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.

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.

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.

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.

Numerical simulation of the delay arming process of initiating explosive brakes

The delay arming process of initiating explosive （ IE ） brakes for fuse is complex and hard to be verified. A numerical simulation model of IE brakes was established based on the arbitrary La- grange-Euler method. The model included the structure, the air filed, etc. The simulation boundary conditions were defined, including the contacts, blasting parameters of the explosive and the fluid- solid coupling interface. The simulation results show that the shear pin of the chosen IE can be cut off. When the piston needs to move 0.8 cm, the time set to the delay arming of the IE brakes model is about 40μS. The maximum displacement of the piston is 1. 17 cm. The model provides basis for parameters design and further improvement of IE brakes.

Simulation and analysis of vehicle stability based on ADAMS/CAR differential brake

To improve the braking safety of automobiles, the author studied the effect of differential brake on the stabilities. To analyze the mechanical characteristics of differential brake, automotive subsystem models were built by applying ADAMS/CAR, and automotive mechanics simulation model was built by setting the main subsystems such as body, engine and brake. The simulation model studied the distribution mode of three kinds of differential brake, and beeline braking stability and turning braking stability were simulated. It shows that differential brake can amend turning shortage of automobile brake and improve its braking stability, but the effect of automobile mass on its braking stability is great. So the distribution mode of braking force and the effect of mass change should be considered while differential brake is applied.

Computer aided design and analysis of a tunable muzzle brake

This research work deals with the design of a tunable muzzle brake [10] for a rifle chambered in 5.56 x 45 NATO ammunition. It proposes to solve the problem of handling differences from shooter to shooter by incorporating the feature of tunability. Beside this, it also solves the problem of requirement of optimum recoil in short recoil weapons. This innovation gives this design an edge over its already existing counterparts in the market. The product is designed using the internal ballistics calculations and the investigations been performed using solidworks flow simulation tool and ANSYS static structural to check the parameters like velocity distribution, pressure growth, and muzzle brake force along the series of ports and comparison of the so found results with those devised by the authors of the documents mentioned in references. This assures the market adaptability of the product for satisfactory performance, when brought among its already existing counterpart, though with a slight edge over them due to tunability. The results so found shall be concluded satisfactory regarding the performance of muzzle brake.

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.

Optimum Position of Electromagnetic Brake on Slab Caster

Three-dimensional mathematical models were developed for studying the molten steel flow and the trajectories of inclusions and bubbles in continuous casting mold with electromagnetic brake.The results show that the effect of the electromagnetic brake on the molten steel flow and the movement of inclusions and bubbles depends on the position of electromagnetic brake.While EMBR Ruler is installed at the exit of the submerged entry nozzle,the velocity of the main jet of molten steel from the nozzle can be decreased effectively,the velocity of the molten steel streams near the free surface and the narrow face is reduced obviously;Meantime more inclusions and bubbles could float up to the slag layer.

Investigation into precision engineering design and development of the next-generation brake discs using Al/SiC metal matrix composites

Substantially lightweight brake discs with high wear resistance are highly desirable in the automotive industry.This paper presents an investigation of the precision-engineering design and development of automotive brake discs using nonhomogeneous Al/SiC metal-matrixcomposite materials.The design and development are based on modeling and analysis following stringent precision-engineering principles,i.e.,brake-disc systems that operate repeatably and stably over time as enabled by precision-engineering design.The design and development are further supported by tribological experimental testing and finite-element simulations.The results show the industrial feasibility of the innovative design approach and the application merits of using advanced metal-matrix-composite materials for next-generation automotive and electric vehicles.

Aerodynamic Brake for Formula Cars

In the last years, in formula racing cars championships, the aerodynamic had reached an ever more important stance as a performance parameter. In the last four seasons, Red Bull Racing Technical Officer had designed their Formula 1 car with the specific aim to generate the optimal downforce, in relation to the car instantaneous setup. However, this extreme research of higher downforce brings some negative effects when a car is within the wake of another car;indeed, it is well known that under these condition the aerodynamic is disturbed, and it makes difficult to overtake the leading car. To partially remedy this problem, Formula 1 regulations introduced the Drag Reduction System (DRS) in 2011, which was an adjustable flap located on the rear wing;if it is flattened, allowing to reduce the downforce, increasing significantly the velocity and, therefore, the chances to overtake the leading car. Vice versa, when the flap is closed, it ensures a higher grip, which is very useful especially in medium-slow speed turns. Keeping the focus on the rear wing, but by shifting attention from the increased top speed to increase the grip in the middle and slow speed curves, we decided to study a similar device to the DRS, but with the opposite effect. The aim is to design an aerodynamic brake integrated with the rear wing. In particular, the project idea was to sculpt, on the upper surface of the wing (pressure side), a series of 'C' shaped cavity, normally covered by adequate sliding panels. These cavities, when they are discovered, at the beginning of the braking phase, produce a turbulence and additional increase downforce, lightening the load on the braking system and allowing the pilot to substantially reduce slippage and to delay the braking. Since it seems that the regulations adopted by the FIA Formula 1 Championship do not allow such a device, it has been decided to apply the concept on a Formula 4 vehicle. This paper describes the design and analyzes the effects of these details on a standard wing cavity, using a commercial CFD software.

Numerical Efficient Thermal Network for Calculating the Brake Disc Temperature

The simulation of the brake disc temperature is an important tool in the development of passenger cars.Nowadays thermal models of brake discs are real-time applications,running on electronic control units(ECUs)of cars to improve the vehicle safety in several ways.These models are often working with full empirical methods,leading to large deviations between calculation and measurement.To meet the requirements of automotive safety integrity levels(ASILs),these thermal models cannot rely on the state of the art ambient air temperature sensors,which causes unacceptable deviations.Focusing on numerical efficient thermal simulations,a new approach of a semi-analytical thermal network for simulating the brake disc temperature with minimal effort is proposed.The thermal network is based on lumped parameters,using two thermal capacity nodes and a constant ambient temperature.Using semi-analytical correlations,the model can be adapted to different geometries and car lines effortlessly.The empirical parameters of the model result only from two standardized tests.These parameters are used to evaluate the estimation accuracy in real driving situations.Additionally,the adaptability is tested for two different car lines and four brake disc dimensions.These tests are initially performed with unchanged parameters and afterwards with refitted parameters.The model shows a good estimation for the tested load cases.Compared to the state of the art,the proposed model is less accurate than complex finite element method(FEM)models and computational fluid dynamic(CFD)approaches,but shows a higher accuracy and better adaptability than other lumped parameter models with comparable numerical effort.Hence,possible applications can be dimensioning the brake system in the development process of new car lines or a real-time simulation on the latest ECU in the vehicle.

On Implementing a Simulated Moment of Inertia in a Reduced Scale Brake Dynamometer

This paper describes the implementation of brake procedures with simulated inertia on a reduced scale brake dynamometer For this purpose, the theoretical foundations are first explained, and test measurements are carried out. The results show good agreement between calculated and measured accelerations during brake applications. Furthermore, braking processes with various driver models were carried out using associated normal force functions, and examined with regard to their coefficients of friction. A clear difference between these models can be observed. This introduces the possibility for new measurement methods for the analysis of NVH-behavior in brake systems. This work is the first step towards identifying a transfer function between full- and reduced-scale brake dynamometers. In a second step, the temperature scaling must be taken into account. Based on these results, it is possible to isolate the influences of the braking system components from those of the dynamics of the friction coefficient in the boundary layer.

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.

Investigation of Braking Timing of Drivers for Design of Pedestrian Collision Avoidance System

The braking behavior of drivers when a pedestrian comes out from the sidewalk to the road was analyzed using a driving simulator. Based on drivers＇ braking behavior, the braking control timing of the system for avoiding the collision with pedestrians was proposed. In this study, the subject drivers started braking at almost the same time in terms of TTC （Time to Collision）, regardless of the velocity of a subject vehicle and crossing velocity of pedestrians. This experimental result showed that brake timing of the system which can minimize the interference for braking between drivers and the system is 1.3 s of TTC. Next, the drivers＇ braking behavior was investigated when the system controlled braking to avoid collision at this timing. As a result, drivers did not show any change of braking behavior with no excessive interference between braking control by the system and braking operation by drivers for avoiding collisions with pedestrians which is equivalent to the excessive dependence on the system.

基于SimulationX的电子驻车制动系统仿真与分析

电子驻车制动系统(EPB)是车辆驻车制动系统的发展方向,属于线控制动的一种。采用SimulationX对汽车电子驻车制动系统进行仿真分析,根据EPB系统机械部分的构造和工作原理,搭建了减速机构、传动机构、活塞顶出机构的仿真模型,并对Simula⁃tionX与Matlab/Simulink的联合仿真进行了探索,在Matlab/Simulink中搭建控制模型,结合这2款软件的优势,完成了EPB系统的仿真模型。对EPB系统夹紧释放的过程进行仿真分析,并与用纯数学理论搭建的仿真模型夹紧力结果对比。结果表明:利用Simula⁃tionX搭建的物理模型是真实可靠的,且符合EPB系统的设计要求。与纯数学理论模型相比,基于SimulationX的物理建模更加简单,有助于提高建模仿真效率,并为线控制动系统产品的开发尤其是虚拟平台的搭建提供了重要的技术支撑。

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.

基于剩余碰撞时间的线控制动分层控制策略

针对不同制动工况需求的制动策略存在差异的情况,提出一种线控制动分层控制策略.在该分层策略的上层,利用二阶TTC安全碰撞时间模型计算出车辆与前车的剩余碰撞时间,以此作为依据进行制动策略的选取,并建立了汽车二自由度模型、车身法向受力模型和Burckhardt轮胎模型;在该分层策略的下层,进行了制动力在轮间的分配,使用序列二次规划(SQP)方法,分别在一般制动、紧急制动、失稳制动3种工况下,以轮胎滑移率为对象建立优化函数,对车辆制动力进行了优化分配.使用MATLAB/Simulink和Carsim进行了联合仿真,对所提出3种工况下的制动分配策略进行了有效性验证.结果表明:在一般制动工况下,采用该策略时相比对照工况制动距离减少18.08%,制动时间减少25.12%;在紧急制动工况下,采用该策略时相比对照工况制动距离减少19.17%,制动时间减少12.79%;在失稳制动工况下,该策略可通过轮胎差扭来提升车辆的横向稳定性.采用文中制动策略显著提升了车辆的制动效能.

基于SimulationX的推土机转向制动阀仿真研究

推土机转向制动阀是实现推土机转向制动操纵的关键部件,对整机性能有重要影响。本研究首先对转向制动阀的工作原理进行了分析,建立详细的数学模型;然后基于Simulation X软件仿真平台,建立其系统仿真模型,通过对比分析仿真结果与实测参数,验证了仿真模型的准确性。最后研究了各参数变化对系统性能的影响,着重分析了与离合器压力曲线及操纵力相关的性能参数,为今后产品开发设计及性能优化提供了数据参考及理论依据。

SIMULATION ANALYSIS OF INFLUENCE OF ROAD SURFACE ROUGHNESS ON TYRE DYNAMIC PERFORMANCE IN AUTOMOTIVE BRAKING

Using a nonlinear time varying tyre model, this paper simulatively analyzes the influence of road surface roughness amplitude and road spatial frequency on automobile ground adhesion ability. The result shows that with the increase of road surface roughness, the tyre adhesion ability declines, and the automotive braking distance increases. Moreover, the reliability of the nonlinear time varying tyre model in reflecting the influence of the road surface roughness is validated. It is testified that this model is an effective dynamic one in the simulation of automotive braking performance on uneven road.