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.

Full Power Hydraulic Brake System Based on Double Pipelines for Heavy Vehicles

The hydraulic caliper disc brake system with air-over-oil is widely adopted at present for heavy vehicles,which makes use of air pressure system propelling the hydraulic pressure system acting on friction plates divided and combined for braking.There are some disadvantages such as pneumatic components failure,dust polluted and produce lots of heat in hydraulic caliper disc brake system.Moreover,considering the demands of the high speed,heavy weight,heavy load and fast brake of heavy vehicles,the full power hydraulic brake system based on double pipelines for heavy vehicles is designed and analyzed in this paper.The scheme of the full power hydraulic brake system,in which the triloculare cylinder is controlled by dual brake valve,is adopted in the brake system.The full power hydraulic brake system can accomplish steering brake,parking brake and emergent brake for heavy vehicles.Furthermore,electronic control system that is responsible for coordinating the work of hydraulic decelerator and hydraulic brake system is developed for different speed brakes.Based on the analysis of the influence of composed unit and connecting pipeline on braking performance,the nonlinear mathematic model is established for the full power hydraulic brake system.The braking completion time and braking pressure in braking performance of the double-pipeline steering brake and parking brake are discussed by means of simulation experiments based on Matlab/Simulink,and the simulation results prove that the braking performance of steering brake and parking brake meets the designing requirement of the full power hydraulic brake system.Moreover,the test-bed experiments of the brake system for heavy vehicles are carried out.The experimental data prove that the braking performance achieves the goal of the design,and that the full power hydraulic brake system based on double pipelines can effectively enhance braking performance,ensure braking reliability and security for heavy vehicles.

Assessing performance of collision mitigation brake system in Chinese traffic environment

Advanced driver-assistance systems such as Honda’s collision mitigation brake system(CMBS)can help achieve traffic safety.In this paper,the naturalistic driving study and a series of simulations are combined to better evaluate the performance of the CMBS in the Chinese traffic environment.First,because safety-critical situations can be diverse especially in the Chinese environment,the Chinese traffic-accident characteristics are analyzed according to accident statistics over the past 17 years.Next,10 Chinese traffic-accident scenarios accounting for more than 80%of traffic accidents are selected.For each typical scenario,353 representative cases are collected from the traffic-management department of Beijing.These real-world accident cases are then reconstructed by the traffic-accident-reconstruction software PC-Crash on the basis of accident-scene diagrams.This study also proposes a systematic analytical process for estimating the effectiveness of the technology using the co-simulation platform of PC-Crash and rateEFFECT,in which 176 simulations are analyzed in detail to assess the accident-avoidance performance of the CMBS.The overall collision-avoidance effectiveness reaches 82.4%,showing that the proposed approach is efficient for avoiding collisions,thereby enhancing traffic safety and improving traffic management.

COMPARISON OF NO-LINE MONITORING AND FAULT DIAGNOSIS FOR HOISTER BRAKE SYSTEM

This paper puts forward the LPM fault diagnosis method in the view of the important purpose of on-line monitoring and fault diagnosis for hoister brake system. The feasibility of the two diagnosis methods are proved in theories; two methods are proved about feasibility and reliability through testing. Two methods are manifestoed that they can undertake the on-line monitoring and fault diagnosis for hoister brake system with satisfied effect.

Identification and Modeling of Automotive Electrical Parking Brake System for SiL Simulation

To evaluate the software behavior of the electronic control unit （ECU） of automotive electrical parking brake （EPB）, a software- in-the-loop （SiL） simulation system is built. The EPB is simulated by ARX （auto-regressive with auxiliary input） model, ARMAX （auto-regressive moving average with auxiliary input） model, and NNARMAX （neural network ARMAX） model. By system identification, the ARX（3,4,2）, ARX（4,4,2）, ARMAX（3,3,1,1）, and ARMAX（4,4,3,2） models are derived. Validation results show that the four-order ARMAX model and the NNARMAX model better simulate the actuator of the EPB.

Comprehensive modeling strategy for thermomechanical tribological behavior analysis of railway vehicle disc brake system

A comprehensive modeling strategy for studying the thermomechanical tribological behaviors is proposed in this work.The wear degradation considering the influence of temperature(T)is predicted by Archard wear model with the help of the UMESHMOTION subroutine and arbitrary Lagrangian–Eulerian(ALE)remeshing technique.Adopting the proposed method,the thermomechanical tribological behaviors of railway vehicle disc brake system composed of forged steel brake disc and Cu-based powder metallurgy(PM)friction block are studied systematically.The effectiveness of the proposed methodology is validated by experimental test on a self-designed scaled brake test bench from the perspectives of interface temperature,wear degradation,friction noise and vibration,and contact status evolution.This work can provide an effective way for the investigation of thermomechanical tribological behaviors in the engineering field.

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.

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.

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 novel integrated self-powered brake system for more electric aircraft

Traditional hydraulic brake systems require a complex system of pipelines between an aircraft engine driven pump（EDP） and brake actuators, which increases the weight of the aircraft and may even cause serious vibration and leakage problems. In order to improve the reliability and safety of more electric aircraft（MEA）, this paper proposes a new integrated self-powered brake system（ISBS） for MEA. It uses a hydraulic pump geared to the main wheel to recover a small part of the kinetic energy of a landing aircraft. The recovered energy then serves as the hydraulic power supply for brake actuators. It does not require additional hydraulic source, thus removing the pipelines between an EDP and brake actuators. In addition, its self-powered characteristic makes it possible to brake as usual even in an emergency situation when the airborne power is lost. This paper introduces the working principle of the ISBS and presents a prototype. The mathematical models of a taxiing aircraft and the ISBS are established. A feedback linearization control algorithm is designed to fulfill the anti-skid control. Simulations are carried out to verify the feasibility of the ISBS, and experiments are conducted on a ground inertia brake test bench. The ISBS presents a good performance and provides a new potential solution in the field of brake systems for MEA.

Road Identification for Anti-Lock Brake Systems Equipped with Only Wheel Speed Sensors

Anti lock brake systems (ABS) are now widely used on motor vehicles. To reduce product cost and to use currently available technologies, standard ABS uses only wheel speed sensors to detect wheel angular velocities, which is not enough to directly obtain wheel slip ratios needed by the control unit, but can be used to calculate reference slip ratios with measured wheel angular velocities and the estimated vehicle speed. Therefore, the road friction coefficient, which determines the vehicle deceleration during severe braking, is an important parameter in estimating vehicle speed. This paper analyzes wheel acceleration responses in simulations of severe braking on different road surfaces and selects a pair of specific points to identify the wheel acceleration curve for each operating condition, such as road surface, pedal braking torque and wheel vertical load. It was found that the curve using the selected points for each road surface clearly differs from that of the other road surfaces. Therefore, different road surfaces can be distinguished with these selected points which represent their corresponding road surfaces. The analysis assumes that only wheel speed sensors are available as hardware and that the road cohesion condition can be determined in the initial part of the severe braking process.

A trailer car dynamics model considering brake rigging of a high-speed train and its application

Brake systems are essential for the speed regulation or braking of a high-speed train.The vehicle dynamic performance under braking condition is complex and directly affects the reliability and running safety.To reveal the vehicle dynamic behaviour in braking process,a comprehensive trailer car dynamics model(TCDM)considering brake systems is established in this paper.The dynamic interactions between the brake system and the other connected components are achieved using the brake disc-pad frictions,brake suspension systems,and wheel-rail interactions.The force and motion transmission from the brake system to the wheel-rail interface is performed by the proposed TCDM excited by track irregularity.In addition,the validity of TCDM is verified by experimental test results.On this basis,the dynamic behaviour of the coupled system is simulated and discussed.The findings indicate that the braking force significantly affects vehicle dynamic behaviour including the wheel-rail forces,suspension forces,wheelset torsional vibration,etc.The dynamic interactions within the brake system are also significantly affected by the vehicle vibration due to track irregularity.Besides,the developed TCDM can be further employed to the dynamic assessment of such a coupled mechanical system under different braking conditions.

Typical faults and safety analysis of brake controller for AC locomotive

Purpose–The brake controller is a key component of the locomotive brake system.It is essential to study its safety.Design/methodology/approach–This paper summarizes and analyzes typical faults of the brake controller,and proposes four categories of faults:position sensor faults,microswitch faults,mechanical faults and communication faults.Suggestions and methods for improving the safety of the brake controller are also presented.Findings–In this paper,a self-judgment and self-learning dynamic calibration method is proposed,which integrates the linear error of the sensor and the manufacturing and assembly errors of the brake controller to solve the output drift.This paper also proposes a logic for diagnosing and handling microswitch faults.Suggestions are proposed for other faults of brake controller.Originality/value–The methods proposed in this paper can greatly improve the usability of the brake controller and reduce the failure rate.

Development and experimental validation of an automatic parking brake system with less driveline sensor

Electrical Parking Brake(EPB) has been popularly used in passenger cars over the past ten years. With the help of the several kinds of sensors mounted in driveline for the total traction force estimation, EPB can obtain well performance on drive-off assistance and automatic parking brake. Furthermore, its AUTOHOLD function can realize automatic parking brake and ease the driver. However, given that the higher cost and complexity of this traction force estimation method based on the driveline sensors and its slower response resulted by applying maximum parking force for safety parking while driving off, a novel automatic parking brake system without these transmission system sensors, such as clutch position sensor for the cars with manual transmission, is proposed in this paper, including its control scheme and application test. Firstly, the indirect judgement method of the appropriate moment to release the parking brake, which is based on the car pitch moment when it drives off, is introduced according to the force analysis when the car is ready to go. Then a pragmatic mass estimation method for proper brake force calculation is proposed for improving the drive-off performance. In addition, for the convenience and drivability of skillful driver, as well as the system reliability, a mechanical redundant design to reserve the conventional handbrake lever is also described. Finally, various simulations based on CarSim software and road tests are performed to validate its effectiveness.

A finite element analysis(FEA)approach to simulate the coefficient of friction of a brake system starting from material friction characterization

The coefficient of friction(COF)is one of the most important parameters to evaluate the performance of a brake system.To design proper brake systems,it is important to know the COF when estimating the brake force and resulting torque.It is challenging to simulate the COF since friction in disc brakes is a complex phenomenon that depends on several parameters such as sliding velocity,contact pressure,materials,and temperatures,etc.There is a lack of studies found in the literature focusing on simulation of the COF for a full brake system based on tribometer material characterization.The aim of this work is therefore to investigate the possibility to use a finite element analysis(FEA)approach combined with a COF pv-map to compute the global COF of a disc brake system.The local COF is determined from a pv-map for each local sliding velocity and contact pressure determined by the FEA.Knowing the local COF,the braking force of the entire brake system and the global COF can be evaluated.Results obtained by the simulation are compared with dyno bench test of the same brake system to investigate the validity of the simulation approach.Results show that the simulation is perfectly in line with the experimental measurements in terms of in-stop COF development,but slightly higher with a positive offset for every braking.

Development and Control of a Magnetorheological Damper‑Based Brake Pedal Simulator for Vehicle Brake‑by‑Wire Systems

Recent developments have demonstrated that the brake pedal simulator(BPS)is becoming an indispensable apparatus for the break-by-wire systems in future electric vehicles.Its main function is to provide the driver with a comfortable pedal feel to improve braking safety and comfort.This paper presents the development and control of an adjustable BPS,using a disk-type magnetorheological(MR)damper as the passive braking reaction generator to simulate the traditional pedal feel.A detailed description of the mechanical design of the MR damper-based BSP(MRDBBPS)is presented in this paper.Several basic performance experiments on the MRDBBPS prototype are conducted.A returnto-zero(RTZ)algorithm is proposed to avoid hysteresis and improve the repeatability of the pedal force.In addition,an RTZ algorithm-based real-time current-tracking controller(RTZRC)is designed in consideration of the response lag of the coil circuit.Finally,an experimental system is established by integrating the MRDBBPS prototype into a selfdeveloped automotive MR braking test bench(AMRBTB),and several control and braking experiments are performed.This research proposes a RTZRC control algorithm which can significantly increase the tracking accuracy of the brake pedal characteristic curve,particularly at a high pedal velocity.Additionally,the designed MRDBBPS prototype can achieve an effective and favorable control of the AMRBTB with a good repeatability.

Research on motor rotation anomaly detection based on improved VMD algorithm

Purpose–The electromechanical brake system is leading the latest development trend in railway braking technology.The tolerance stack-up generated during the assembly and production process catalyzes the slight geometric dimensioning and tolerancing between the motor stator and rotor inside the electromechanical cylinder.The tolerance leads to imprecise brake control,so it is necessary to diagnose the fault of the motor in the fully assembled electromechanical brake system.This paper aims to present improved variational mode decomposition(VMD)algorithm,which endeavors to elucidate and push the boundaries of mechanical synchronicity problems within the realm of the electromechanical brake system.Design/methodology/approach–The VMD algorithm plays a pivotal role in the preliminary phase,employing mode decomposition techniques to decompose the motor speed signals.Afterward,the error energy algorithm precision is utilized to extract abnormal features,leveraging the practical intrinsic mode functions,eliminating extraneous noise and enhancing the signal’s fidelity.This refined signal then becomes the basis for fault analysis.In the analytical step,the cepstrum is employed to calculate the formant and envelope of the reconstructed signal.By scrutinizing the formant and envelope,the fault point within the electromechanical brake system is precisely identified,contributing to a sophisticated and accurate fault diagnosis.Findings–This paper innovatively uses the VMD algorithm for the modal decomposition of electromechanical brake(EMB)motor speed signals and combines it with the error energy algorithm to achieve abnormal feature extraction.The signal is reconstructed according to the effective intrinsic mode functions(IMFS)component of removing noise,and the formant and envelope are calculated by cepstrum to locate the fault point.Experiments show that the empirical mode decomposition(EMD)algorithm can effectively decompose the original speed signal.After feature extraction,signal enhancement and fault identification,the motor mechanical fault point can be accurately located.This fault diagnosis method is an effective fault diagnosis algorithm suitable for EMB systems.Originality/value–By using this improved VMD algorithm,the electromechanical brake system can precisely identify the rotational anomaly of the motor.This method can offer an online diagnosis analysis function during operation and contribute to an automated factory inspection strategy while parts are assembled.Compared with the conventional motor diagnosis method,this improved VMD algorithm can eliminate the need for additional acceleration sensors and save hardware costs.Moreover,the accumulation of online detection functions helps improve the reliability of train electromechanical braking systems.