulate the speed of robotic

Military and Defense: In the field, brake booster motors may be used to enhance the mobility and safety of vehicles.

Special Vehicles: For special vehicles such as fire trucks and ambulances, brake booster motors can provide rapid response braking force to handle emergencies.

Testing and Simulation: In the field of automotive testing and simulation, brake booster motors can be used to simulate various driving conditions and braking scenarios.

6. Requirements for Brake Booster Motor Manufacturing Equipment

As an important component of the automotive safety system, the brake booster motor has strict requirements for motor manufacturing equipment.

Precision Manufacturing: Each part of the motor requires high-precision manufacturing processes to ensure the performance and reliability of the motor. It usually involves precision mechanical processing equipment, such as CNC machines and precision grinders.

Automation: To improve production efficiency and reduce costs, the motor manufacturing process should use automated equipment as much as possible, such as automatic winding machines, automatic assembly lines, and automatic testing equipment.

Performance Testing: Motor manufacturing equipment should include devices for testing motor performance, such as endurance test benches, waterproof and dustproof test benches, noise test benches, and performance test benches, ensuring the motor works properly in various environments.

Material Selection: The selection of raw materials for the motor must meet specific standards and specifications to ensure the quality and performance of the motor. It includes the motor’s magnets, winding wires, and insulating materials.

Stator and Rotor Manufacturing: The stator and rotor of the motor are its core components, requiring specialized manufacturing equipment to ensure their precision and performance. It may include winding machines for the stator and dynamic balance testing machines for the rotor.

Environmental Adaptability: Motors need to operate over a wide temperature range, so manufacturing equipment should be able to produce motor products that can adapt to extreme temperature environments.

Safety: Ensure the safety of motor manufacturing equipment during operation, including motor fault diagnosis functions, overload protection, and personal safety mechanisms for operators.

The brake booster motor is a testament to the innovation and technological advancements in the automotive industry. As vehicles continue to evolve towards greater electrification and intelligence, the role of the brake booster motor will only grow in importance. It is not just a component of the braking system; it is a key enabler of safety, efficiency, and performance in the vehicles of today and tomorrow.