Abstract:
An anti-lock braking system includes a moveable member to be braked and a friction brake for applying a braking force. A controller actuates the friction brake in accordance with braking force demands. Braking force demands are determined by the controller by electrical input signals received from a signal generator that is mechanically linked to the brake pedal, as well as by signals from a slip sensor. The slip sensor records values from wheel speed sensor and computes values that may indicate a slippage condition. Based on the recorded and computed values, the slip sensor and sends electric signals to the controller. The friction brake includes a prestressed piezoelectric element that is lightweight, less cumbersome, and highly controllable as compared with prior anti-lock braking devices, and is actuated via electrical signals rather than a mechanical system. A modification is disclosed in which an anti-lock system is placed on each wheel with independent slip sensors providing signals to controllers that control application of braking forces over each wheel as necessary.

Description:
This application is a Continuation-in-Part of application Ser. No. 08/834,233 filed Apr. 15, 1997, now abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of Invention 
     The present invention relates to anti-lock brake systems. More particularly, the present invention relates to brake systems (principally anti-locking automotive brake systems) in which a braking force is applied by an electrically actuated piezoelectric element. 
     2. Description of the Prior Art 
     Prior automobile braking systems typically comprise a toot pedal to which the driver applies a force, means for multiplying the foot pedal force, and means for transmitting this force to one or more stationary brake pads which press (either directly or indirectly) against the rotating wheel(s). When the brake friction pads press against the turning wheels (or, more specifically, against the brake drums or brake discs associated with the wheels), the rotation of the wheels slows down due to the friction between the brake friction pads and the wheels. The amount of braking friction at each wheel is typically proportional to the force each brake friction pad applies to the respective wheels. 
     In the prior art, transmission of the (multiplied) foot pedal forces to the brake pads is typically accomplished by mechanical means. Such prior systems include hydraulic, pneumatic, lever-action, and other power transmission systems, as well as combinations of such mechanisms. 
     A problem with prior mechanical foot pedal-to-brake pad force transmission systems is that they are subject to wearing out (particularly at linkage connections, at seals, and at other areas where parts move against each other). Another problem with prior mechanical foot pedal-to-brake pad force transmission systems comprising hydraulic or pneumatic lines, is that they are susceptible to failure by leaking hydraulic fluid or air. Another problem with prior mechanical foot pedal-to-brake pad force transmission systems comprising hydraulic or pneumatic lines is that they are relatively expensive, heavy, cumbersome, and take up a lot of space. 
     When an automobile driver applies pressure to the brake pedal in a vehicle initially moving at a uniform rate of speed, the wheels tend to slow down relative to the ground. As the brake pressure applied is increased, the braking forces on the vehicle increase in response to the driver&#39;s commands. The braking forces on the vehicle will continue to increase with increased brake pedal pressure until the maximum braking capability of the particular tire and road surface is reached. Upon further application of the brake input, the rotational speed of a wheel becomes lower than the vehicle speed, and “slippage” occurs between the tire and the driving surface. This slippage, when severe, can lead to lock-up of a wheel and skidding of the vehicle. When wheel slip occurs between the wheel and the road surface, the ability of the vehicle to follow driver&#39;s commands is reduced, and the braking distance is considerably increased. 
     Anti-lock Braking Systems have been proposed to minimize or eliminate slippage between the wheel and the road surface. Anti-lock Braking Systems (ABS) are feedback control systems that attempt to maintain controlled braking under all operating conditions. This is typically accomplished by prior braking systems by controlling the slip at each wheel so as to obtain optimum braking forces within the limits of the tire-road combination. 
     Although various ABS schemes have been proposed in the prior art, virtually all prior ABS designs use the same fundamental elements, namely: a foot pedal which is operated by the vehicle&#39;s driver; a booster/master cylinder/modulator which increases the braking force deliverable to the wheels; mechanical (hydraulic or pneumatic) transmission lines; a wheel speed sensor; control circuitry to automatically adjust the braking force in response to the signals from the wheel speed sensor; and wheel brakes. 
     In ABS systems, signals from the wheel speed sensor are sent to control circuitry which determines from these signals whether tire/road slippage is imminent (or has occurred). The control circuitry then sends an electrical signal to the booster/master cylinder/modulator, which typically causes a mechanical valve to open within the booster/master cylinder/modulator, thereby reducing pressure in the mechanical (hydraulic or pneumatic) transmission lines. The reduction of pressure in the transmission lines causes each of the wheel brakes connected thereto to release from engagement with the respective wheels. 
     One method by which a wheel slip condition is identified in an ABS system is by comparing the speed of each wheel (as measured by the wheel speed sensor) to a reference speed (either a standard value or a measured value). The reference speed is an estimate of the true vehicle speed based on current and previous measured values of the individual wheel speeds. If the speed of a wheel is significantly less than the reference speed, then the wheel is deemed by the control circuitry to be excessively slipping. The control circuitry then reduces the pressure at the master cylinder/booster/modulator actuating the brake in order to reduce brake torque. The reduction of brake torque causes a reduction of the braking force, which then causes a reduction of the slip in the wheel. After a period of constant braking pressure following the pressure reduction, the pressure actuating the brake is increased until wheel slip occurs again. The cycle of decreasing the brake pressure, maintaining constant brake pressure, and then increasing brake pressure is repeated until excessive slip no longer occurs. 
     In other ABS systems, determination of the slip condition is based on the sensed peripheral speed of the wheel, and the computed acceleration or deceleration of the wheel. Acceleration and deceleration (with a negative value) are derivatives of the velocity of the wheel that are computed by the control circuitry. Based on the changing curve of the peripheral speed of the wheel, a velocity the vehicle body is also obtained (computed). From the velocity of the vehicle body and the peripheral velocity of the wheel the slip ratio is calculated. From the wheel acceleration (or deceleration) and the slip ratio, the control circuitry determines whether the state of the vehicle corresponds to a condition of excessive slipping (or in a state of slip recovery). In other words, when the wheel slip ratio exceeds a certain fixed (previously computed) value or when wheel acceleration (wheel speed) decreases beyond a certain fixed value, the control circuitry reduces brake pressure. 
     The control circuitry also determines when there is a state of recovery from slippage. When the wheel slip ratio decreases beyond a certain fixed value and wheel acceleration (wheel speed) acquires a tendency to increase brake pressure is increased. Thus, when the control circuitry determines that tire/road slippage is no longer imminent, the same electrical-mechanical control circuitry causes the full pressure in the mechanical transmission lines to recover (corresponding to the amount of displacement of the foot pedal) and the brakes to re-engage. In prior ABS designs this described sensing and engagement-disengagement sequence of the wheels brakes typically takes place many times per second. 
     All of the problems discussed above with respect to prior automobile braking systems also apply to prior ABS designs. 
     Another problem with prior ABS designs is that, due to the time delay between electrical signal input from the controller to the booster/master cylinder/modulator and the actual engagement or disengagement of the wheel brake from the wheel, the efficiency and precision of the ABS system (and therefore the degree of control afforded the vehicle&#39;s driver) are each inherently limited. 
     Another problem with prior ABS designs is that because the controller-generated electrical signal causes mechanical transmission line pressure changes which affect at least two (and in most cases four) wheels, it is not usually possible or practical to individually and independently control the braking at each wheel. 
     SUMMARY OF THE INVENTION 
     Accordingly, it is a primary object of the present invention to provide a braking system, adapted for use on automotive wheels and similar applications, in which brake pad motion is effected by electrical actuators positioned in close proximity to each individual wheel. 
     It is another object of the present invention to provide a braking system of the character described in which the electrical actuators comprise piezoelectric elements. 
     It is another object of the present invention to provide a braking system of the character described in which the pressure applied by the brake pad to the wheel varies in accordance with voltage, frequency, and/or current applied to the piezoelectric element(s). 
     It is another object of the present invention to provide a braking system of the character described in which the electric signal to the piezoelectric element(s) varies in accordance with brake pedal displacement. 
     It is another object of the present invention to provide a braking system of the character described in which brake pad motion is responsive to a signal communicated to the piezoelectric element by electric transmission lines, and which is therefore, relatively less expensive, heavy, cumbersome and space consuming than mechanical transmission lines, is not subject to frictional wear, and is not subject to leaking hydraulic fluid or air. 
     It is another object of the present invention to provide a braking system of the character described which is provided with an anti-lock braking sensor and controller, wherein the piezoelectric element is in electrical communication with the controller, such that deformation of the piezoelectric element (and therefore the amount of pressure applied by the brake pad) is controllable by electric input to the piezoelectric element by the controller. 
     It is another object of the present invention to provide a braking system of the character described in which there is little or no time delay between electrical signal generation by the controller and actual engagement or disengagement of the brake pad with the wheel. 
     It is another object of the present invention to provide a braking system of the character described in which the anti-locking of individual wheels of a multi-wheel automobile is independently controlled at each wheel. 
     Further objects and advantages of my invention will become apparent from a consideration of the drawings and ensuing description thereof. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a schematic view showing a brake system constructed in accordance with the present invention; and 
     FIG. 2 is a schematic view of a brake system similar to FIG. 1, showing the brake pad in the actuated position; 
     FIG. 3 is a schematic view of a brake system constructed in accordance with the present invention, showing independent antilock wheel control for two wheels; and 
     FIG. 4 is an elevation of a piezoelectric actuator and friction braking means of the present invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     As illustrated in the accompanying figures, an anti-lock braking system has a foot pedal  10  which is connected via a mechanical link  12  to an electric signal generator  9 . The electric signal generator  9  is in communication with an electric controller  11  via electric conductor  8 . The electric signal generator  9  produces a variable electric signal output (at conductor  8 ) corresponding to the positioning of a slider mechanism  15  (or the equivalent) associated with the foot pedal  10  and the controller  11 . Based upon the electric signal output (conductor  8 ) of the electric signal generator  9 , the controller  11  produces a corresponding electric signal which it communicates to piezoelectric actuators  6  via electric conductors  7 . 
     Referring to FIG.  4 : The piezoelectric actuators  6  preferably comprise unimorph piezoelectric elements. The unimorph piezoelectric elements comprise a piezoelectric ceramic layer having opposing major faces. On one major face of the piezoelectric ceramic layer is bonded a pre-stress layer. The pre-stress layer normally applies a compressive force to the piezoelectric ceramic layer in a longitudinal direction parallel to the major faces of the piezoelectric ceramic layer. A piezoelectric actuator  6  thus constructed has a normally arcuate shape as illustrated in FIGS. 1-4. The piezoelectric actuator  6  is a flextensional piezoelectric transducer. Various constructions of flextensional piezoelectric actuators  6  may be used (including, for example, “moonies”, “rainbows”, and other unimorph, bimorph, multimorph or monomorph devices, as disclosed in U.S. Pat. No. 5,471,721), but the piezoelectric actuator  6  preferably comprises a Thin Layer Unimorph Driver and Sensor (“THUNDER™”) actuator constructed in accordance with the following description. 
     THUNDER™ piezoelectric actuators  6  are composite structures as illustrated in FIG.  4 . Each THUNDER™ piezoelectric actuator  6  is preferably constructed with a PZT piezoelectric ceramic layer  67  which is electroplated  65  and  65   a  on its two opposing faces. A steel, stainless steel, beryllium alloy or other metal first pre-stress layer  64  is adhered to the electroplated  65  surface on one side of the ceramic layer  67  by a first adhesive layer  66 . The first adhesive layer  66  is preferably LaRC™-SI material, as developed by NASA-Langley Research Center and commercially marketed by IMITEC, Inc. of Schenectady, N.Y. A second adhesive layer  66   a , also preferably comprising LaRC™-SI material, is adhered to the opposite side of the ceramic layer  67 . 
     During manufacture of the THUNDER™ piezoelectric actuator  6  the ceramic layer  67 , the adhesive layers  66  and  66   a  and the first pre-stress layer  64  are simultaneously heated to a temperature above the melting point of the adhesive material, and then subsequently allowed to cool, thereby re-solidifying and setting the adhesive layers  66  and  66   a . During the cooling process the ceramic layer  67  becomes compressively stressed, due to the higher coefficient of thermal contraction of the material of the pre-stress layer  64  than for the material of the ceramic layer  67 . 
     Also, due to the greater thermal contraction of the laminate materials (e.g. the first pre-stress layer  64  and the first adhesive layer  66 ) on one side of the ceramic layer  67  relative to the thermal contraction of the laminate material(s) (e.g. the second adhesive layer  66   a ) on the other side of the ceramic layer  67 , the ceramic layer deforms in an arcuate shape having a normally concave face  6   b  and a normally convex face  6   c , as illustrated in FIG.  4 . One or more additional pre-stressing layer(s)  64   a  may be similarly adhered to either or both sides of the ceramic layer  67  in order, for example, to increase the stress in the ceramic layer  67  or to strengthen the piezoelectric actuator  6 . 
     Electrical energy is introduced to the piezoelectric actuator by a conductors  7  attached to opposite sides of the piezoelectric actuator  6  in communication with the electroplated  65  and  65   a  faces of the ceramic layer  67 . As discussed above, the pre-stress layers  64  and  64   a  are preferably adhered to the ceramic layer  67  by LaRC™-SI material. The wires  7  may be connected (for example by glue or solder  69 ) directly to the electroplated  65  and  65   a  faces of the ceramic layer  67 , or they may alternatively be connected to the pre-stress layers  64  and  64   a . LaRC™-SI is a dielectric. When the conductors  7  are connected to the pre-stress layers  64  and  64   a , it is desirable to roughen a face of each pre-stress layer  64  and  64   a , so that the pre-stress layers  64  and  64   a  intermittently penetrate the respective adhesive layers  66  and  66   a , and make electrical contact with the respective electroplated  65  and  65   a  faces of the ceramic layer  67 . 
     When the piezoelectric actuator  6  is energized by an electric field (via electric conductors  7 ), it principally deforms in one direction (in the direction of arrows  13 ) in a direction perpendicular to its major faces  6   b  and  6   c  (becoming more arcuate) as illustrated in FIGS. 2 and 3. When the electric field is decreased or removed, the piezoelectric actuator relaxes, becoming less arcuate or returning to its normal arcuate shape, as shown in FIG.  1 . 
     In the preferred embodiment of the invention, two piezoelectric actuators  6  are each mounted on a rigid frame  4  and are aligned along a common axis on opposite sides of a moveable brake disc  3 . Preferably, the axis of deformation of the piezoelectric actuator  6  is perpendicular to the planar surfaces  3   a  of the brake disc  3 . Brake pads  5  are preferably mounted on the faces  6   c  of the piezoelectric actuators  6  that face the brake disc faces  3   a.    
     Under normal braking operations, when the foot pedal  10  is depressed (as indicated at arrow  14 ) the mechanical link  12  displaces the slider mechanism  15 , which causes the electric signal generator  9  to produce an electric output signal. This electrical output signal is transmitted to the controller  11  via conductor  8 . The controller  11  produces an output electric signal, the character of which (e.g. voltage, power, and/or frequency, etc.) depends upon the amount of foot pedal  10  displacement, and communicates that (or a corresponding) electric signal to the piezoelectric actuators  6  via electric conductors  7 . Depending upon the character (e.g. voltage, power, frequency, etc.) of the electric signal which is received by the piezoelectric actuator  6  (via conductor  7 ) from the controller  11 , the piezoelectric element will axially deform as indicated by arrows  13  so as to press brake pads  5  against the brake disc  3 , thereby applying a braking force to the (rotatable) brake disc  3 . 
     When the (spring loaded) foot pedal  10  is released, the electric signal produced by the electric signal generator  9  changes, which causes the electric signal output from the controller  11  to cease (or diminish), which causes the piezoelectric actuators  6  to relax, thus relieving brake pad  5  pressure against the brake disc  3 . 
     As shown in the figures, the braking system may be provided with anti-locking (or “anti-skidding”) control elements. In addition to receiving electric signal input (via conductor  8 ) from the electric signal generator  9  (indicative of the positioning of the brake pedal  10 ), the controller  11  may also be in communication (via electric conductor  20 ) with a slip sensor  21 . The slip sensor  21  receives electrical signals (via electric conductor  2 ) from the wheel speed sensor  1 . The wheel speed sensor  1  sends an electric signal (via conductor  2 ) to the slip sensor  21  corresponding to the sensed rotational (peripheral) speed of the wheel. From the sensed peripheral wheel speed, the slip sensor  21  computes acceleration and deceleration, as well as the vehicle body speed. The slip sensor  21  also compares the sensed peripheral wheel speed to the computed vehicle body speed and acceleration (deceleration) to determine if a slip condition is imminent (or exists). 
     When the slip sensor  21  receives electric signals from the wheel speed sensor  1  (via conductor  2 ) the slip sensor  21  records the peripheral wheel speed and computes the vehicle body speed and/or wheel acceleration. Based upon a comparison of recorded and computed values, the slip sensor  21  determines whether the values are indicative of incipient wheel slippage. If the slip sensor  21  determines that wheel-road slippage is imminent (or exists), the slip sensor  21  sends an electric signal (via conductor  20 ) to the controller  11 . In response to the electric signal from the slip sensor  21 , the controller  11  varies (i.e. reduces) the electric signal which it sends (via conductor  7 ) to the piezoelectric actuators  6 . The reduced electric signal, in turn, causes the piezoelectric elements to relax, thereby reducing (or releasing) pressure of the brake pads  5  against the brake disc  3  and allowing the brake disc  5  and the wheel (not shown) to freely rotate without wheel-road slippage. 
     When the wheel begins freely rotating, the wheel speed sensor  1  again sends electric signals to the slip sensor  21  which records the peripheral wheel speed and computes the values for acceleration and vehicle body speed. Based on a comparison of these values, the slip sensor  21  may determine that wheel-road slippage is no longer imminent, and the slip sensor  21  will send an electric signal to the controller  11  indicative of there being no slip condition. In response to the electric signal from the slip sensor  21 , the controller  11  adjusts the electric signal it sends to the piezoelectric actuators  6  (via electric conductor  7 ) accordingly. The piezoelectric actuators  6  will again deform and apply braking pressure in accordance with the positioning of the foot pedal  10 . If, however, the slip sensor  21  again senses incipient wheel-road slippage, it will again cause the controller  11  to vary its signal (via conductor  20 ), again causing the brake pads  5  to disengage (temporarily) from the brake disc  3 . 
     It will be understood that in an anti-locking braking system constructed in accordance with the present invention the described engagement-disengagement cycling of the brake pads  5  and the brake disc  3  can occur many times per second. It will further be understood that brake pad application or release is accomplished by the controlled deformation of the piezoelectric actuators  6 , which are directly responsive to electric signals corresponding to foot pedal positioning, measured wheel speed and values computed by the slip sensor  21  on the basis of wheel speed which indicate a slip condition. Accordingly, it will be understood that there is virtually no time delay between foot pedal displacement and brake pad displacement, or between incipient wheel-road slippage detection and brake pad displacement. 
     It will also be understood that an anti-lock braking system constructed in accordance with the present invention does not require the use of either hydraulic or pneumatic transmission lines, and therefore is not susceptible to hydraulic fluid or air leaks. 
     FIG. 3 illustrates a braking system constructed in accordance with the present invention in which each of a plurality of wheels (not shown) is provided with independent anti-locking control. This modification of the invention operates the same as the embodiment described above, except the output electric signal (i.e. via conductor  8 ) is communicated simultaneously to two controllers  11  and  11   a,  each of which controls (via electric conductors  7  and  7   a , respectively) the operation the piezoelectric actuators ( 6  and  6   a , respectively) to which it is electrically connected. It will be understood that in a multiple-wheel braking system constructed in accordance with this modification of the invention, each wheel is provided with independent anti-lock control (i.e., wheel speed sensors  1  and  1   a,  slip sensors  21  and  21   a  and controllers  11  and  11   a ) while being responsive to a single brake foot pedal input. 
     The foregoing describes the application of the present invention in automobiles. However, the present invention has application to many fields other than to automobile wheel braking in particular and to automobiles generally. It will be understood that a braking system constructed in accordance with the foregoing disclosure may be used to in conjunction with any form of moving machinery, regardless of whether the moving element to be braked moves linearly, angularly or otherwise relative to the braking element (e.g. the brake pad  5 ). In addition, the foregoing describes an embodiment of the invention wherein piezoelectric braking elements are configured to operate in opposing fashion against a rotatable brake disc  3 . However, it is also understood that the present invention, (particularly the piezoelectric actuators  6  and the brake pads  5 ) can alternatively be configured to operate against the inside of a rotatable brake drum. 
     While the above description contains many specificities, these should not be construed as limitations on the scope of the invention, but rather as an exemplification of one preferred embodiment thereof. Many other variations are possible, for example: 
     A piezoelectrically actuated braking system may be constructed in a modification of the present invention without anti-locking controls by omitting the wheel speed sensor, slip sensor and/or the controller; 
     The piezoelectric elements (i.e. the actuators) may be in the shape of toroids, and the shaft (axle) of the braked wheel may pass through a central hole in the piezoelectric element; 
     The brake pad member  5  may be omitted such that the piezoelectric element  6  applies pressure directly to a brake disc  3 , a brake drum, or an equivalent moving component; 
     The piezoelectric actuator  6  may apply pressure directly to a brake pad  5 , brake “shoe” or the equivalent, or it may apply pressure to a force multiplying mechanism (eg. piston, lever, etc.) which, in turn, applies pressure to a brake pad  5 , brake “shoe” or the equivalent; 
     The piezoelectric actuator  6  may comprise multiple piezoelectric elements working in concert; 
     Inasmuch as the disclosed braking system can be used in applications other than automotive, the originating braking signal may be produced by an operator other than by a foot pedal  10 , including both mechanical and electrical, and digital and analog, switching devices; 
     A modified embodiment of the present invention may be constructed in which the electric signal generator  9  and the electric conductor  8  are replaced by a mechanical (rather than electrical) energy transmission system, such that an input ( 8 ) to the controller  11  is mechanical in nature rather than electrical; 
     The piezoelectric actuator may be biased such that braking pressure is applied only when the piezoelectric element is electrically excited; or, alternatively, it may be biased such that braking pressure is normally applied, and releases only when the piezoelectric element is electrically excited. 
     The multiple-controller  11  and  11   a  arrangement shown in FIG. 3 may be replaced with a single controller having multiple inputs and outputs; 
     The output signal  7  from a single controller  11  may be transmitted to one or more piezoelectric actuators  6  which may brake one or more brake discs, brake drums, or their equivalents; 
     The electric signal generator  9  may be a piezoelectric device which generates variable electric signal outputs  8  corresponding the displacement of pressure applied to the foot pedal  10  (or equivalent device).