Blended Regenerative Anti-Lock Braking System and Electronic Wedge Brake Coordinate Control Ensuring Maximal Energy Recovery and Stability of All-Wheel-Motor-Drive Electric Vehicles

ABS is an active safety system which showed a valuable contribution to vehicle safety and stability since it was first introduced. Recently, EVs with in-wheel-motors have drawn increasing attention owing to their greatest advantages. Wheels torques are precisely and swiftly controlled thanks to electric motors and their advanced driving techniques. In this paper, a regenerative-ABS control RABS is proposed for all-in-wheel-motors-drive EVs. The RABS is realized as a pure electronic braking system called brake-by-wire. A coordination strategy is suggested to control RABS compromising three layers. First, wheels slip control takes place, and braking torque is calculated in the higher layer. In the coordinate interlayer, torque is allocated between actuators ensuring maximal energy recovery and vehicle stability. While in the lower layer, actuator control is performed. The RABS effectiveness is validated on a 3-DOF EVSimulink model through two straight-line braking manoeuvres with low and high initial speeds of 50 km/h and 150 km/h, respectively. Both regular and emergency braking manoeuvres are considered with ABS enabled and disabled for comparison. Simulation results showed the high performance of the proposed RABS control in terms of vehicle stability, brake response, stopping distance, and battery re-charging.

Development of a Low-cost Hardware-in-the-loop Simulation System as a Test Bench for Anti-lock Braking System

Nowadays validation of anti-lock braking systems（ABS） relies mainly on a large amount of road tests.An alternative means with higher efficiency is employing the hardware-in-the-loop simulation（HILS） system to substitute part of road tests for designing,testing,and tuning electronic control units（ECUs） of ABS.Most HILS systems for ABS use expensive digital signal processor hardware and special purpose software,and some fail-safe functions with regard to wheel speeds cannot be evaluated since artificial wheel speed signals are usually provided.In this paper,a low-cost ABS HILS test bench is developed and used for validating the anti-lock braking performance and tuning control parameters of ABS controllers.Another important merit of the proposed test bench is that it can comprehensively evaluate the fail-safe functions with regard to wheel speed signals since real tone rings and sensors are integrated in the bench.A 5-DOF vehicle model with consideration of longitudinal load transfer is used to calculate tire forces,wheel speeds and vehicle speed.Each of the four real-time wheel speed signal generators consists of a servo motor plus a ring gear,which has sufficient dynamic response ability to emulate the rapid changes of the wheel speeds under strict braking conditions of very slippery roads.The simulation of braking tests under different road adhesion coefficients using the HILS test bench is run,and results show that it can evaluate the anti-lock braking performance of ABS and partly the fail-safe functions.This HILS system can also be used in such applications as durability test,benchmarking and comparison between different ECUs.The test bench developed not only has a relatively low cost,but also can be used to validate the wheel speed-related ECU design and all its fail-safe functions,and a rapid testing and proving platform with a high efficiency for research and development of the automotive ABS is therefore provided.

New Method of Road Surface Identification in Anti-Lock Braking System

Based on the vehicle-road dynamic model, the road characteristic parameter, which depends on different types of road surfaces, is introduced and a new method of road surface identification for automotive anti-lock braking system (ABS) is proposed. According to the characteristics of vehicle-road dynamic model, a simple math resolution method of the model's factors is established. Only using the information of wheel speed, the vehicle reference velocity and the wheel slip ratio are estimated real-timely. And based on the wheel dynamic model, the road characteristic parameter is determined to identify the road surface for the determination of thresholds of ABS regulative parameters. With this new method, the road surface identification can be accurately obtained and calculation time is short that it can meet the ABS real time control need, and it also improves the performance of ABS.

Design and Analysis of Electro-mechanical Hybrid Anti-lock Braking System for Hybrid Electric Vehicle Utilizing Motor Regenerative Braking

Braking on low adhesion-coefficient roads, hybrid electric vehicle＇s motor regenerative torque is switched off to safeguard the normal anti-lock braking system （ABS） fimction. When the ABS control is terminated, the motor regenerative braking is readmitted. Aiming at avoiding permanent cycles from hydraulic anti-lock braking to motor regenerative braking, a novel electro-mechanical hybrid anti-lock braking system using fuzzy logic is designed. Different from the traditional single control structure, this system has a two-layered hierarchical structure, The first layer is responsible for harmonious adjustment or interaction between regenerative system and anti-lock braking system. The second layer is responsible for braking torque distribution and adjustment. The closed-loop simulation model is built. Control strategy and method for coordination between regenerative and anti-lock braking are developed. Simulation braking on low adhesion-coefficient roads with fuzzy logic control and real vehicle braking field test are presented. The results from simulating analysis and experiment show braking performance of the vehicle is perfect, harmonious coordination between regenerative and anti-lock braking function, significant amount of braking energy can be recovered and the proposed control strategy and method are effective.

The Development of a Fuzzy Predictive Control System for Automotive Anti-lock Braking System

This paper presents the model of one-tire kinetics、tires、the braking system and the model of control system.On virtual road,this paper builds a fuzzy predictive control system to insure the best attachment coefficient between tires and road. And it turns out to be that this fuzzy predictive control method has achieved good performances.

Integrated Active Suspension and Anti-Lock Braking Control for Four-Wheel-Independent-Drive Electric Vehicles

This paper presents an integrated control scheme for enhancing the ride comfort and handling performance of a four-wheel-independent-drive electric vehicle through the coordination of active suspension system(ASS)and anti-lock braking system(ABS).First,a longitudinal-vertical coupled vehicle dynamics model is established by integrating a road input model.Then the coupling mechanisms between longitudinal and vertical vehicle dynamics are analyzed.An ASS-ABS integrated control system is proposed,utilizing an H∞controller for ASS to optimize load transfer effect and a neural network sliding mode control for ABS implementation.Finally,the effectiveness of the proposed control scheme is evaluated through comprehensive tests conducted on a hardware-in-loop(HIL)test platform.The HIL test results demonstrate that the proposed control scheme can significantly improve the braking performance and ride comfort compared to conventional ABS control methods.

A numerical method for the simulation of freight train emergency braking operations based on the UIC braked weight percentage

The present paper shows the development of a strategy for the calculation of the air brake forces of European freight trains. The model is built to upgrade the existing Politecnico di Torino longitudinal train dynamics(LTD) code LTDPoliTo, which was originally unable to account for air brake forces. The proposed model uses an empirical exponential function to calculate the air brake forces during the simulation, while the maximum normal force on the brake friction elements is calculated according to the indication of the vehicle braked weight percentage.Hence, the model does not require to simulate in detail the fluid dynamics in the brake pipe nor to precisely know the main parameters of the braking system mounted on each vehicle. The model parameters are tuned to minimize the difference between the braking distance computed by the LTDPoliTo code and the value prescribed by the UIC544-1 leaflet in emergency braking operations. Simulations are run for different configurations of freight train compositions including a variable number of Shimmns wagons trailed by an E402B locomotive at the head of the train, as suggested in a reference literature paper. The results of the proposed method are in good agreement with the target braking distances calculated according to the international rules.

Copper-Free Resin-Based Braking Materials:A New Approach for Substituting Copper with Fly-Ash Cenospheres in Composites

Copper particles emitted from braking have become a significant source of environmental pollution.However,copper plays a crucial role in resin-based braking materials.Developing high-performance braking materials without copper has become a significant challenge.In this paper,the resin-based braking materials were filled with flyash cenospheres to develop copper-free braking materials.The effects of fly-ash cenospheres on the physical properties,mechanical and friction and wear properties of braking materials were studied.Furthermore,the wear mechanism of copper-free resin-based braking materials filled with fly-ash cenospheres was discussed.The results indicate that the inclusion of fly-ash cenospheres in the braking materials improved their thermal stability,hardness and impact strength,reduced their density,effectively increased the friction coefficient at medium and high temperatures,and enhanced the heat-fade resistance of the braking materials.The inclusion of fly-ash cenospheres contributed to the formation of surface friction film during the friction process of the braking materials,and facilitated the transition of form from abrasive wear to adhesive wear.At 100-350℃,the friction coefficient of the optimal formulation is in the range of 0.57-0.61,and the wear rate is in the range(0.29-0.65)×10^(-7) cm^(3)·N^(-1)·m^(-1),demonstrating excellent resistance to heat-fade and stability in friction coefficient.This research proposes the use of fly-ash cenospheres as a substitute for environmentally harmful and expensive copper in brake materials,which not only improves the performance of braking materials but also reduces their costs.

Thermal fatigue and wear of compacted graphite iron brake discs with various thermomechanical properties

The increase in payload capacity of trucks has heightened the demand for cost-effective yet high performance brake discs.In this work,the thermal fatigue and wear of compacted graphite iron brake discs were investigated,aiming to provide an experimental foundation for achieving a balance between their thermal and mechanical properties.Compacted graphite iron brake discs with different tensile strengths,macrohardnesses,specific heat capacities and thermal diffusion coefficients were produced by changing the proportion and strength of ferrite.The peak temperature,pressure load and friction coefficient of compacted graphite iron brake discs were analyzed through inertia friction tests.The morphology of thermal cracks and 3D profiles of the worn surfaces were also discussed.It is found that the thermal fatigue of compacted graphite iron discs is determined by their thermal properties.A compacted graphite iron with the highest specific heat capacity and thermal diffusion coefficient exhibits optimal thermal fatigue resistance.Oxidization of the matrix at low temperatures significantly weakens the function of alloy strengthening in hindering the propagation of thermal cracks.Despite the reduced hardness,increasing the ferrite proportion can mitigate wear loss resulting from low disc temperatures and the absence of abrasive wear.

Sustainable Biocomposites Materials for Automotive Brake Pad Application:An Overview

Research into converting waste into viable eco-friendly products has gained global concern.Using natural fibres and pulverized metallic waste becomes necessary to reduce noxious environmental emissions due to indiscriminately occupying the land.This study reviews the literature in the broad area of green composites in search of materials that can be used in automotive brake pads.Materials made by biocomposite,rather than fossil fuels,will be favoured.A database containing the tribo-mechanical performance of numerous potential components for the future green composite was established using the technical details of bio-polymers and natural reinforcements.The development of materials with diverse compositions and varying proportions is now conceivable,and these materials can be permanently connected in fully regulated processes.This explanation demonstrates that all of these variables affect friction coefficient,resistance to wear from friction and high temperatures,and the operating life of brake pads to varying degrees.In this study,renewable materials for the matrix and reinforcement are screened to determine which have sufficient strength,coefficient of friction,wear resistance properties,and reasonable costs,making them a feasible option for a green composite.The most significant,intriguing,and unusual materials used in manufacturing brake pads are gathered in this review,which also analyzes how they affect the tribological characteristics of the pads.

Numerical and Experimental Analysis of the Aerodynamic Torque for Axle-Mounted Train Brake Discs

As the velocity of a train increases,the corresponding air pumping power consumption of the brake discs increases proportionally.In the present experimental study,a standard axle-mounted brake disc with circumferential pillars was analyzed using a 1:1 scale model and a test rig in a wind tunnel.In particular,three upstream velocities were selected on the basis of earlier investigations of trains operating at 160,250,and 400 km/h,respectively.Moreover,3D steady computational fluid dynamics(CFD)simulations of the flow field were conducted to compare with the wind tunnel test outcomes.The results for a 3-car train at 180 km/h demonstrated:(1)good agreement between the air resistance torques obtained from the wind tunnel tests and the related numerical results,with differences ranging from 0.95%to 5.88%;(2)discrepancies ranging from 3.2 to 3.8 N·m;(3)cooling ribs contributing more than 60%of the air resistance torque;(4)the fast rotation of brake discs causing a significantly different flow field near the bogie area,resulting in 25 times more air pumping power loss than that obtained in the stationary brake-disc case.

Regenerative Braking Energy Recovery System of Metro Train Based on Dual-Mode Power Management

In order to fully utilize the regenerative braking energy of metro trains and stabilize the metro DC traction busbar voltage,a hybrid regenerative braking energy recovery system with a dual-mode power management strategy is proposed.Firstly,the construction of the hybrid regenerative braking energy recovery system is explained.Then,based on the power demand of low-voltage load in metro stations,a dual-mode power management strategy is proposed to allocate the reference power of each system according to the different working conditions,and the control methods of each system are set.Finally,the correctness and effectiveness of the dual-mode strategy are verified through simulation,and the proposed braking energy utilization scheme is compared with other singleform utilization schemes.The results illustrate that the hybrid system with the dual-mode strategy can effectively recycle the regenerative braking energy of metro train and inhibit the busbar voltage fluctuation;the proposed braking energy utilization scheme has certain advantages on energy recovery and DC bus voltage stabilization compared with other single-form schemes;the proposed power management strategy can correctly allocate the reference power of each system with a lower construction cost.

Dynamic Response Impact of Vehicle Braking on Simply Supported Beam Bridges with Corrugated Steel Webs Based on Vehicle-Bridge Coupled Vibration Analysis

A novel approach for analyzing coupled vibrations between vehicles and bridges is presented,taking into account spatiotemporal effects and mechanical phenomena resulting fromvehicle braking.Efficient modeling and solution of bridge vibrations induced by vehicle deceleration are realized using this method.The method’s validity and reliability are substantiated through numerical examples.A simply supported beam bridge with a corrugated steel web is taken as an example and the effects of parameters such as the initial vehicle speed,braking acceleration,braking location,and road surface roughness on the mid-span displacement and impact factor of the bridge are analyzed.The results show that vehicle braking significantly amplifies mid-span displacement and impact factor responses in comparison to uniform vehicular motion across the bridge.Notably,the influence of wheelto-bridge friction forces is of particular significance and cannot be overlooked.When the vehicle initiates braking near the middle of the span,both the mid-span displacement and impact factor of the bridge exhibit substantial increases,further escalating with higher braking acceleration.Under favorable road surface conditions,the midspan displacement and the impact factor during vehicle braking may exceed the design values stipulated by codes.It is important to note that road surface roughness exerts a more pronounced effect on the impact factor of the bridge in comparison to the effects of vehicle braking.

ISO releases a standard on braking systems of railway vehicles

ISO 24221:2024, Railway applications-Braking system-General requirements, the first of its kind, was recently released. With the leading efforts of National Railway Administration of China, China has made new breakthrough in railway international standardization by the development of the international standard.

Optimal allocation method of electric/air braking force of high-speed train considering axle load transfer

Reasonable distribution of braking force is a factor for a smooth,safe,and comfortable braking of trains.A dynamic optimal allocation strategy of electric-air braking force is proposed in this paper to solve the problem of the lack of consideration of adhesion difference of train wheelsets in the existing high-speed train electric-air braking force optimal allocation strategies.In this method,the braking strategy gives priority to the use of electric braking force.The force model of a single train in the braking process is analyzed to calculate the change of adhesion between the wheel and rail of each wheelset after axle load transfer,and then the adhesion of the train is estimated in real time.Next,with the goal of maximizing the total adhesion utilization ratio of trailer/motor vehicles,a linear programming distribution function is constructed.The proportional coefficient of adhesion utilization ratio of each train and the application upper limit of braking force in the function is updated according to the change time point of wheelset adhesion.Finally,the braking force is dynamically allocated.The simulation results of Matlab/Simulink show that the proposed algorithm not only uses the different adhesion limits of each trailer to reduce the total amount of braking force undertaken by the motor vehicle,but also considers the adhesion difference of each wheelset.The strategy can effectively reduce the risk and time of motor vehicles during the braking process and improve the stability of the train braking.

Virtually coupled train set control subject to space-time separation:A distributed economic MPC approach with emergency braking configuration

The emerging virtual coupling technology aims to operate multiple train units in a Virtually Coupled Train Set(VCTS)at a minimal but safe distance.To guarantee collision avoidance,the safety distance should be calculated using the state-of-the-art space-time separation principle that separates the Emergency Braking(EB)trajectories of two successive units during the whole EB process.In this case,the minimal safety distance is usually numerically calculated without an analytic formulation.Thus,the constrained VCTS control problem is hard to address with space-time separation,which is still a gap in the existing literature.To solve this problem,we propose a Distributed Economic Model Predictive Control(DEMPC)approach with computation efficiency and theoretical guarantee.Specifically,to alleviate the computation burden,we transform implicit safety constraints into explicitly linear ones,such that the optimal control problem in DEMPC is a quadratic programming problem that can be solved efficiently.For theoretical analysis,sufficient conditions are derived to guarantee the recursive feasibility and stability of DEMPC,employing compatibility constraints,tube techniques and terminal ingredient tuning.Moreover,we extend our approach with globally optimal and distributed online EB configuration methods to shorten the minimal distance among VCTS.Finally,experimental results demonstrate the performance and advantages of the proposed approaches.

Thermal analysis for brake disks of SiC/6061 Al alloy co-continuous composite for CRH3 during emergency braking considering airflow cooling

The mass of high-speed trains can be reduced using the brake disk prepared with SiC network ceramic frame reinforced 6061 aluminum alloy composite （SiCn/Al）. The thermal and stress analyses of SiCn/Al brake disk during emergency braking at a speed of 300 km/h considering airflow cooling were investigated using finite element （FE） and computational fluid dynamics （CFD） methods. All three modes of heat transfer （conduction, convection and radiation） were analyzed along with the design features of the brake assembly and their interfaces. The results suggested that the higher convection coefficients achieved with airflow cooling will not only reduce the maximum temperature in the braking but also reduce the thermal gradients, since heat will be removed faster from hotter parts of the disk. Airflow cooling should be effective to reduce the risk of hot spot formation and disc thermal distortion. The highest temperature after emergency braking was 461 °C and 359 °C without and with considering airflow cooling, respectively. The equivalent stress could reach 269 MPa and 164 MPa without and with considering airflow cooling, respectively. However, the maximum surface stress may exceed the material yield strength during an emergency braking, which may cause a plastic damage accumulation in a brake disk without cooling. The simulation results are consistent with the experimental results well.

Distribution and Dissipation of Braking Power of Wet Multidisc Brake

To study the distribution and dissipation of braking power of wet multidisc brake and determine thermal load and thermal flux distribution between mated discs, the concept of distributing brake power four times was put forward. The third and the fourth distribution of brake power were calculated by using finite element(FE) software ANSYS. The third and the fourth distribution of wet multidisc brake are mainly related to material characteristics of discs during emergency braking, while most of the braking power is carried off during continuous braking. Basis is provided for further analysis of disc failure and applicability of different friction materials.

Electronic Brake-Force Distribution Control Methods of ABS-Equipped Vehicles During Cornering Braking

Based on the dynamics of ABS-equipped vehicles during cornering braking, the electronic brake- force distribution （EBD） control methods of ABS-equipped vehicles during cornering braking are proposed. According to the dynamics and the tire model under tire adhesion limit, the stability acceptance criteria of vehicles during cornering braking are proposed. According to the stability acceptance criteria and the ABS control, the EBD control methods of ABS-equipped vehicles during cornering braking are implemented by adjusting the threshold values of tires slip independently. The vehicle states during cornering braking at two typical initial velocities of the vehicle are analyzed by the EBD control methods, whose results indicate the EBD control methods can improve the braking performances of the vehicle during cornering braking comparing with the ABS control.

An approach for simulating the air brake system of long freight trains based on fluid dynamics

Air brake systems are critical equipment for railway trains, which affects the running safety of the trains significantly. To study air braking characteristics of long freight trains, an approach for simulating air brake systems based on fuid dynamics theory was proposed. The structures and working mechanisms of locomotive and wagon air brakes are introduced, and mathematical models of the pipes, brake valves, reservoirs or chambers, cylinders, etc., are presented.Besides, the dynamic motions of parts in the main valve are considered. The simulation model of the whole air brake system is then formulated, and the solving method based on the finite-difference method is used. New efficient pipe boundary conditions without iterations are developed for brake pipes and branch pipes, which can achieve higher computational efficiency. The proposed approach for simulating the air brake system is validated by comparing with published measured data. Simulation results of different train formations indicate that models that consider the dynamic behavior of brake pipes are recommended for predicting the characteristics of long trains under service braking conditions.