Sensorless clamping force estimation and control for electro-mechanical brakes using fusion-data-based kissing point detection and stiffness-based displacement compensation

To address the issues of insufficient clamping force estimation accuracy and poor control stability in electro-mechanical brake (EMB) systems, this paper proposes a sensorless clamping force estimation and control method based on fusion-data-based kissing point detection. By integrating motor current and position signals, the method accurately identifies the kissing point and estimates the clamping force without additional sensors. Furthermore, displacement compensation mechanism is introduced to enhance estimation precision by accounting for kissing point detection errors and mechanical backlash. The proposed control framework employs a three-stage intelligent control architecture, including gap elimination, clamping force regulation, and motor return, with a smooth transition strategy to ensure stability. Simulation and experimental results demonstrate that the method achieves high precision, with the Root Mean Square Error (RMSE) of the estimated clamping force reduced to 0.5 kN, and the overall control error maintained within 10%. The integration of kissing point detection and stiffness compensation ensures high precision and robustness, making the approach suitable for practical EMB systems.