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.

Diesel Engine Emissions and Performance Characteristics under Cape Chestnut Biofuel

Cape Chestnut oil was processed to biodiesel through transesterification. Cape Chestnut kennels are reported to have oil content of 60% - 63% [1]. Properties of biodiesel were determined and compared with those of diesel and engine tests done at a constant speed of 1500 RPM on the biodiesel blends to evaluate their performance and emissions characteristics. Performance evaluation was in terms of Brake Specific Fuel Consumption (BSFC), Brake Horse Power (BHP) and Brake Thermal Efficiency (ETE). The engine was initially run on diesel to establish the reference characteristics before running on biodiesel blends. The biodiesel was blended with diesel volumetrically to 80% (B80), 50% (B50), 20% (B20) and 5% (B5) the percentage being the volume of biodiesel in the blended fuel. Diesel fuel had the lowest BSFC followed by B5 whose BSFC was 7.3% higher than that of diesel. BTE for B100 was lower than that of diesel by 20.3% while that of B5 was 7.6% lower. Concentration of SO2 in B100 was 92.7% lower than that of diesel fuel while that of B20 was 24.7% lower. NO and NO2 concentrations for B100 were around 15% higher than that of diesel. Particulate matter of less than 10 μm diameter (PM10) for diesel was found to be 72% of the total collected from all the test fuels as compared to that of biodiesel blends at 28%. The study concluded that Cape Chestnut biodiesel blends containing up to 20% biodiesel can be used in an unmodified diesel engine since their performance and emission characteristics were very similar to that of diesel but with reduced toxic gas emissions therefore friendly to the environment.

Investigating the Effects of Eichhornia Crassipes Biodiesel and Liquefied Petroleum Gas on the Performance and Emissions of a Dual-Fuel Engine

This study considers the effect of Eichhornia Crassipes Biodiesel(ECB)blends on the performances,combustion,and emission characteristics of a direct injection compression ignition engine operated in a dual-fuel mode(DFM)and equipped with an Exhaust gas recirculation technique(EGR).In particular,a single-cylinder,four-stroke,water-cooled diesel engine was utilized and four modes of fuel operation were considered:mode I,the engine operated with an ordinary diesel fuel;mode II,the engine operated with the addition of 2.4 L/min of lique-fied petroleum gas(LPG)and 20%EGR;mode III,20%ECB with 2.4 L/min LPG and 20%EGR;mode IV,40%ECB with 2.4 L/min LPG and 20%EGR.The operation conditions were constant engine speed(1500 rpm),var-iation of load(25%,50%,75%,and 100%),full load,with a compression ratio of 18,and a time injection of 23°BTDC(Before top died center).With regard to engine emissions,carbon dioxide(CO_(2)),carbon monoxide(CO),hydrocarbons(UHC),and nitrogen oxide(NOX)were measured using a gas analyzer.The smoke opacity was measured using an OPABOX smoke meter.By comparing the results related to the different modes with mode I at full load,the BTE(Brake thermal efficiency)increased by 20.17%,11.45%,and 12.66%with modes II,III,and IV,respectively.In comparison to the results for mode II,the BTE decreased due to the combustion of ECB blends by 7.26%and 6.24%for mode III and mode IV,respectively,at full load.In comparison to mode II,the Brake specific energy consumption(BSEC)increased with the ECB substitution.With ECB blends,there is a noticeable decrease in the CO,CO_(2),and UHC emissions at a partial load.Furthermore,the 20%ECB has no effect on CO emissions at full load.For modes II and IV,the CO_(2)increased by 33.33%and 19%,respectively,while the UHC emissions were reduced by 14.49%for mode III and 26.08%for mode IV.The smoke of mode III was lower by 7.21%,but for mode IV,it was higher by 12.37%.In addition,with mode III and mode IV,the NOx emissions increased by 30.50%and 18.80%,respectively.

Numerical optimisation and experimental validation of divided rail freight brake disc crown

In this study, numerical optimisation and experimental validation of a divided rail freight brake disc crown made of grey cast iron EN-GJL-250 is presented.The analysed brake disc is used in rail freight wagons and possesses a load capacity of 22.5 tons per axle. Two of the divided rail freight brake discs are mounted on each axle.With the aid of numerical analysis, the thermal dissipation properties of the brake disc were optimised and ventilation losses were reduced, and the numerical results were compared with experimental results. A one-way fluid–structure interaction analysis was performed. A computational fluid dynamic model of a divided rail freight brake disc, used to predict air flow properties and heat convection, was incorporated into a finite element model of the disc and used to evaluate the temperature of the disc. A numerical parametrical optimisation of cooling ribs of the brake disc was also performed, and novel optimised cooling ribs were developed. A transient thermal numerical analysis of the brake disc was validated using temperature measurements obtained during a braking test on a test bench. The ventilation losses of the brake disc were measured on a test bench specifically designed for the task, and the losses were compared to the simulation results. The experimentally obtained ventilation losses and temperature measurements compared favourably with the simulation results, confirming that this type of simulation process may be confidently applied in the future. Through systematic optimisation of the divided rail freight brake disc, ventilation losses were reduced by 37% and the mass was reduced by 21%, resulting in better thermal performance that will bring with it substantial energy savings.

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.

重型载货汽车长下坡制动控制策略

单一制动器温度升高出现制动热衰退现象后,其余制动器热负荷增加会影响整车制动效能,针对此问题提出了基于制动力观测模型的重型载货汽车长大下坡制动控制策略。首先,利用制动鼓温度能够准确表征制动力的特性建立了制动力观测模型;其次,依据整车制动器热衰退演变机理及车辆制动失稳机理,提出了结合散热量、地面附着率、滑移率及轴载的控制策略;然后,为了实现制动力的跟踪控制,建立了基于MPC制动力优化控制模型;为了验证提出的控制策略,建立了基于TruckSim和Matlab联合仿真模型;最后,进行低温制动工况、高温制动工况和基于滑移率的制动控制策略仿真验证。结果表明:低温工况能够抑制制动器温度的快速升高;高温工况能够降低制动器提前出现热衰退的风险,在保证整车制动效能的同时,预留了必要安全措施时间;基于滑移率的控制策略可以保证车辆制动稳定性。结果表明:所提出的控制策略既能相对均衡地控制制动器温度上升速度,又能避免因某一制动器温度快速升高而增加其余制动器热负荷,且保证制动稳定性,从而提高了重型载货汽车长下坡制动安全性。

集成式电液制动系统自适应压力控制

针对集成式电液制动系统(integrated electro-hydraulic brake system,IEHB)存在的复杂液压非线性特性和时变摩擦干扰,提出一种自适应压力控制策略。外环压力控制器引入液压特性的动态线性化模型并基于滑模观测器对模型参数实时辨识实现对非线性液压特性的自适应。内环伺服控制器采用基于压力的连续摩擦补偿和反步动态面控制应对传动机构摩擦阻碍。硬件在环实验结果表明,与现有的先进级联压力控制相比,设计的压力控制策略在多种工况下均表现出更高的控制精度和鲁棒性,并显著提升了IEHB在不同液压回路结构下的压力控制效果。

动态气门运行特性及二冲程制动性能耦合研究

基于自主研发的变模式气门驱动装置,进行发动机和该气门驱动装置联合仿真,研究了二者的强耦合运行特性,为该装置的装机应用提供理论依据.研究结果表明:缸内压力和气门运行之间的强耦合关系在上止点附近排气门运行阶段尤为明显,尤其是在2300 r/min以下,发动机转速越高,气门动态升程损失程度越大,最大缸内压力越高;高于该转速后,二者变化程度逐渐减小;排气制动凸轮在上止点后设置过渡升程可消除排气门反跳的问题,并且可进一步改善制动功率和最大缸内压力之间的矛盾关系;与理想四冲程制动相比,二冲程制动的制动功率明显增加,最大缸内压力明显降低,发动机转速分别为1600、1900和2400 r/min时,实际二冲程制动功率分别提高了35.94%、45.61%和27.54%,最大缸内压力分别降低了45.42%、27.20%和7.35%.

考虑多维非线性扰动的电子助力制动系统自适应压力控制

针对电子助力制动系统(EBBS)面临的机-电-液多维非线性扰动问题,提出了一种自适应压力控制策略。外层液压控制器引入自适应径向基函数神经网络和鲁棒滑模理论克服液压时变不确定性,中间层位置控制器采用Karnopp摩擦前馈补偿和滑模控制应对传动机构非线性摩擦阻碍,内层电流控制器通过李雅普诺夫理论解决电机电磁特性耦合问题。仿真和硬件在环试验结果表明,设计的压力控制策略能够在多种工况中将EBBS主动制动稳态压力跟随误差维持在0.15MPa之内。

道面平整度对湿滑道面-飞机轮胎相互作用影响分析

湿滑条件下,跑道不平整使积水厚度随道面起伏而变化,影响飞机起降安全。因此,引入国际平整度指数(international roughness index,IRI),搭建基于IRI的轮胎-积水-道面有限元模型,通过仿真模拟,分析不同IRI的道面对飞机临界滑水速度的影响;结合IRI,对比不同飞机轮胎速度、积水厚度条件下道面视摩擦因数较平整道面的降低幅度,分析IRI对道面摩擦性能的影响;并依据某机场视摩擦因数实测试验结果,对仿真实验结果进行修正,探究IRI对飞机刹车效应的影响。结果表明:道面平整段积水厚度一定时,飞机临界滑水速度随IRI增加而降低,当IRI=5时,飞机临界滑水速度较平整道面降低约30%;飞机轮胎速度一定时,视摩擦因数随道面平整度等级降低而减小,当IRI=5时,视摩擦因数较平整道面降低幅度高达98%,严重影响飞机运行安全;道面平整度等级为“好”时,相同平整度段积水厚度下,飞机轮胎与道面视摩擦因数随IRI的增加而减小;综合考虑IRI和经试验数据修正后的视摩擦因数对飞机刹车效应产生的影响发现,随着平整度指数与平整段积水厚度逐渐增加,飞机刹车效应会产生降级。国内某机场道面在1.5<IRI≤2,平整段积水厚度≥7.66 mm的道面条件下,飞机刹车效应最大降低了3级,即由“中到差”降至“差”,此时飞机方向操纵与减速能力严重下降;积水道面平整度评价为“中”和“差”时,飞机刹车效应降级幅度突增,导致道面条件无法保障飞机运行安全;平整段积水厚度为7.66~13 mm时飞机刹车效应受IRI变化的影响较大,降级变化明显,在维护过程中须尤为注意。

基于自适应权重MPC的AEB-P控制策略研究

为进一步优化面向行人的汽车自动紧急制动系统(AEB-P)控制算法,提出了一种综合考虑驾驶舒适性和行人损伤风险的AEB-P分层控制策略。针对C-NCAP的AEB-P评价标准,设计了考虑制动时驾驶员舒适感的制动安全距离模型;通过引入模糊规则综合考虑行人损伤风险和场景工况得到权重系数调整策略,并基于此设计自适应权重系数MPC上层控制器,采用PID下层控制器对自车实际减速度进行修正;建立车辆纵向动力学模型并通过CarSim与Matlab/Simulink搭建测试场景和控制算法,通过硬件在环实验对本文方法和固定TTC阈值算法进行对比。结果表明,所提控制算法能够在93.75%的测试工况中有效避撞,而固定TTC阈值算法避障成功率仅有43.75%。相较于传统控制策略,该方法能使自车和前方行人保持较稳定的最小间距,鲁棒性更好,可为AEB-P控制理论提供参考依据。

预喷参数对乙醇/柴油双燃料发动机燃烧和排放特性的影响

为了改善乙醇/柴油双燃料发动机工作特性,对一台高压共轨柴油机进气系统改造实现了乙醇/柴油双燃料燃烧模式,并开展了预喷参数(预喷正时、预喷油量和预-主喷间隔)对双燃料发动机燃烧过程和排放特性影响的试验研究。结果表明:提前预喷正时使得双燃料燃烧相位提前,放热率峰值也随之增加;但预喷正时为上止点前(BTDC)22~25°CA时,会导致放热率曲线由双峰分布转变为三峰分布,CO、HC、Soot、甲醛、乙醛和乙烯排放量均降低,而NOx排放量呈现增高趋势,有效热效率(BTE)逐渐降低。在预喷正时为19°CA BTDC时,当预喷油量由2.5 mg/cyc逐渐增加至4.5 mg/cyc时,CO和HC排放量逐渐降低,而NOx排放量逐渐增加,BTE呈先增加后降低的趋势,Soot排放量在预喷油量3.0 mg/cyc下达到最低值0.07 FSN。在预喷策略下,提前主喷正时能够使双燃料发动机主喷燃烧相位逐渐提前并靠近上止点,最大缸内压力增加,CO、HC、Soot、甲醛、乙醛和乙烯排放量显著降低,同时发动机的燃油经济性得到改善;在平均有效压力(BMEP)为1.05 MPa和主喷正时11°CA BTDC的工况下,乙醇/柴油双燃料发动机的BTE达到最高值40.31%。

基于比例继动阀的解耦式制动能量回收

针对纯电动商用车在连续制动时,气源压力偏低会导致驱动轴耦合制动力响应速度变慢,影响制动能量回收效率的问题,提出一种基于比例继动阀的解耦式制动能量回收系统(uncoupled braking energy recovery system,URBS)方案。首先,基于比例继动阀的迟滞特性,采用前馈-单神经元PID控制方法,实现制动气压的准确输出;其次,以电池SOC、车速等为约束条件,根据气源压力信号确定供压模式,并制定解耦式制动能量回收控制策略;最后,基于AMESim,MATLAB/Simulink及TruckSim搭建联合仿真平台,选取单次制动工况与循环工况验证了制动力耦合效果及系统的制动能量回收效果。结果表明,基于比例继动阀的URBS可实现耦合制动力的快速响应,达到稳态压力值75%的时间小于0.1 s,且在中国重型商用车行驶工况和中国重型商用车瞬态工况下有效制动能量回收率分别为10.13%,17.17%。所提URBS方案能有效提高驱动轴耦合制动力的响应速度及耦合精度,可为纯电动商用车气压式URBS方案设计提供参考。

内外液流通道筒式磁流变制动器制动性能分析

针对传统磁流变制动器磁场利用率不高的问题,提出了一种具有内外液通道的筒式磁流变制动器;通过在缸筒和旋转套筒中增设非磁性器件,使得磁力线蜿蜒通过内外轴向液流通道的6段有效阻尼间隙,从而使该制动器在外形尺寸不变的前提下能产生较好的转矩性能;阐述了内外液流通道筒式磁流变制动器的结构和工作原理,并对有效阻尼间隙在磁场作用下的磁路进行分析;同时推导建立了制动转矩和温度场数学模型;基于COMSOL软件对磁流变制动器电磁场和温度场进行了仿真分析。由电磁场仿真可知,在外加电流为2.0 A、转速400 r/min时,制动转矩可达101.96 N·m,转矩动态可调范围由1.00增加至29.69;由温度场仿真可知,在多次紧急制动下最高温度为42.88℃,符合磁流变液正常工作范围。

泵控直驱式线控制动单元的设计与分析

为简化传统汽车制动系统结构,更好地满足智能网联汽车对制动力快速调节的需求,提出了一种泵控直驱式线控制动单元,采用泵控直驱容积伺服技术,通过伺服电机直接驱动双向齿轮泵,实现对制动轮缸压力的控制和快速调节,消除阀控系统的节流损失,有效提升系统效率。在泵控直驱式线控制动单元参数设计及数学建模的基础上,试制了制动单元样机与性能测试平台,分析了轮缸压力变化的响应曲线以及跟随特性。仿真和试验结果证明了泵控直驱式线控制动单元的可行性,12 MPa压力阶跃响应时间为200 ms,系统具有良好的响应速度和稳定性,为线控制动技术提供了一种新的实施方案。

涡轴发动机台架刹车起动试验研究

旋翼刹车起动是涡轴发动机一种特有的起动方式,为减少装机试验风险,须在台架模拟涡轴发动机刹车起动。介绍了涡轴发动机刹车起动原理,给出了在台架条件下模拟涡轴发动机刹车起动试验方法,并证明了试验方法的可行性。试验结果表明:涡轴发动机可以在台架模拟直升机旋翼刹车起动;与正常起动相比,刹车起动可以使动力涡轮转速在起动阶段具有较快的加速度,在较短时间内加速到慢车状态,但直升机传动系统要承受较大负载。

天然气发动机制动功率提升试验分析

为进一步提升某装配有压缩释放式缓速器的天然气发动机辅助制动功率,以满足市场需要,分析了压缩释放制动和高功率制动的工作原理,并进行台架制动性能对比试验。结果表明:相比现有压缩释放制动,应用高功率制动可以使该天然气发动机制动功率提升30%以上,标定点升功率达-25 kW。研究结果可为后续发动机尤其是天然气低压缩比发动机在开发设计缓速器选择合适的发动机制动技术时提供参考,以提高车辆制动安全性。

汽车保养中发动机、底盘传动与起制动研究

我国经济处于新常态状态下,国民消费能力不断提升,对于汽车的需求量也在不断扩大。各类新型汽车被研发出来,汽车本身的性能受到国民关注的同时,汽车的保养也日渐受到重视。为进一步普及汽车保养并帮助车主及时发现车辆隐患,汽车维修与保养行业从业人员需要不断提升自身汽车维修与保养技巧,注意各项汽车维修与保养事项。文章讨论汽车保养的重要性并介绍汽车保养的方法,从发动机、底盘传动系统、起制动系统等方面讨论汽车零部件保养技巧,期望可以进一步推动汽车维修与保养行业发展,并引起更多汽车车主的重视。

基于三维模型的铁路工程车空气制动系统管路设计

为了高效、准确设计空气制动系统管路,以采用JZ-7型空气制动机的工程车用空气制动系统为例,介绍空气制动系统组成和工作原理。依据空气制动系统原理图,采用基于三维布管模型的布管设计方法,设计空气制动系统三维图,生成布管工程图,并在JJC型接触网检修作业车上装车验证。验证结果表明,采用基于三维布管模型的布管设计方法设计的布管工程图准确,利用布管工程图进行管路装配施工,能提高现场装配效率,减少管路干涉。

GCY-450型轨道工程车停放制动失效分析及预防措施

针对GCY-450型轨道工程车停放制动时出现的溜逸问题,在介绍停放制动和单元制动器的工作原理基础上,从换向阀故障、减压阀压力值偏低等方面,分析轨道工程车停放制动失效原因,确定是由于减压阀压力值低于标准值导致停放制动失效。针对失效原因,提出在维护保养中增加减压阀压力值检查,以及定期校验压力开关、减压阀和压力表等预防措施。