Nowadays, hydraulic brakes are already being replaced by electromechanical brakes (EMB) to improve quick-response brakes, efficient fuel consumption, environmentally sound, simple maintenance, and enhanced safety design. It is suggested that the electromechanical brake will be one of the most important brake systems in the future. This study focuses on designing and implementing an electromechanical brake based on a brushless DC (BLDC) motor and position controller to generate and control the required braking force at a variable friction coefficient between disc and pad. A feedback controller equipped with a measuring sensor is usually utilized to control this type of brake. Thus, three controllers for current, speed, and position were implemented in successive loops to control the motor movement. This system has current, speed, and force sensors. Due to implementation difficulties and cost issues of braking, the clamping sensor should be replaced with a position sensor with some modification where a position controller has been designed and implemented. The results showed that the clamping force of the brake system can follow the target accurately and it has good performance. Also, it is shown that this system can adjust the brake force more accurately and quickly compared with the traditional.
- Pad wear result is affected by the nature of calculating the coefficient of friction.
- The dissipated heat due radiation has small effect on the total heat loss and the wear.
- The EMB braking force path changes dramatically when including the pad wear.