Conventional Braking Research Articles

Enhancing Estimating the Charge Level in Electric Vehicles: Leveraging Force Fluctuation and Regenerative Braking Data

Accurate determination of the state of charge is vital to optimize the performance and lifespan of electric vehicle batteries. Traditional methods which rely on battery models and direct measurements can be error-prone due to fluctuating operating conditions and battery degradation over time. Regenerative braking systems are crucial in electric and hybrid vehicles for improving energy efficiency by transforming kinetic energy into electrical energy during braking. However, force fluctuation is a challenge that can affect the performance and comfort of regenerative braking. It is known to us that electric motors and generators used in regenerative braking have non- linear torque characteristics, especially at low speeds, leading to inconsistent braking force. Variations in road conditions, such as wet or uneven surfaces, can affect the grip of the tires, leading to fluctuations in deceleration. Interactions of regenerative braking system with conventional friction brakes can cause force fluctuations, especially during the transition between the two systems. This study introduces an improved state of charge estimation technique based on force fluctuation and a regenerative braking system. This research shows that this approach significantly enhances state of charge accuracy compared to traditional methods, especially in urban driving conditions with frequent braking. The findings underscore the potential of using regenerative braking as well as force fluctuation condition data as a valuable input for state of charge estimation, ultimately leading to better battery management and an extended electric vehicle range.

Investigation of the friction and deformation behaviour of high-speed brakes

Spring-applied brakes are widely used components in industrial drive systems. They provide a braking torque by friction between a mostly organic friction lining and a metallic counter surface. Increasing with decreasing size, they currently achieve speeds of up to 6,000 rpm, which corresponds to a sliding speed in frictional contact of up to 35 m/s. At the same time, there is a trend towards high-speed drives, with speeds of 10,000 rpm and above. So far, little is known about the behaviour of the friction value and torque of conventional spring-applied brakes with low-cost organic friction linings under these operating conditions. For this reason, a test rig was develop - ed that allows testing at sliding speeds of up to 120 m/s with different load inertias. The tests carried out at KAt so far showed that with limited friction work, the conventional spring-applied brake reaches the nominal braking torque at higher sliding speeds. In addition to thermal overload of the friction lining, plastic deformation of the friction bodies can also permanently disrupt the operating behaviour of brakes operated at high sliding speeds. The plastic deformation of the friction discs manifests itself, for example, in a saucer-like shape of the discafs, leading to a reduction in the air gap and causing unwanted changes in the friction conditions. This paper describes the relationship between friction work and friction coefficient in organic linings and the physical mechanism of the deformation process of the friction discs. Based on these possible measures to reduce deformation are explained.

ELECTROMAGNETIC BRAKING SYSTEM

In this paper, we delve into the intricacies of Electromagnetic Braking systems and their influence on traditional braking methods. Ensuring driver safety and comfort on the road is paramount for any braking system. Conventional braking systems, including Drum Brakes, Disc Brakes, Hydraulic Brakes, and Pneumatic Brakes, rely on friction to decelerate vehicles, leading to heat generation and wear on braking components, thereby diminishing efficiency over time. Electromagnetic Braking emerges as a viable alternative, boasting superior efficiency characterized by a high power-to-torque ratio and reduced friction. This paper examines the transition to electromagnetic braking and its implications for conventional braking methodologies. Keywords: Electromagnetic Braking; Traditional Braking; Friction; Heat Generation; Efficiency.

Comparison of performance and tribological properties of electromechanical brake with magnetorheological fluid and magnetic powder

Brakes, which are the safety component of any automobile used to control the motion of the vehicle as per the driver's choice. In conventional brakes, friction lining materials are used, which affect the health of human beings and pollute the environment. Hence, there is a need to look for new types of brake systems. In the present work, a new type of electromechanical (EM) drum brake is designed that does not use friction lining materials for brake application. It can use magnetorheological (MR) fluid as well as magnetic powder (MP) for brake application. The presented brake has been designed to operate in hybrid mode that is, shear plus compression mode. When MR fluid is used, these brakes face the problem of the leakage of MR fluid which motivates to use of MP. In addition to the design of the new brake, the performance of the new brake has been tested with MR fluid and MP separately on a full-scale brake inertia dynamometer. The performance test results have been compared for both MR fluid and MP and compared with conventional friction brakes. 14.56% and 11.38% more braking torque have been observed for MP compared to that of MR fluid in shear and hybrid mode respectively. In addition to the performance study, the effect of MR fluid and MP on brake shoe surface properties has been studied.

On Torque Vectoring Control: Review and Comparison of State-of-the-Art Approaches

Torque vectoring is a widely known technique to improve vehicle handling and to increase stability in limit conditions. With the advent of electric vehicles, this is becoming a key topic since it is possible to have distributed powertrains, i.e., multiple motors are adopted, in which each motor is controlled separately from the others. Moreover, electric motors deliver the torque required by the controller faster and more precisely than internal combustion engines, active differentials and conventional hydraulic brakes. The state of the art of Direct Yaw Moment Control (DYC) techniques, ranging from classical to modern control theories, are analyzed and discussed in this paper. The aim is to give an overview of the currently available approaches while identifying their drawbacks regarding performances and robustness when dealing with common issues like model uncertainties, external disturbances, friction limit and common state estimation problems. This contribution analyzes all the steps from the lateral dynamics reference generation to the desired control action computation and allocation to the available actuators. In addition, some of the presented control logic is evaluated in a simulation environment for a passenger car. Results of both open-loop and closed-loop maneuvers allow the comparison and clarification of each control strategy’s key advantages.

Simulation of screw size effect on performance of electro-mechanical braking system

Electro-mechanical brakes (EMB) are promising alternatives to conventional braking systems, as they are eco-friendly and have lower maintenance requirements. Currently, researchers and automotive manufacturers are interested in developing the performance of EMB systems for implementation in commercial vehicles. Current studies are either conducted experimentally and/ or modeled using mathematical based simulation models using different vehicles kinematic and dynamic models. These models are time-consuming, and expensive in case of experimental implementation. This paper presents a simple and easy-to-construct simulation model using MATLAB Simulink Graphical user interface (GUI) without using conventional mathematical modelling techniques. The presented simulation model studies the effect of the lead screw size on performance of EMB in terms of the generated clamping force and system response time. The accuracy and reliability of the proposed model were statistically verified using ANOVA. In addition, its performance was verified by comparing its results with the same input data used in previously validated experimental and mathematical-based simulation models from the literature review. The proposed model can be used to improve the performance of EMB systems and facilitate comparisons among different EMB designs.

Novel Unscented Kalman Filter-based method to assess the thermal behavior of carbon brake discs for high-performance motorcycles

In the past few decades, braking systems with carbon discs have become the dominant technology for many racing applications, such as in the MotoGP class. Indeed, they provide higher friction coefficients. Moreover, thanks to their lightweight materials (with respect to conventional steel brakes), the unsprung masses and the gyroscopic effects can be reduced. Therefore, the motorcycle dynamic performance can be significantly improved. The usage of carbon brakes requires a very accurate assessment of their thermal behavior. In fact, although their operating temperature in real racing conditions may cover a wide range, their optimal braking performance can be achieved only within a relatively narrow temperature range. This work focuses on the development of the Unscented Kalman Filter (UKF) algorithm as a suitable mathematical tool for assessing the temperature gradient of the carbon disc mounted on the motorcycles competing in the MotoGP™ world championship. A one-dimensional (1D) finite element (FE) model of the disc is developed to provide the a priori state estimate that the filter will combine with the information measured by the temperature sensor available on board to compute the optimal posterior temperature estimation. Besides estimating temperature, the UKF is also exploited to identify the convection heat transfer coefficient (h) of the disc, which is a fundamental parameter for a proper model calibration.

Research on multi-system integrated and coordinated control of automotive chassis

Abstract In this paper, we analyze automotive chassis system modeling and subsystem control to construct a nonlinear chassis system by analyzing the dynamics of the whole vehicle, handling process, and manufacturing process. Secondly, the integrated braking system decoupling controller is designed to control both friction and electromagnetic integrated brake systems effectively. Finally, the Simulink simulation model is integrated into Matlab software to conduct an imitation study of the control system. When the brake controller is activated, the findings show that the wheel’s slip rate drops to almost 0.2, which is close to the desired value. The vehicle’s braking distance with conventional braking is close to 40m, but it is reduced to about 30m under the action of the ABS system, which effectively shortens the braking distance and ensures the vehicle’s safety in braking.

Design, Development and Innovation of Rotating Brake-Pads

The aim of this contribution is to provide with new approach and improved technology of braking which even though exists in just theoretical sense can be a potential replacement of the system which shares similar building blocks and concepts used in any other conventional braking systems. It consists of 4 calipers running all around the rotor with the shear intension of giving a support structure to the pads who along with just working as any other conventional disc brake, also rotates in the opposite direction of the rotor which not only suffice all the benefits of conventional disc brake but also offers more adjustments and tunability for the new system. This reverse rotation of pads help in mitigating the inertial forces being applied on the rotor while in motion and in general theoretical perspective improves the consistency and efficiency of braking system. It has a specially designed& developed CAD model for brake pads which sharetooth profile of a sprocket on the circumference of the pressure plate (after which on the face of the plate are usually the brake pads assembled). It also exhibits a novel and versatile mechanism developed using designing software to run the whole system effortlessly without compromising much. As this mechanism is a standalone system it can be mounted on the exact mounting points as any other assembly of rotor and calliper in a braking system. These results and finding can be incorporated in ample fields where there is a need for better and effective braking technology which usually runs in high risk environment

Research on the Braking Control Strategy of Automobile Driven Independently by Front and Rear Dual Motors

Regenerative braking is one of the most important methods to solve the difficulty of energy loss in city driving. The dual-motor pure electric vehicle is considered to be the object of study with the goal of energy utilization of the reproductive system of braking. The PSO (particle swarm optimization) algorithm is adopted to solve the problems under these constraints of ECE-R13 braking regulations and I-curve. The results of the simulation indicate that compared to the conventional braking tactic of AVL CRUISE, the energy renewal effect of the steering strategy is raised by almost 19.24% and the driving distance is increased by as much as 23.8%.

Regenerative Braking Control Strategy Based on AI Algorithm to Improve Driving Comfort of Autonomous Vehicles

Recent studies on autonomous vehicles focus on improving driving efficiency and ignore driving comfort. Because acceleration and jerk affect driving comfort, we propose a comfort regenerative braking system (CRBS) that uses artificial neural networks as a vehicle-control strategy for braking conditions. An autonomous vehicle driving comfort is mainly determined by the control algorithm of the vehicle. If the passenger’s comfort is initially predicted based on acceleration and deceleration limits, the control strategy algorithm can be adjusted, which would be helpful to improve ride comfort in autonomous vehicles. We implement numerical analysis of the control strategy, ensuring reduced jerk conditions. In addition, backward propagation was applied to estimate the braking force limits of the regenerative braking systems more accurately. The developed algorithm was verified through the Car Sim and MATLAB/Simulink simulations by comparing them with the conventional braking system. The proposed CRBS offers effective regenerative braking within limits and ensures increased driving comfort to passengers.

SIMULATION-BASED INVESTIGATION OF THE EFFECTS OF MAJOR PARAMETERS ON MAGNETORHEOLOGICAL BRAKE TORQUE

In this paper, a magnetorheological brake (MRB) model that supports a van truck going downhill without interfering with the conventional braking system installed on this vehicle is designed and simulated. The simulation model demonstrates the impact of key variables on brake torque, including operation conditions, MRB tooth tilt angle, MRB rotor thickness, and MRB tooth count. As a result, the simulation results show that the maximum brake torque value is about 136.41 Nm at the 75-degree inclination angle of the tooth disk. The MRB rotor thickness does not have many effects on the brake torque. The maximum brake torque (138.7 Nm) can be achieved at 10 cm rotor thickness. The brake torque increases following an increase in the number of MRB teeth. The brake torque increases by 6% when the number of teeth increases from 1 to 3. Keywords: Magnetorheological Fluid, Magnetorheological Brake, MRB Tooth Tilt Angle, MRB Rotor Thickness, Braking Torque DOI： https://doi.org/10.35741/issn.0258-2724.58.3.21

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: the first 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 microcontroller 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 conventional braking system and the simulated proposed system. Further, the experimental 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-saving actuation signal for magnetorheological valve train by leveraging hysteresis effect

• Analysis of electromagnetic hysteresis effect in magnetorheological valve train. • Customized pulse actuation signal for leveraging the hysteresis effect in magnetorheological valve train. • Pulse signal optimization for energy saving operation of VVL that improves the engine efficiency. • Customized pulse signal saves actuation energy of magnetorheological valve train. Smart, adaptive, and effective magnetorheological (MR) technology-based devices are replacing conventional brakes, clutches, valves, and dampers. MR valve improves engine performance by enabling variable valve actuation. Constructing an MR valve train is simpler than other active valve systems. However, similar to other electromagnetic valves, the MR valve train consumes considerable electrical energy in controlling the resistance force of the MR fluid such that the valve can remain partially open or fully closed. Thus, an engine equipped with an MR valve expends additional fuel for the actuation of the valve system. In this study, instead of conventional direct current (DC) actuation, an energy-saving customized pulse (CP) signal is proposed for valve actuation by leveraging the electromagnetic hysteresis effect. The applied CP signal causes fluctuations in the generated magnetic flux, resistance force, and consequent valve position. Therefore, the variation in MR resistance force at various duty cycles and negative half cycles was investigated and compared with the required force to perform variable valve lift (VVL). Simulations indicated that a 35% duty cycle with 75% current during the negative half cycle was able to maintain the required force but results in negligible deviation in the resistance force which doesn’t affect the VVL operation. Therefore, the proposed method is advantageous over conventional DC input, conferring actuation energy-savings of approximately 28%.

Design and fabrication of air brake system using IC engine exhaust gas

The aim of this project is to design and fabricate an Air Brake System based on Exhaust gases of an IC engine. The main objective is to reduce the workloads of the engine drive to operate the air compressor, because the compressor is not operated by the engine drive. A turbine is placed in the path of exhaust from the engine. The turbine is connected to a dynamo by means of coupling, which is used to generate power. Depending upon the airflow the turbine will start rotating, and then the dynamo will also start to rotate. A dynamo is a device which is used to convert the kinetic energy into electrical energy. The generated power can be stored in the battery and then this electric power has loaded to the DC compressor. The air compressor compresses the atmospheric air and it stored in the air tank and the air tank has pressure relief valve to control the pressure in the tank. The air tank supplies the compressed pneumatic power to the pneumatic actuator through solenoid valve to apply brake. The pneumatic actuator is a double acting cylinder which coverts pneumatic pressure into linear motion. The generated electric power from the turbine used to compress the air in the DC compressor then supplied the pneumatic power to the air braking system. The exhaust gas was effectively utilized to perform the air braking system in addition to the conventional braking system and found the improvement in the braking performance.

A novel coordinated control strategy of regenerative braking and anti-lock system for electric vehicles

Regenerative braking is one of the core technologies to improve the economy of pure electric vehicles. To realize the improvement of the energy recovery effect under conventional braking conditions and the coordinated control between regenerative braking and anti-lock system under emergency braking conditions of pure electric vehicles, this paper studies a front and rear axle braking force distribution method with the actual road adhesion coefficient and braking strength as the premise, while using fuzzy control to distribute the front axle electromechanical braking force. The sliding mode controller with double power convergence law is designed to enhance the stability of the anti-lock system. Finally, the braking coordination control strategy is proposed by combining the designed regenerative braking and anti-lock control. Through simulations and experiment, it has been proved that the control strategy is effective and can effectively improve the economy of pure electric vehicles.

An improved parallel regenerative braking system for small battery electric vehicle

PurposeThe purpose of this paper is to design an improved parallel regenerative braking system (IPRBS) for electric vehicles (EVs) that increases energy recovery with a constant brake pedal feel (BPF).Design/methodology/approachThe conventional hydro-mechanical braking system is redesigned by incorporating a reversing linear solenoid (RLS) and allowed to work in parallel with a regenerative brake. A braking algorithm is proposed, and correspondingly, a control system is designed for the IPRBS for its proper functioning, and a mathematical model is formulated considering vehicle drive during braking. The effectiveness of IPRBS is studied by analyzing two aspects of regenerative braking (BPF and regenerative efficiency) and the impact of regenerative braking contribution to range extension and energy consumption reduction under European Union Urban Driving Cycle (ECE).FindingsIPRBS is found to maintain a constant BPF in terms of deceleration rate vs pedal displacement during the entire braking period irrespective of speed change and deceleration rate. The regenerative ratio of IPRBS is found to be high compared with conventional parallel regenerative braking, but it is quite the same at high deceleration.Originality/valueA constant BPF is achieved by introducing an RLS between the input pushrod and booster input rod with appropriate controller design. Comparative analysis of energy regenerated under different regenerative conditions establishes the originality of IPRBS. An average contribution ratio to energy consumption reduction and driving range extension of IPRBS in ECE are obtained as 18.38 and 22.76, respectively.

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

Investigation on the intermittent braking strategy of high-speed train

In this article, an intermittent braking strategy (IBS) was proposed to improve the thermal-mechanical performance of the brake system under emergency braking, and its feasibility was performed by the thermal-mechanical-wear coupling analysis model validated with experiment results. According to the simulation results, the maximum thermal stress of brake disk for the conventional continuous braking strategy is about 879 MPa at initial brake speed of 350 km/h, which has exceeded the material property limits, yet the intermittent braking strategies can alleviate it obviously with a decrease of 139 MPa. Furthermore, the maximum temperature and thermal stress of the optimal IBS can be decreased by 18% and 40%, respectively, which shows the significance and validity of the proposed IBS.

Review Paper of Design and Fabrication of Smart Electromagnetic Breaking System

Abstract: According to a study 20-30% of the road accident cases are caused due to less attentiveness of vehicle driver or the failure of brakes and vehicles have mechanical brakes which requires a high mechanical force that cause a problem to handicap person so to overcome above described problem we came up with the idea of intelligent braking system with obstacles detection which has 3 parts first is electromagnets to provide automation to the brakes and second part is infrared sensor by sensing braking system can detect obstacles so that it can automatically send signal to relay and brakes can be applied third part is brake for which we electromagnet braking to provide smoothness and effective braking and the last and main part or brain of the system is infrared sensor and relay which gets the signal from sensor and activates the brakes So from this braking system we can provide the automation to a mechanical braking system which can be further modify and can be implement to vehicles the brakes in which we can fully rely on and can also be used in vehicles for handicaps that aren't able to apply conventional braking. 1) BRAKE • A brake is a mechanical device which retards motion. • Brakes use friction between two surfaces to convert the kinetic energy of the moving object into heat. 2) Need for Alternative These systems are prone to the wear and tear on usage a) Conventional braking systems produces continuous power dissipation as heat and may fail if the temperature rises too high b) Friction based braking methods are also not efficient under wet conditions