Design and Optimization of a Novel Electronic Mechanical Brake Actuator Based on Cam

The electronic mechanical brake (EMB) is considered an ideal actuator for brake-by-wire systems. We applied the negative radius roller cam mechanism as the clamping mechanism of the EMB, solving the problem of large size, poor load-bearing capacity, and the inefficiency of the existing EMBs. When designing a cam as a clamping transmission mechanism, it is necessary to take the pressure angle, contact stress, motion law, etc., as goals and constraints. Existing design methods cannot easily solve this problem. Therefore, we propose a new analysis method from the cam profile and combine it with an improved particle swarm optimization (PSO) algorithm to design the cam profiles. This method can handle various complex goals and constraints of the EMB and obtain the required negative radius roller cam profile. Finally, the logical consistency of the profile-based analysis method was verified, and the EMB design objectives and accuracy were compared using ADAMS. Under the same conditions, the result showed that the optimized cam mechanism requires only 40.52% motor power and only 65.65% clearance elimination time compared to the EMB with the lead screw mechanism.