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.

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.

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.

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.

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.

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.

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.

Energy model based sensorless estimation method for operational temperature of braking resistor onboard metro vehicles

Purpose–This study aims to improve the availability of regenerative braking for urban metro vehicles by introducing a sensorless operational temperature estimation method for the braking resistor(BR)onboard the vehicle,which overcomes the vulnerability of having conventional temperature sensor.Design/methodology/approach–In this study,the energy model based sensorless estimation method is developed.By analyzing the structure and the convection dissipation process of the BR onboard the vehicle,the energy-based operational temperature model of the BR and its cooling domain is established.By adopting Newton’s law of cooling and the law of conservation of energy,the energy and temperature dynamic of the BR can be stated.To minimize the use of all kinds of sensors(including both thermal and electrical),a novel regenerative braking power calculation method is proposed,which involves only the voltage of DC traction network and the duty cycle of the chopping circuit;both of them are available for the traction control unit(TCU)of the vehicle.By utilizing a real-time iterative calculation and updating the parameter of the energy model,the operational temperature of the BR can be obtained and monitored in a sensorless manner.Findings–In this study,a sensorless estimation/monitoring method of the operational temperature of BR is proposed.The results show that it is possible to utilize the existing electrical sensors that is mandatory for the traction unit’s operation to estimate the operational temperature of BR,instead of adding dedicated thermal sensors.The results also validate the effectiveness of the proposal is acceptable for the engineering practical.Originality/value–The proposal of this study provides novel concepts for the sensorless operational temperature monitoring of BR onboard rolling stocks.The proposed method only involves quasi-global electrical variable and the internal control signal within the TCU.

The effect of controllable train-tail devices on the longitudinal impulse of the combined trains under initial braking

The 20,000-ton combined train running has greatly promoted China’s heavy-haul railway transportation capability. The application of controllable train-tail devices could improve the braking wave of the train and braking synchronism, and alleviate longitudinal impulse.However, the characteristics of the controllable train-tail device such as exhaust area, exhaust duration and exhaust action time are not uniform in practice, and their effects on the longitudinal impulse of the train are not apparent,which is worth studying. In this work, according to the formation of the Datong-Qinhuangdao Railway, the train air brake and longitudinal dynamics simulation system(TABLDSS) is applied to establish a 20,000-ton combined train model with the controllable train-tail device, and the braking characteristics and the longitudinal impulse of the train are calculated synchronously with changing the air exhaust time, exhaust area, and action lag time under initial braking. The results show that the maximum coupler force of the combined train will decrease with the extension of the continuous exhaust time, while the total exhaust time of the controllable train-tail device remains unchanged;the maximum coupler force of the combined train reduces by32.5% with the exhaust area increasing from 70% to 140%;when the lag time between the controllable train-tail device and the master locomotive is more than 1.5 s, the maximum coupler force of the train increases along with the time difference enlargement.

Braking distance prediction for vehicle consist in low-speed on-sight operation:a Monte Carlo approach

The first and last mile of a railway journey, in both freight and transit applications, constitutes a high effort and is either non-productive(e.g. in the case of depot operations) or highly inefficient(e.g. in industrial railways). These parts are typically managed on-sight, i.e. with no signalling and train protection systems ensuring the freedom of movement. This is possible due to the rather short braking distances of individual vehicles and shunting consists. The present article analyses the braking behaviour of such shunting units. For this purpose, a dedicated model is developed. It is calibrated on published results of brake tests and validated against a high-definition model for lowspeed applications. Based on this model, multiple simulations are executed to obtain a Monte Carlo simulation of the resulting braking distances. Based on the distribution properties and established safety levels, the risk of exceeding certain braking distances is evaluated and maximum braking distances are derived. Together with certain parameters of the system, these can serve in the design and safety assessment of driver assistance systems and automation of these processes.

Simulation and Experimental Design of Load Adaptive Braking System on Two Wheeler

The braking quality is considered the main execution of the adaptive control framework that impacts the vehicle safety and rides solace astoundingly notably the stopping distance.This research work aims to create a pattern and design of an electromechanically adjusted lever that multiplies the applied braking force depending on the inputs given by the sensors to reduce the stopping distance of the vehicle.It is carried out using two main parts of the two-wheeler vehicle:thefirst part deals with the detection of load acting on the vehicle and identifying the required braking force to be applied,and the second part deals with the micro-controller which activates the stepper motor for varying the mechanical leverage ratio from various loads on the vehicle using two actively movable wedges.The electromechanically operated variable braking force system is developed to actuate the braking system based on the load on the motorcycle.The MATLAB simulation and experimental work are carried out for various loading(driver and pillion)conditions on a two-wheeler.The results indicate that the proposed electronically operated braking system is more effective than the conventional braking system for various loads and vehicle speeds.Specifically,the stopping distance of the vehicle is decreased significantly by about 4.9%between the con-ventional braking system and the simulated proposed system.Further,the experi-mental results show that the stopping distance is condensed by about 4.1%.The validation between simulated and experimental results revealed a great deal with the least error percentage of about 0.8%.

Energy Management of Networked Smart Railway Stations Considering Regenerative Braking, Energy Storage System, and Photovoltaic Units

The networking of microgrids has received significant attention in the form of a smart grid.In this paper,a set of smart railway stations,which is assumed as microgrids,is connected together.It has been tried to manage the energy exchanged between the networked microgrids to reduce received energy from the utility grid.Also,the operational costs of stations under various conditions decrease by applying the proposed method.The smart railway stations are studied in the presence of photovoltaic(PV)units,energy storage systems(ESSs),and regenerative braking strategies.Studying regenerative braking is one of the essential contributions.Moreover,the stochastic behaviors of the ESS’s initial state of energy and the uncertainty of PV power generation are taken into account through a scenario-based method.The networked microgrid scheme of railway stations(based on coordinated operation and scheduling)and independent operation of railway stations are studied.The proposed method is applied to realistic case studies,including three stations of Line 3 of Tehran Urban and Suburban Railway Operation Company(TUSROC).The rolling stock is simulated in the MATLAB environment.Thus,the coordinated operation of networked microgrids and independent operation of railway stations are optimized in the GAMS environment utilizing mixed-integer linear programming(MILP).

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.

Exploring Crowdsourced Hard—Acceleration and Braking Event Data for Evaluating Safety Performance of Low-Volume Rural Highways in Iowa

There are over four million miles of two-lane roadways across the United States, of which a substantial portion is low-volume roads (LVR). Traditionally, most traffic safety efforts and countermeasures focus on high-volume high-crash urban locations. This is because LVRs cover an extensive area, and the rarity of crashes makes it challenging to use crash data to monitor the safety performance of LVRs regularly. In addition, obtaining up-to-date roadway information, such as pavement or shoulder conditions of an extensive LVR network, can be exceptionally difficult. In recent times, crowdsourced hard-acceleration and braking event data have become commercially available, which can provide precise geolocation information and can be readily acquired from different vendors. The present paper examines the potential use of this data to identify opportunities to monitor the safety of LVRs. This research examined approximately 12 million hard-acceleration and hard-braking events over a 3-months period and 26,743 crashes, including 9373 fatal injuries over the past 5-year period. The study found a moderate correlation between hard acceleration/hard-braking events with historical crash events. This study conducted a hot spot analysis using hard-acceleration/hard-braking and crash datasets. Hotspot analysis detected spatial clusters of high-risk crash locations and detected 848 common high-risk sites. Finally, this paper proposes a combined ranking scheme that simultaneously considers historical crash events and hard-acceleration/hard-braking events. The research concludes by suggesting that agencies can potentially use the hard-acceleration and hard-braking event dataset along with the historical crash dataset to effectively supervise the safety performance of the vast network of LVRs more frequently.

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.

A new braking force distribution strategy for electric vehicle based on regenerative braking strength continuity

Regenerative braking was the process of converting the kinetic energy and potential energy, which were stored in the vehicle body when vehicle braked or went downhill, into electrical energy and storing it into battery. The problem on how to distribute braking forces of front wheel and rear wheel for electric vehicles with four-wheel drive was more complex than that for electric vehicles with front-wheel drive or rear-wheel drive. In this work, the frictional braking forces distribution curve of front wheel and rear wheel is determined by optimizing the braking force distribution curve of hydraulic proportional-adjustable valve, and then the safety brake range is obtained correspondingly. A new braking force distribution strategy based on regenerative braking strength continuity is proposed to solve the braking force distribution problem for electric vehicles with four-wheel drive. Highway fuel economy test(HWFET) driving condition is used to provide the speed signals, the braking force equations of front wheel and rear wheel are expressed with linear equations. The feasibility, effectiveness, and practicality of the new braking force distribution strategy based on regenerative braking strength continuity are verified by regenerative braking strength simulation curve and braking force distribution simulation curves of front wheel and rear wheel. The proposed strategy is simple in structure, easy to be implemented and worthy being spread.

Influence of quick release valve on braking performance and coupler force of heavy haul train

We establish a simulation model based on the theory of air flow to analyze the accelerated release effect of the quick release valve inside the air brake control valve.In addition, the combined simulation system of train air brake system and longitudinal train dynamics is used to analyze how the parameters of the quick release valve in the 120/120–1 brake control valve affect the propagation characteristics of the train brake pipe pressure wave, the release action range of the accelerated brake, and the longitudinal coupler force for a 20,000-ton heavy haul train on the section of the Datong–Qinhuangdao Railway. The results show that the quick release valve can effectively accelerate the rising speed of the train brake pipe pressure during the initial release, as the accelerated release effect is evident before the train brake pipe pressure reaches582 k Pa. The quick release valve can effectively accelerate the release of the rear cars, reducing the longitudinal coupler force impact due to time delay of the release process. The quick release valve can effectively reduce the tensile coupler force in the train by as much as 20% in certain cases.

New Method to Restrain Pumping Voltage of Braking Procedure for Brushless DC Motor of Electric Armored Vehicle

In order to restrain the high pumping voltage of braking procedure which is harmful to the system of electric armored vehicle. Based on the analysis of pumping voltage of the braking procedure, the relation between pumping voltage and PWM ratio is derived and a new digital control method to restrain the pumping voltage by changing PWM ratio is put forward. Because the capacitance is decreased effectively, the volume of controller is reduced and the performance to price ratio is improved. The results of computer simulation and experiment proved that this method is feasible and valid.

Influence of pavement frictional properties on braking distance

In order to study the relationship between pavement friction management criteria and braking distance requirements of road geometric design, an approach for determining the braking distance considering pavement frictional properties is proposed. A finite element model （FEM） of a rolling tire under steady state is established based on theoretical hydrodynamics and mechanics principles, in which factors, including tire type, water film thickness, pavement surface properties, and vehicle speed, are considered. With the FEM, braking distances under different operating conditions are calculated. Furthermore, the allowable water film thickness is determined by comparing braking distances calculated with friction management criteria and that required by road geometric design. The results show that the braking distance is affected by the above operating conditions. As a result, it is necessary to maintain consistency between geometric design braking distance requirements and pavement friction management to achieve safe road operations.