Automobile Braking System Research Articles

Reliability analysis of an automotive car braking system using logic diagram technique

Reliability analysis of an automotive car braking system using logic diagram technique

Tyre and brake thermal management in NASCAR

The need to manage race car tyres is routine faire and several academic papers have already appeared on this topic. We contribute to this literature with refined tyre grip and wear-rate models. Less well known is a methodology for managing the thermal transients in the car's braking system. This knowledge gap is addressed with a physically-based disc-and-calliper brake-heating model. The parameters in each of the models are optimised against measurement data captured on an instrumented Generation 7 (Gen 7) NASCAR driven on the Darlington speedway. These models are replicated on each corner of the vehicle. The remainder of the paper is directed to studying the minimum lap time performance of a Gen 7 NASCAR that is subject to tyre wear and temperature variations; brake heating influences are emphasised. Due to their novelty, the results focus on the performance impact of temperature variations and constraints on the front brake disc temperatures. Constraints on the brake temperatures are introduced to protect the brakes from fade and thermally-induced damage.

Development of an Operational Digital Twin of a Freight Car Braking System for Fault Diagnosis

AbstractIn the evolving landscape of digital technology, the concept of digital twinning has emerged as one of the most important innovations. Digital twinning, characterized by a one‐to‐one correlation with physical structures in a digital environment, has become an important tool in transferring physical dynamics into digital replicas. This platform, integrating advanced sensor technologies and analytical tools, enables a comprehensive monitoring, diagnosis, and optimization concept. The present research focuses on the application of digital twinning in addressing the complex challenge of managing fault types in freight car brakes. A Digital Twin (DT) model of a freight car braking system is developed that forms the basis for an innovative approach to fault classification. This approach leverages the ability of the DT to emulate and analyze the behavior of the braking system under different conditions. The effectiveness of the proposed method is evaluated through extensive testing and analysis with an experimental data set. The results show that the method is able to accurately diagnose different types of faults. This represents a significant advance in the field of freight car brake system diagnosis.

Research on CNN-LSTM Brake Pad Wear Condition Monitoring Based on GTO Multi-Objective Optimization

As the core component of the automobile braking system, brake pads have a complex structure and high failure rate. Their accurate and effective state monitoring can help to evaluate the safety performance of brake pads and avoid accidents caused by brake failure. The wear process of automobile brake pads is a gradual, nonlinear, and non-stationary time-varying system, and it is difficult to extract its features. Therefore, this paper proposes a CNN-LSTM brake pad wear state monitoring method. This method uses a Convolutional Neural Network (CNN) to complete the deep mining of brake pad wear characteristics and realize data dimensionality reduction, and a Long Short-Term Memory (LSTM) network to capture the time dependence of the brake pad wear sequence, so as to construct the nonlinear mapping relationship between brake pad wear characteristics and brake pad wear values. At the same time, the artificial Gorilla Troops Optimization (GTO) algorithm is used to perform multi-objective optimization of the network structure parameters in the CNN-LSTM model, and its powerful global search ability improves the monitoring effect of the brake pad wear status. The results show that the CNN-LSTM model based on GTO multi-objective optimization can effectively monitor the wear state of brake pads, and its coefficient of determination R2 value is 0.9944, the root mean square error RMSE value is 0.0023, and the mean absolute error MAE value is 0.0017. Compared with the BP model, CNN model, LSTM model, and CNN-LSTM model, the value of the coefficient of determination R2 is the closest to 1, which is increased by 8.29%, 5.52%, 4.47%, 3.30%, respectively, which can more effectively realize the monitoring and intelligent early warning of the brake pad wear state.

Changes in the technical condition of vehicle brakes compared to 2014 year

Purpose: The purpose of the tests is to determine whether and to what extent there has been a change in the parameters of the car's braking system, assessed during the technical inspection. Design/methodology/approach: Diagnostic tests were performed, braking force measurements on a roller device, the following were analyzed: differences in braking force on axle wheels, non-linear increases in braking force, deceleration of braking force, changes in the value of braking force. Findings: Changes in the technical condition of vehicle braking systems in 2022 compared to 2014 were demonstrated. Research limitations/implications: In the future, a trend line of changes in the technical condition of vehicle braking systems can be created. Practical implications: In the course of the research, it was found that the technical tests made it possible to determine the direction of positive changes in the technical condition of the braking systems in the tested vehicles, which translates into vehicle safety in road traffic. Originality/value: Changes in the condition of the brake system in 2022 compared to 2014. Keywords: Safety and quality of transport, braking system, changes of conditions. Category of the paper: Technical paper.

A Rapid Verification System for Automatic Emergency Braking Control Algorithm of Passenger Car

The automatic emergency braking (AEB) system of the passenger car is responsible for auxiliary braking judgment and decision-making in an emergency. Due to the inevitable pressure response delay of passenger car pneumatic braking systems, a large number of verification tests should be carried out to propose appropriate strategies and algorithms. To realize the rapid verification of the AEB control algorithm, a verification system integrating software-in-the-loop (SIL) and hardware-in-the-loop (HIL) was proposed for a two-axle passenger car. It can verify the logic feasibility of the control algorithm through SIL testing, and can verify the implementation effect of the control algorithm through HIL testing. The verification system is composed of IPG, dSPACE, and a pneumatic braking bench. Considering the influence of pneumatic braking delay, it is well-matched with the actual vehicle AEB system. The AEB hierarchical control algorithm was verified under three typical test conditions. The results show that the SIL testing results of speed and relative distance are in good agreement with the HIL testing results, and the average relative deviation of relative distance is only 1.7 m. The single test time of the SIL testing is about 228 s, which can meet the requirements of rapid verification of the AEB control algorithm of the passenger car.

Development of Asbestos-free Disc Brake Pad Using Periwinkle Shell Powder and Coconut Shell Ash as Base Materials

Brake pads are integral part of an automobile braking system that contribute to the full control of the vehicle. The composite materials for their production must therefore possess adequate chemical, mechanical, physical, and thermal properties. The development of asbestos-free disc brake pad using Periwinkle Shell (PS) powder and Coconut Shell Ash (CSA) as reinforcement and frictional filler material respectively is presented. This was done with a view of establishing suitability of PS powder and CSA as replacements for asbestos which has been found to be carcinogenic and capable of causing Asbestosis and Mesothelioma [1]. Other ingredients used are graphite as lubricant, epoxy resin as binder, copper, zinc, and aluminum powders as abrasives and also to impact mechanical strength. The optimum percentage formulation of these materials for the pad was arrived at by using the ANOVA tool of the Box-Behnken technique of Design Expert Software, DX-13. The CSA and PS powders were sieved into grades of 106 µm, 150 µm, 212 µm and 300 µm and then combined with other constituents to produce the brake pad. The pads were characterized in terms of their physical, mechanical and tribological properties. It was observed that increase in particle size distributions leads to decrease in densification and carbon crosslinking of the produced composite brake pads. Therefore, the 106 µm particle size sample has better properties than others. Comparison analysis shows that the performance parameters of the 106 μm size brake pad compares well, and in some cases better, with typical after-market replacement pads, an asbestos-based brake pad and brake pads developed from past research works.

Research on Fuzzy Control Method of Automobile Antilock Braking System

The automobile Antilock Braking System (ABS) can prevent the wheel from locking by automatically adjusting the brake pressure at a high speed during emergency braking. While improving the braking effect of the car, it can also keep the steering ability of the car and ensure the safety of passengers. The automobile braking process has a strong nonlinearity and uncertainty, so exploring a simple and reliable control strategy is the focus of current research. Based on this, this paper proposes a variable-domain fuzzy proportional integral differential (PID) control strategy using a particle swarm optimization (PSO) algorithm to iteratively find the optimal theoretical domain. First, the PSO strategy is used to obtain the optimal regulation parameters. Then, the dynamic antiinterference ability of the control system is guaranteed by the variable theory domain fuzzy PID control, and the PID parameters and variable theory domain expansion factor are optimized by the PSO to increase the utilization degree of fuzzy rules initially set. Finally, compared with the traditional control strategy, the simulation and real vehicle test prove that the proposed system can significantly improve the control accuracy of abs. The proposed system has the advantages of small overshoot, short adjustment time, strong antiinterference ability, and practicability, which greatly improves the tracking performance of the ABS.

БЕЗОПАСНОСТЬ ЭКСПЛУАТАЦИИ ВОЗДУШНЫХ РЕЗЕРВУАРОВ ТОРМОЗНОГО ОБОРУДОВАНИЯ АВТОМОБИЛЕЙ

The study objective is to substantiate the possibility of using products made of composite materials instead of metals in the automotive industry, in particular, for air tanks of the braking system of KAMAZ vehicles.
 The problem to which the paper is devoted is to provide the possibility of replacing metal products of the car braking system with products made of composite materials, for example, for air tanks.
 Research methods. A mathematical model of the loading conditions of heated cylindrical shells of vessels made of composite materials under axial loading is substantiated, the basics of some issues to use cylindrical shells in the problems of dynamic deformation of shell structural elements are justified.
 The novelty of the work. For the first time in the automotive industry, the possibility is theoretically and experimentally substantiated to replace metal products with products made of composite materials, which in terms of their technical characteristics, weight, temperature and strength are not inferior or superior to metal ones, in particular, ensuring corrosion resistance, tightness and safety.
 The results of the study. As a result, it was found that after removing the load and cooling down, the walls of the shells remain in the same position which they occupied at the time of buckling, and the surface disintegration in the area of the wave crests was not detected. However, upon visual inspection of the cross-sections of the shells, wall delamination is observed, with increasing temperature, the value of the critical load decreases and tends to zero at a certain limit temperature.
 Conclusions: The studies conducted allow to conclude that in terms of weight, temperature and strength characteristics, composite materials are not inferior and even superior to metal ones in ensuring corrosion resistance, tightness and safety of operation. In the automotive industry, products made of composite materials can improve the reliability and safety of vehicle systems, including braking, reduce accident rates for transport processes, reduce injuries and death of people.

Design and analysis of brake system for FSAE race car

The objective of this research paper is to design, simulate and compare components of a race car braking system. The Racecar is an FSAE car that is designed around the rules and regulations of the FSAE rulebook, the main aim of this project is to make components lightweight and improve their performance as compared to their OEM counterparts. The braking system involves the mathematical calculation of pedal ratio, brake torque, heat generated in brake discs, and required clamping force using MATLAB to achieve peak deceleration after which these values would be used to design and simulate the components. The paper presents some innovative new ideas applied in an FSAE car and also involves designing techniques like topology optimization which was done using Altair inspire. Finally, all the components were designed in Solidworks, and simulations like Factor of safety, von mises stress, and strain were performed using ANSYS 18.1. The paper also compares the work of other authors as well and explains the differentiating factors between our and their design.

A Review on Design Optimization and Analysis of Brake System with Student SAE International Safety Rules

Abstract: Formula Student Competitions are held globally. In these competition students design, fabricate and compete with a formula style race car. The braking system is the most important system in a car. If the brakes fail, the Result may be disastrous. An FSAE race car brake system is different from the conventional brakes. Thus the methodology followed while designing such a braking system Is different. We as a part of an FSAE team have taken up this project to develop a Hydraulic Braking system of an FSAE car. The design of an effective braking system plays a major role in high Performance formula cars since the stopping distance and speed control during cornering are the important part of any race. Everyone wants their Car to go fast, but the braking system should be capable to stop Immediately and safely. Any car with a highly effective braking system Fills confidence in the driver. It also increases driving pleasure. Keywords: callipers, Wilwood, Master cylinder, Rotors, Ansys

Flow and Thermal Analysis of a Racing Car Braking System

The braking system of a racing car is one of the main design challenges. The flow around and inside the wheel of an F1 car with all braking system components is analyzed in order to evaluate the heat transfer after a braking event. Very few studies have been published on this topic, mainly due to the high confidentiality level in the racing car sector. In the present work, using an actual geometry of an early 2000s F1 car, the braking system is simulated using a CFD approach. The boundary conditions for the wheel and brake system are taken from the simulation of a vehicle model with a front wing. Different heat transfer phenomena are progressively added to the model in order to understand their effects, including thermal convection only, radiation and conjugate heat transfer. Two different vehicle velocities are simulated to quantify and compare the heat removal after a braking event. The different heat transfer mechanisms have dramatic effects on the prediction of the brake cooling results, and these are quantified in order to understand the limitations of the simplified approaches. Finally, the influence of the ambient pressure at two different altitudes on the heat transfer from a braking event is studied.

Analysis of the Cooling Concept of the Braking System of a Formula Student Racing Car Using CFD Simulation and 1D Simulation

In order to guarantee the performant operation of the braking system of a racing car under high load an optimized thermal design of the braking system is an important factor. Especially in motorsports, a lot of braking energy is converted into heat due to short and intense braking events. Therefore, a suitable cooling concept is a crucial point to ensure a reliable thermal management of the braking system to dissipate the generated heat. In this work, the braking system of the formula student racing car of the UAS Esslingen is analysed using the racing car of the season 2019. A transient 1D simulation model of the heat balance of the braking system is created. For the determination of the heat transfer coefficients a steady 3D Conjugate Heat Transfer (CHT) simulation model is set up. The logging data of a real race are used for the validation of the presented model (s). The heat balance of the braking system, its entire heat flows as well as the time-dependent temperature evaluation of the brake disc are analysed and compared. The results of this analysis are used to create a cooling concept for the racing car’s braking system, to ensure an optimized braking performance over the entire race. Several different (geometrical) variants of the thermal design of the braking system are investigated using the above mentioned numerical models and the results are presented. Furthermore, the implementation of a cooling duct for the braking system is studied.

An enhanced double homogeneously weighted moving average control chart to monitor process location with application in automobile field

AbstractThe memory control charts, including cumulative sum (CUSUM) and exponentially weighted moving average (EWMA) control charts, are widely used to monitor small‐to‐moderate shifts in the process location and/or dispersion. The homogenously weighted moving average (HWMA) control chart is the advanced form of the EWMA control chart to monitor process location shifts. Besides, the auxiliary information‐based memory control charts efficiently monitor process location shifts. The objective of this study is to propose an auxiliary information based double HWMA, symbolized as control chart to further enhance the monitoring of process location shifts. The control chart is modeled by mixing the auxiliary information‐based HWMA plotting statistic features into the other HWMA control chart. For numerical results, Monte Carlo simulations are used as a computational technique. Famous performance measures including average run length (), extra quadratic loss, relative , and performance comparison index are used to compare the performance of proposed control chart against other control charts including classical CUSUM and EWMA, mixed ‐, auxiliary information based EWMA (), HWMA, auxiliary information based HWMA (), and double HWMA control charts. The comparisons revealed that the proposed control chart outperformed other control charts, especially for small‐to‐moderate process location shifts. An automobile braking system application is also provided for users and practitioners to demonstrate the importance of the proposed study from a practical perspective.

Research on Anti-lock Braking System of Electro-mechanical Braking Vehicle Based on Feature Extraction

With the increase of vehicle speed, the increase of road traffic density and people’s higher requirements for vehicle safety, the Anti-lock Braking System (ABS) has become an important safety device on vehicles. It not only has the braking function of the common braking system, but also can prevent the wheels from locking. Automobile ABS is an important device that affects the safety of automobile braking system and driving safety. It can shorten braking distance and improve directional stability and operability during braking. Electro-mechanical braking control system adopts advanced electro-mechanical braking technology and is applied to automobile braking control system together with anti-lock braking system. Emb (electro-mechanical brake) uses electric energy as the energy source of the braking system, and uses the motor to drive the actuator to generate braking force, which responds quickly and can effectively improve the active safety of automobiles. In this paper, based on feature extraction algorithm, the brake pressure estimation method of EMB actuator is proposed, and the anti-lock braking control algorithm of automobile is analyzed.

Parameterized Structure Design of Giant-magnetostrictive Disc Brake

Brake is one of the important components of automobile braking system. The speed, safety and stability of its performance are the important evaluation indexes of automobile braking system. The existing brakes have some shortcomings in these aspects. The paper designed a new type of disc brake, which has the advantages of faster response speed, stronger reliability and simpler structure compared with traditional brake. At the same time, it provides a new idea for the design of disc brake.

Research on Vehicle Driving Stability Based on Dynamics Co-simulation

Automobile braking system is an important guarantee for automobile driving safety, and improving automobile braking performance is an important task in automobile development. ESP system can effectively reduce the accident rate and improve driving safety. This paper systematically introduces the development of vehicle stability control technology from four aspects: dynamic modeling, state observation, control strategy and industrialization. It mainly introduces the state observation and control strategy.

Simulation modeling of the automobile braking system performance

Simulation model of the automobile braking system performance taking into account not only the wheel, brake pads, brake drum dynamics but the dynamics of the hydraulic brake system: the main hydraulic cylinder, the brake gear hydraulic cylinders has been presented. Effect of changing parameters of the braking system elements on the braking distance of the automobile has been considered. Road users’ safety relies heavily on effectiveness of vehicle braking system. Thus, braking system design is essential when designing a new vehicle. Modeling of the functionality of the designed system is one of the most important phases of design. Time and material expenses for imitational modeling are always less than actually producing models and conducting experiments on them. Experiments should prove theoretical abstracts stated while modeling. Thus, the imitational model should be well designed and adequate. Imitational model allows efficient operation of brake system with different system of control.

Development of a method for optimizing a product quality inspection plan by the risk of non-conformity slippage

Risk-based approaches are a feature of the modern quality management system. A method of optimization of product quality inspection plan by the risk of non-conformity slippage is proposed. The method is based on a risk ranking matrix, criteria of the failure mode and effects analysis (FMEA), block classification of inspection plans, approaches to non-conformity prediction, and probability multiplication theorem for independent events.The risk of non-conformity slippage was defined as a criterion of inspection plan optimization. The proposed method allows determining the acceptability of the risk, with 100 % quality inspection, in case of abandoning the inspection operation, the possibility of applying sampling and minimum sampling volumes necessary to ensure an acceptable risk level. Relationships were derived to determine the minimum required number of inspected units out of 1,000, with an acceptable risk level in product quality inspection. The initial data for the calculation are the main characteristics of the inspection plan: the probability of the object conformity with the requirements for the controlled quality characteristic, the probability of not detecting non-conformity with the provided inspection method, the rate of non-conformity slippage, which ensures an acceptable risk level. The formula allows calculating the minimum sampling volume that provides an acceptable level of non-conformity slippage risk during the implementation of the product quality inspection plan (QIP).The proposed method was tested on the inspection plan for welds of air tanks of the railway car braking system. It is possible to abandon the original 100 % inspection plan and apply sampling, which provides an acceptable level of non-conformity slippage risk. This allows reducing the volume and costs of inspection by 18 %

Дослідження процесу гальмування вивішених коліс автомобіля з гідравлічним приводом гальм

For diagnosing car braking systems, bench methods have become the most widespread, and on power stands with running drums. The main disadvantage of these methods is the high cost of brake stands with low quality diagnostic information. At the same time the method of diagnosing brake systems on change of angular speed of the hung up wheels is perspective. But the considered method does not have a sufficiently complete theoretical justification, especially for cars with hydraulic brakes and therefore requires research. Therefore, the work substantiates the diagnostic modes and diagnostic parameters, obtained analytical dependences of the process of braking car wheels with hydraulic brakes, which describe the change in the angular deceleration of the suspended wheels over time in different parts of the brake diagram and the delay time of the brake system. The mathematical model is based on the differential equation of motion of the braked wheel when braking a car with a connected transmission (with clutch engaged) on a straight horizontal section of road. The change in braking torque during braking is determined by the nature of the pressure change in the drive. When braking the wheel, the braking force acts on the radius of the brake drum. The obtained analytical dependences make it possible to study the influence of various factors of the technical condition of brake systems on the performance of the braking process. In order to substantiate the diagnostic modes and diagnostic parameters, analytical dependences of the process of braking car wheels with hydraulic brakes have been developed, describing the change of angular deceleration of suspended wheels in time at different parts of the brake diagram and time delay of the brake system. The obtained analytical dependences make it possible to study the influence of various factors of the technical condition of brake systems on the performance of the braking process.