Hybrid Model Predictive and PI Control for Enhanced Performance of a Self-Locking Dual-Side Wedge Brake

Brake-by-wire (BBW) systems face challenges such as structural complexity, high energy consumption, and control inaccuracies induced by nonlinear factors. This study develops a novel self-locking dual-side synchronously clamping electronic wedge brake (EWB) system as an advanced BBW architecture. This novel design consists of a single screw with opposite-handed threads to drive the wedge mechanism bidirectionally, leveraging the self-energizing effect and the self-interlocking effect to significantly reduce energy consumption while achieving hydraulic-free synchronous braking. Additionally, the inherent precise displacement control of the screw transmission offers a simplified solution for air gap management. A multi-domain coupled model integrating mechanical dynamics and control algorithms is developed based on the proposed architecture, with finite element analysis (FEA) validating the mechanical strength and thermal degradation resistance of key components under extreme conditions. A hybrid control algorithm combining model predictive current control (MPCC) and a PI controller is developed. Compared with the active disturbance rejection control (ADRC), the proposed method achieves a 55% improvement in dynamic response and a $69.1$% reduction in steady-state error. The vehicle braking performance is validated through a CarSim–Simulink co-simulation, while the rapid dynamic response and precise clamping force control of the key actuator are verified via bench testing, demonstrating the effectiveness of the proposed EWB system architecture and its control strategy, thereby laying a solid theoretical foundation for its future industrial implementation.