Abstract: The invention provides an electric brake system and method. The electric brake system includes an electric motor having a portion moveable along a path between a plurality of positions for moving a brake pad and applying a selectable amount of braking force on a brake rotor. One of the plurality of positions is a minimal contact position. The minimal contact position is operable to change among the plurality of positions over time. The electric brake system also includes an electric controller for controlling the electric motor to move the portion along the path between the minimal contact position and at least one other of the plurality of positions for moving the brake pad and for selecting the amount of braking force. The electric brake system also includes at least one sensor for sensing at least one of motor current, motor acceleration, controller voltage, motor speed, motor voltage, and motor temperature, and communicating a sensed condition to the controller.

Abstract: A ball screw and nut assembly includes a ball screw component having a threaded outer surface and a ball nut component having a bore in which the ball screw component is received. The ball nut component includes a threaded inner surface that cooperates with the threaded outer surface of the ball screw component to achieve axial movement of the ball nut component between a fully retracted position and a fully extended position as the ball screw rotates relative to the ball nut. A positive stop prevents rotation of the ball screw component relative to the ball nut component at an axial position between the fully retracted position and the fully extended position as the ball nut component is retracted.

Abstract: A method of initializing a brake-by-wire system is provided. The method includes connecting multiple braking actuators to a controller to allow for communication between the braking actuators and the controller. The braking actuators are associated with one or more wheels of a vehicle. Subsequent to connecting the multiple braking actuators to a controller, the method includes dynamically assigning a primary identifier to the braking actuators using the controller.

Abstract: A parking brake system including at least one braking unit actuated by at least one cable, a cylinder having a piston chamber and a rod chamber, a piston slidably received within the cylinder and having a rod connected thereto, the rod extending through the rod chamber and operably connected to the cable, a pressurized fluid source connected to the piston chamber, and a valve for controlling the flow of the fluid to the piston chamber, wherein the piston and rod move through the cylinder when the fluid pressurizes the piston chamber, thereby actuating the braking unit.

Abstract: A method for balancing brake force is disclosed. The method includes determining whether a deceleration value reaches a first deceleration threshold in response to a braking event and determining brake condition and vehicle motion. Based on brake condition and vehicle motion determination and the first deceleration threshold determination, the method determines whether the deceleration value reaches a second deceleration threshold, and applies threshold balancing when the second deceleration threshold is reached.

Abstract: A shape memory alloy actuator includes a housing, a plunger, a shaft, a resilient member, and a shape memory alloy component. The plunger is slidably but non-rotatably received in the housing and has a first locking component. The shaft has a second locking component. The resilient member is positioned to slidably urge the plunger into a disengagement position of the first and second locking components allowing rotation of the shaft. The shape memory alloy component is positioned to slidably urge the plunger into an engagement position of the first and second locking components, when the shape memory alloy component is heated, preventing rotation of the shaft. In one application, the first and second locking components are interdigitable vehicle-parking-brake latch teeth.