The current research of master cylinder pressure estimation mainly relies on hydraulic characteristic or vehicle dynamics.But they are not independently applicable to any environment and have their own scope of applic...The current research of master cylinder pressure estimation mainly relies on hydraulic characteristic or vehicle dynamics.But they are not independently applicable to any environment and have their own scope of application.In addition,about the master cylinder pressure control,there are few studies that can simultaneously balance pressure building accuracy,speed,and prevent pressure overshoot and jitter.In this paper,an adaptative fusion method based on electro-hydraulic characteristic and vehicle mode is proposed to estimate the master cylinder pressure.The fusion strategy is mainly based on the prediction performance of two algorithms under different vehicle speeds,pressures,and ABS states.Apart from this,this article also includes real-time prediction of the friction model based on RLS to improve the accuracy of the electro-hydraulic mode.In order to simultaneously balance pressure control accuracy,response speed,and prevent overshoot and jitter,this article proposes an adaptative LQR controller for MC pressure control which uses fuzzy-logic controller to adjust the weights of LQR controller based on target pressure and difference compared with actual pressure.Through mode-in-loop and hardware-in-loop tests in ramp,step and sinusoidal response,the whole estimation and control system is verified based on real hydraulic system and the performance is satisfactory under these scenes.This research proposes an adaptative pressure estimation and control architecture for integrated electro-hydraulic brake system which could eliminate pressure sensors in typical scenarios and ensure the comprehensive performance of pressure control.展开更多
In ground vehicles, the brake is an essential system to ensure the safety of movement. Multiple braking mechanisms have been introduced for use in vehicles. This study explores the potential of using magneto-rheologic...In ground vehicles, the brake is an essential system to ensure the safety of movement. Multiple braking mechanisms have been introduced for use in vehicles. This study explores the potential of using magneto-rheological fluid (MRF) brakes in automotive applications. MRF brakes offer controllable braking force due to a magnetic field, but their use is limited by simulation challenges. In this study, a 7-tooth MRF brake model is proposed. The brake model is simulated in Altair Flux software to analyze magnetic field distribution, braking torque, and its variation under different currents and disc speeds. The simulation conditions also consider both viscous and electromagnetic torque components. Then, the results are analyzed across different brake regions, including rotor, stator, and fluid gap. These results provide valuable insights for designing, manufacturing, installing, and testing MRF brakes for automotive use.展开更多
A new electrical toothed band brake is proposed based on the planetary gear shifting transmission.The corresponding mathematical model and the finite element model are established to investigate the braking dynamic ch...A new electrical toothed band brake is proposed based on the planetary gear shifting transmission.The corresponding mathematical model and the finite element model are established to investigate the braking dynamic characteristics and the stress distribution of brake components.According to the structural features and working principle of the brake,the braking process can be divided into a gap elimination stage,a sliding stage,a meshing stage,and a collision stage.The greater the initial speed of brake drum,the higher the impact torque in the collision stage,and the larger the stress of brake components.The ideal range of initial speed is 50-100 r/min,and the ultimate stress is 514 MPa appeared in the right brake band.This study present a wide range of possibilities for further investigation and application of the electrical toothed band brake.展开更多
In this paper,the problem of brake orbits with minimal period estimates are considered for the first-order Hamiltonian systems with anisotropic growth,i.e.,the Hamiltonian functions may have super-quadratic,sub-quadra...In this paper,the problem of brake orbits with minimal period estimates are considered for the first-order Hamiltonian systems with anisotropic growth,i.e.,the Hamiltonian functions may have super-quadratic,sub-quadratic and quadratic behaviors simultaneously in different variable components.展开更多
Brake wear particle(BWP)emissions are considered one of the dominant sources of particulate matter pollution in urban environments.BWP emissions have increased significantly under high-temperature conditions,emerging ...Brake wear particle(BWP)emissions are considered one of the dominant sources of particulate matter pollution in urban environments.BWP emissions have increased significantly under high-temperature conditions,emerging as a focal point of research interest.This study investigates the effect of brake temperatures on BWP emissions.The brake pad materials undergo violent decomposition and oxidation reactions and generate large amounts of incompletely oxidized organic products at temperatures above 475℃.These organic products cause particles below 200 nm to proliferate,and nanoparticles below 40 nm account for the largest contribution of total BWPs.When the friction surface temperature exceeds 475℃,the high-concentration BWPs below 200 nm will agglomerate into larger particles.High temperatures also cause the brake pad surface to delaminate and fragment into particles above 2.5μm.In addition,when the initial brake speed is above 160 km/h,or the brake pressure is above 7 bar,there is a sharp increase in particles below 200 nm.The results suggest that a significant number of nanoparticles below 40 nm are inferred to be generated as the flash temperature of the friction surface reaches the violent reaction temperature.This study provides guidelines for designing low-emission brake pads,as improving the high-temperature resistance of brake pad material components possibly reduces BWP generation.展开更多
The emission of copper-containing particulate matter during braking poses a threat to the natural environment,yet copper plays a crucial role in resin-based brake pads.Developing a copper-free brake pad with high heat...The emission of copper-containing particulate matter during braking poses a threat to the natural environment,yet copper plays a crucial role in resin-based brake pads.Developing a copper-free brake pad with high heat-fade resistance has emerged as a significant current topic.This study employs andalusite-filled resin-based brake pads as a replacement for copper in brake pads.It investigates the effects of andalusite mesh size and content on the physical properties,mechanical properties,and tribological wear performance of the brake pads,and explores the wear mechanism of andalusite-filled copper-free resin-based brake pads.The results indicate that adding andalusite to the brake pads enhances their thermal stability,hardness,impact strength,and density,effectively improving the medium-to-high temperature friction coefficient and heat-fade resistance of the brake pads.As the mesh size of andalusite increases,the hardness of the brake pads also increases,while the impact strength initially increases and then decreases.As the weight content of andalusite increases,the hardness and impact strength of the brake pads gradually increase.When the andalusite mesh size is 320 mesh and the content is 20%,the brake pads exhibit good comprehensive tribological wear performance.The addition of andalusite not only increases the medium-to-high temperature friction coefficient of the brake pads but also strengthens their high-temperature friction surface.This study successfully replaces copper,which is harmful to the environment and costly,with andalusite in brake pads,obtaining a high heat-fade resistance metal-free resin-based brake pad.展开更多
To improve braking performance and achieve lightweight in transport equipment,it is necessary to implement overall plastic forming manufacturing of the brake pad baseboard(BPB),which is the core safety component of th...To improve braking performance and achieve lightweight in transport equipment,it is necessary to implement overall plastic forming manufacturing of the brake pad baseboard(BPB),which is the core safety component of the brake system.This study presents an innovative multi-DOF envelope forming(MDFEF)process to realize the plastic forming of BPB with thin skin and high reinforcing ribs.The MDFEF principle for BPB,and the design methods for the envelope mold are first presented.Through FE simulations,the behavior of metal flow,uneven growth pattern of reinforcing ribs,evolution of equivalent strain and evolution of forming force in MDFEF of BPB are investigated.To realize MDFEF,an innovative MDFEF equipment driven by parallel linkages is exploited.The force states of linkages in MDFEF are calculated,and the reasonable mold position is determined to reduce the maximum force on the linkages and improve the service performance of MDFEF equipment.The MDFEF experiments of BPB are conducted and qualified BPB is obtained,which demonstrates that the presented MDFEF process and equipment are applicable to manufacture BPB with thin skin and high reinforcing ribs.展开更多
With the development of the automobile industry, the popularization of vehicles and the improvement of people's living standards, consumers are paying more and more attention to the NVH performance of the vehicle ...With the development of the automobile industry, the popularization of vehicles and the improvement of people's living standards, consumers are paying more and more attention to the NVH performance of the vehicle while pursuing vehicle safety, functional configuration and reliability. As one of the important factors of vehicle NVH, braking NVH directly affects the performance of vehicle NVH and also affects the car brand image. Due to the complexity of the causes of braking NVH, it involves many disciplines such as tribology, vibration mechanics, materials science and computer simulation. Therefore, braking NVH has become a common problem in various OEMs. The problem of braking NVH seriously affects the driving quality of vehicles. Therefore, various OEMs pay more and more attention to braking NVH. At present, domestic OEMs are committed to improving the bench matching procedure, hoping to find a brake NVH with excellent performance through bench matching. Through the long-term data collection of braking NVH working conditions of various models, the characteristics of the main working conditions of braking NVH in the current market are mastered, and the standard procedures of SAE J2521 are compared and analyzed. Chinese market demand. At the same time, the test requirements and evaluation methods of bench matching are described in detail. Ensure that reliable solutions can be found quickly and efficiently during new model development and problem resolution.展开更多
The mass of high-speed trains can be reduced using the brake disk prepared with SiC network ceramic frame reinforced 6061 aluminum alloy composite （SiCn/Al）. The thermal and stress analyses of SiCn/Al brake disk dur...The mass of high-speed trains can be reduced using the brake disk prepared with SiC network ceramic frame reinforced 6061 aluminum alloy composite （SiCn/Al）. The thermal and stress analyses of SiCn/Al brake disk during emergency braking at a speed of 300 km/h considering airflow cooling were investigated using finite element （FE） and computational fluid dynamics （CFD） methods. All three modes of heat transfer （conduction, convection and radiation） were analyzed along with the design features of the brake assembly and their interfaces. The results suggested that the higher convection coefficients achieved with airflow cooling will not only reduce the maximum temperature in the braking but also reduce the thermal gradients, since heat will be removed faster from hotter parts of the disk. Airflow cooling should be effective to reduce the risk of hot spot formation and disc thermal distortion. The highest temperature after emergency braking was 461 °C and 359 °C without and with considering airflow cooling, respectively. The equivalent stress could reach 269 MPa and 164 MPa without and with considering airflow cooling, respectively. However, the maximum surface stress may exceed the material yield strength during an emergency braking, which may cause a plastic damage accumulation in a brake disk without cooling. The simulation results are consistent with the experimental results well.展开更多
To study the distribution and dissipation of braking power of wet multidisc brake and determine thermal load and thermal flux distribution between mated discs, the concept of distributing brake power four times was pu...To study the distribution and dissipation of braking power of wet multidisc brake and determine thermal load and thermal flux distribution between mated discs, the concept of distributing brake power four times was put forward. The third and the fourth distribution of brake power were calculated by using finite element(FE) software ANSYS. The third and the fourth distribution of wet multidisc brake are mainly related to material characteristics of discs during emergency braking, while most of the braking power is carried off during continuous braking. Basis is provided for further analysis of disc failure and applicability of different friction materials.展开更多
The present paper shows the development of a strategy for the calculation of the air brake forces of European freight trains. The model is built to upgrade the existing Politecnico di Torino longitudinal train dynamic...The present paper shows the development of a strategy for the calculation of the air brake forces of European freight trains. The model is built to upgrade the existing Politecnico di Torino longitudinal train dynamics(LTD) code LTDPoliTo, which was originally unable to account for air brake forces. The proposed model uses an empirical exponential function to calculate the air brake forces during the simulation, while the maximum normal force on the brake friction elements is calculated according to the indication of the vehicle braked weight percentage.Hence, the model does not require to simulate in detail the fluid dynamics in the brake pipe nor to precisely know the main parameters of the braking system mounted on each vehicle. The model parameters are tuned to minimize the difference between the braking distance computed by the LTDPoliTo code and the value prescribed by the UIC544-1 leaflet in emergency braking operations. Simulations are run for different configurations of freight train compositions including a variable number of Shimmns wagons trailed by an E402B locomotive at the head of the train, as suggested in a reference literature paper. The results of the proposed method are in good agreement with the target braking distances calculated according to the international rules.展开更多
A multi-body dynamic rigid-flexible coupling model of landing gear is established to study the gear walk instability caused by the friction characteristics of the brake disc.After validating the model with the experim...A multi-body dynamic rigid-flexible coupling model of landing gear is established to study the gear walk instability caused by the friction characteristics of the brake disc.After validating the model with the experimental results,the influence of the landing gear structure and braking system parameters on gear walk is further investigated.Among the above factors,the slope of the graph for the friction coefficient of the brake disc and the relative velocity of brake stators and rotors is the most influential factor on gear walk instability.Phase trajectory analysis verifies that gear walk occurs when the coupling of multiple factors causes the system to exhibit an equivalent negative damping trend.To consider a more realistic braking case,a back propagation neural network method is employed to describe the nonlinear behavior of the friction coefficient of the brake disc.With the realistic nonlinear model of the friction coefficient,the maximum error in predicting the braking torque is less than 10%and the effect of the brake disc temperature on gear walk is performed.The results reveal that a more negative friction slope may contribute to a more severe unstable gear walk,and reducing the braking pressure is an effective approach to avoid gear walk,which provides help for future braking system design.展开更多
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 b...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.展开更多
Braking system performance is relevant for both railway safety and network optimization. Most trains employ air brake systems;air brake systems of freight trains mostly cannot achieve a synchronous application of brak...Braking system performance is relevant for both railway safety and network optimization. Most trains employ air brake systems;air brake systems of freight trains mostly cannot achieve a synchronous application of brake forces, which is usually customary for passenger trains. The paper generalizes a previous air brake pneumatic model to passenger trains and describes the needed modifications. Among them, the way the pressure reduces in the brake pipe is generalized. Moreover, this paper reports an analytical bi-dimensional function for calculating the nozzle diameter equivalent to the electro-pneumatic(EP) or the electronically controlled pneumatic(ECP)brake valve as a function of the wagon length and the time to vent the brake pipe locally. The numerical results of the new model are compared against several experimental tests of high-speed passenger trains of Trenitalia, namely ETR500 and ETR1000. The model is suitable to be integrated into the UIC software TrainDy, aiming to extend its computational field to passenger trains and to simulate the safety of trains during a recovery.展开更多
A new P/M route based hot powder pre-form forging process has been evolved to develop high density brake materials for heavy duty applications. Number of iron based MMC’s so developed offer better characteristics for...A new P/M route based hot powder pre-form forging process has been evolved to develop high density brake materials for heavy duty applications. Number of iron based MMC’s so developed offer better characteristics for braking applications in comparison to the materials developed through conventional P/M route based on high pressure compaction and pressure sintering. The process so developed in the present investigations is much simpler and easy to adopt by existing P/M industries. Hot powder pre-form forging technique for making heavy duty brake pads offers better opportunity for pore free material with better bonding between various metallic and non-metallic constituents. After conducting an initial characterization such as hardness, density and Pin-on Disc tests, the samples were tested for high energy (32,933kgfm) on Sub-scale dynamometer under Rejected Take Off conditions. The results have also been compared with respect to brake pads employed in heavy duty Military aircraft tested under identical laboratory conditions. The present work indicates that the newly developed materials compare better than the one being currently employed in heavy duty aircraft. The reasons for better performance are improved processing technique and resulting higher levels of density and improved binding of the product.展开更多
A mathematical model and finite element model for analysis of temperature rise of the hoisting machine brake sys- tem was constructed, limit conditions were defined, and the law of temperature rise of brake shoes duri...A mathematical model and finite element model for analysis of temperature rise of the hoisting machine brake sys- tem was constructed, limit conditions were defined, and the law of temperature rise of brake shoes during emergent brake course was analyzed and calculated by using finite element software. By analyzing the calculation results, the law of tempera- ture change of surface of brake disk and shoes during the braking process was found. The law of brake shoes surface tempera- ture distribution and the law of temperature change along with thickness of brake shoes at brake time 0.5 s, 1.0 s and 1.5 s was analyzed. A hoisting machine emergent braking test was carried out. Finally, the author concluded that velocity rebound in the process of hoisting machine emergent brake is due to decreased friction coefficient caused by the temperature rise of the brake shoes surface.展开更多
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 grea...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.展开更多
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 controlle...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.展开更多
基金Supported by National Natural Science Foundation of China(Grant Nos.52202494,52202495)Chongqing Special Project for Technological Innovation and Application Development(Grant No.CSTB2022TIAD-DEX0014).
文摘The current research of master cylinder pressure estimation mainly relies on hydraulic characteristic or vehicle dynamics.But they are not independently applicable to any environment and have their own scope of application.In addition,about the master cylinder pressure control,there are few studies that can simultaneously balance pressure building accuracy,speed,and prevent pressure overshoot and jitter.In this paper,an adaptative fusion method based on electro-hydraulic characteristic and vehicle mode is proposed to estimate the master cylinder pressure.The fusion strategy is mainly based on the prediction performance of two algorithms under different vehicle speeds,pressures,and ABS states.Apart from this,this article also includes real-time prediction of the friction model based on RLS to improve the accuracy of the electro-hydraulic mode.In order to simultaneously balance pressure control accuracy,response speed,and prevent overshoot and jitter,this article proposes an adaptative LQR controller for MC pressure control which uses fuzzy-logic controller to adjust the weights of LQR controller based on target pressure and difference compared with actual pressure.Through mode-in-loop and hardware-in-loop tests in ramp,step and sinusoidal response,the whole estimation and control system is verified based on real hydraulic system and the performance is satisfactory under these scenes.This research proposes an adaptative pressure estimation and control architecture for integrated electro-hydraulic brake system which could eliminate pressure sensors in typical scenarios and ensure the comprehensive performance of pressure control.
文摘In ground vehicles, the brake is an essential system to ensure the safety of movement. Multiple braking mechanisms have been introduced for use in vehicles. This study explores the potential of using magneto-rheological fluid (MRF) brakes in automotive applications. MRF brakes offer controllable braking force due to a magnetic field, but their use is limited by simulation challenges. In this study, a 7-tooth MRF brake model is proposed. The brake model is simulated in Altair Flux software to analyze magnetic field distribution, braking torque, and its variation under different currents and disc speeds. The simulation conditions also consider both viscous and electromagnetic torque components. Then, the results are analyzed across different brake regions, including rotor, stator, and fluid gap. These results provide valuable insights for designing, manufacturing, installing, and testing MRF brakes for automotive use.
基金funded by the National Natural Science Foundation of China(Nos.52205047,52175037)China Postdoctoral Science Foundation(No.2021M700422)Beijing Key Laboratory Foundation(No.KF20212223201).
文摘A new electrical toothed band brake is proposed based on the planetary gear shifting transmission.The corresponding mathematical model and the finite element model are established to investigate the braking dynamic characteristics and the stress distribution of brake components.According to the structural features and working principle of the brake,the braking process can be divided into a gap elimination stage,a sliding stage,a meshing stage,and a collision stage.The greater the initial speed of brake drum,the higher the impact torque in the collision stage,and the larger the stress of brake components.The ideal range of initial speed is 50-100 r/min,and the ultimate stress is 514 MPa appeared in the right brake band.This study present a wide range of possibilities for further investigation and application of the electrical toothed band brake.
基金supported by the NSFC(12301138)the Scientific and Technological Innovation Programs of Higher Education Institutions in Shanxi(2021L377)+1 种基金the Doctoral Scientific Research Foundation of Shanxi Datong University(2018-B-15)The second author’s work was supported by the NSFC(12171108).
文摘In this paper,the problem of brake orbits with minimal period estimates are considered for the first-order Hamiltonian systems with anisotropic growth,i.e.,the Hamiltonian functions may have super-quadratic,sub-quadratic and quadratic behaviors simultaneously in different variable components.
基金supported by the National Natural Science Foundation of China(Nos.52172337 and 52272342)the Postdoctoral Fellowship Program(Grade B)of China Postdoctoral Science Foundation(No.GZB20240352)the Shuimu Tsinghua Scholar Program of Tsinghua University(No.2023SM230)。
文摘Brake wear particle(BWP)emissions are considered one of the dominant sources of particulate matter pollution in urban environments.BWP emissions have increased significantly under high-temperature conditions,emerging as a focal point of research interest.This study investigates the effect of brake temperatures on BWP emissions.The brake pad materials undergo violent decomposition and oxidation reactions and generate large amounts of incompletely oxidized organic products at temperatures above 475℃.These organic products cause particles below 200 nm to proliferate,and nanoparticles below 40 nm account for the largest contribution of total BWPs.When the friction surface temperature exceeds 475℃,the high-concentration BWPs below 200 nm will agglomerate into larger particles.High temperatures also cause the brake pad surface to delaminate and fragment into particles above 2.5μm.In addition,when the initial brake speed is above 160 km/h,or the brake pressure is above 7 bar,there is a sharp increase in particles below 200 nm.The results suggest that a significant number of nanoparticles below 40 nm are inferred to be generated as the flash temperature of the friction surface reaches the violent reaction temperature.This study provides guidelines for designing low-emission brake pads,as improving the high-temperature resistance of brake pad material components possibly reduces BWP generation.
基金Supported by National Natural Science Foundation of China(Grant No.52275178)the Fuzhou Municipal Science and Technology Plan Project(Grant No.2024-Y-004)the Liaoning Provincial Key Laboratory of Aero-engine Materials Tribology(Grant No.LKLAMTF202502).
文摘The emission of copper-containing particulate matter during braking poses a threat to the natural environment,yet copper plays a crucial role in resin-based brake pads.Developing a copper-free brake pad with high heat-fade resistance has emerged as a significant current topic.This study employs andalusite-filled resin-based brake pads as a replacement for copper in brake pads.It investigates the effects of andalusite mesh size and content on the physical properties,mechanical properties,and tribological wear performance of the brake pads,and explores the wear mechanism of andalusite-filled copper-free resin-based brake pads.The results indicate that adding andalusite to the brake pads enhances their thermal stability,hardness,impact strength,and density,effectively improving the medium-to-high temperature friction coefficient and heat-fade resistance of the brake pads.As the mesh size of andalusite increases,the hardness of the brake pads also increases,while the impact strength initially increases and then decreases.As the weight content of andalusite increases,the hardness and impact strength of the brake pads gradually increase.When the andalusite mesh size is 320 mesh and the content is 20%,the brake pads exhibit good comprehensive tribological wear performance.The addition of andalusite not only increases the medium-to-high temperature friction coefficient of the brake pads but also strengthens their high-temperature friction surface.This study successfully replaces copper,which is harmful to the environment and costly,with andalusite in brake pads,obtaining a high heat-fade resistance metal-free resin-based brake pad.
基金Supported by National Natural Science Foundation of China(Grant No.U21A20131)Innovative Research Team Development Program of Ministry of Education of China(Grant No.IRT17R83)111 Project(Grant No.B17034)。
文摘To improve braking performance and achieve lightweight in transport equipment,it is necessary to implement overall plastic forming manufacturing of the brake pad baseboard(BPB),which is the core safety component of the brake system.This study presents an innovative multi-DOF envelope forming(MDFEF)process to realize the plastic forming of BPB with thin skin and high reinforcing ribs.The MDFEF principle for BPB,and the design methods for the envelope mold are first presented.Through FE simulations,the behavior of metal flow,uneven growth pattern of reinforcing ribs,evolution of equivalent strain and evolution of forming force in MDFEF of BPB are investigated.To realize MDFEF,an innovative MDFEF equipment driven by parallel linkages is exploited.The force states of linkages in MDFEF are calculated,and the reasonable mold position is determined to reduce the maximum force on the linkages and improve the service performance of MDFEF equipment.The MDFEF experiments of BPB are conducted and qualified BPB is obtained,which demonstrates that the presented MDFEF process and equipment are applicable to manufacture BPB with thin skin and high reinforcing ribs.
文摘With the development of the automobile industry, the popularization of vehicles and the improvement of people's living standards, consumers are paying more and more attention to the NVH performance of the vehicle while pursuing vehicle safety, functional configuration and reliability. As one of the important factors of vehicle NVH, braking NVH directly affects the performance of vehicle NVH and also affects the car brand image. Due to the complexity of the causes of braking NVH, it involves many disciplines such as tribology, vibration mechanics, materials science and computer simulation. Therefore, braking NVH has become a common problem in various OEMs. The problem of braking NVH seriously affects the driving quality of vehicles. Therefore, various OEMs pay more and more attention to braking NVH. At present, domestic OEMs are committed to improving the bench matching procedure, hoping to find a brake NVH with excellent performance through bench matching. Through the long-term data collection of braking NVH working conditions of various models, the characteristics of the main working conditions of braking NVH in the current market are mastered, and the standard procedures of SAE J2521 are compared and analyzed. Chinese market demand. At the same time, the test requirements and evaluation methods of bench matching are described in detail. Ensure that reliable solutions can be found quickly and efficiently during new model development and problem resolution.
基金Projects (50872018, 50902018) supported by the National Natural Science Foundation of ChinaProject (1099043) supported by the Science and Technology in Guangxi Province, ChinaProject (090302005) supported by the Basic Research Fund for Northeastern University, China
文摘The mass of high-speed trains can be reduced using the brake disk prepared with SiC network ceramic frame reinforced 6061 aluminum alloy composite （SiCn/Al）. The thermal and stress analyses of SiCn/Al brake disk during emergency braking at a speed of 300 km/h considering airflow cooling were investigated using finite element （FE） and computational fluid dynamics （CFD） methods. All three modes of heat transfer （conduction, convection and radiation） were analyzed along with the design features of the brake assembly and their interfaces. The results suggested that the higher convection coefficients achieved with airflow cooling will not only reduce the maximum temperature in the braking but also reduce the thermal gradients, since heat will be removed faster from hotter parts of the disk. Airflow cooling should be effective to reduce the risk of hot spot formation and disc thermal distortion. The highest temperature after emergency braking was 461 °C and 359 °C without and with considering airflow cooling, respectively. The equivalent stress could reach 269 MPa and 164 MPa without and with considering airflow cooling, respectively. However, the maximum surface stress may exceed the material yield strength during an emergency braking, which may cause a plastic damage accumulation in a brake disk without cooling. The simulation results are consistent with the experimental results well.
文摘To study the distribution and dissipation of braking power of wet multidisc brake and determine thermal load and thermal flux distribution between mated discs, the concept of distributing brake power four times was put forward. The third and the fourth distribution of brake power were calculated by using finite element(FE) software ANSYS. The third and the fourth distribution of wet multidisc brake are mainly related to material characteristics of discs during emergency braking, while most of the braking power is carried off during continuous braking. Basis is provided for further analysis of disc failure and applicability of different friction materials.
文摘The present paper shows the development of a strategy for the calculation of the air brake forces of European freight trains. The model is built to upgrade the existing Politecnico di Torino longitudinal train dynamics(LTD) code LTDPoliTo, which was originally unable to account for air brake forces. The proposed model uses an empirical exponential function to calculate the air brake forces during the simulation, while the maximum normal force on the brake friction elements is calculated according to the indication of the vehicle braked weight percentage.Hence, the model does not require to simulate in detail the fluid dynamics in the brake pipe nor to precisely know the main parameters of the braking system mounted on each vehicle. The model parameters are tuned to minimize the difference between the braking distance computed by the LTDPoliTo code and the value prescribed by the UIC544-1 leaflet in emergency braking operations. Simulations are run for different configurations of freight train compositions including a variable number of Shimmns wagons trailed by an E402B locomotive at the head of the train, as suggested in a reference literature paper. The results of the proposed method are in good agreement with the target braking distances calculated according to the international rules.
基金the National Natural Science Foundation of China(No.11872312)the Program of Introducing Talents of Discipline to Universities,China(No.BP0719007)the Innovation Foundation for Doctor Dissertation of Northwestern Polytechnical University,China(No.CX2022002)。
文摘A multi-body dynamic rigid-flexible coupling model of landing gear is established to study the gear walk instability caused by the friction characteristics of the brake disc.After validating the model with the experimental results,the influence of the landing gear structure and braking system parameters on gear walk is further investigated.Among the above factors,the slope of the graph for the friction coefficient of the brake disc and the relative velocity of brake stators and rotors is the most influential factor on gear walk instability.Phase trajectory analysis verifies that gear walk occurs when the coupling of multiple factors causes the system to exhibit an equivalent negative damping trend.To consider a more realistic braking case,a back propagation neural network method is employed to describe the nonlinear behavior of the friction coefficient of the brake disc.With the realistic nonlinear model of the friction coefficient,the maximum error in predicting the braking torque is less than 10%and the effect of the brake disc temperature on gear walk is performed.The results reveal that a more negative friction slope may contribute to a more severe unstable gear walk,and reducing the braking pressure is an effective approach to avoid gear walk,which provides help for future braking system design.
基金Western Countries,Traffic IT Projects Traffic (No.200431800048)
文摘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.
文摘Braking system performance is relevant for both railway safety and network optimization. Most trains employ air brake systems;air brake systems of freight trains mostly cannot achieve a synchronous application of brake forces, which is usually customary for passenger trains. The paper generalizes a previous air brake pneumatic model to passenger trains and describes the needed modifications. Among them, the way the pressure reduces in the brake pipe is generalized. Moreover, this paper reports an analytical bi-dimensional function for calculating the nozzle diameter equivalent to the electro-pneumatic(EP) or the electronically controlled pneumatic(ECP)brake valve as a function of the wagon length and the time to vent the brake pipe locally. The numerical results of the new model are compared against several experimental tests of high-speed passenger trains of Trenitalia, namely ETR500 and ETR1000. The model is suitable to be integrated into the UIC software TrainDy, aiming to extend its computational field to passenger trains and to simulate the safety of trains during a recovery.
文摘A new P/M route based hot powder pre-form forging process has been evolved to develop high density brake materials for heavy duty applications. Number of iron based MMC’s so developed offer better characteristics for braking applications in comparison to the materials developed through conventional P/M route based on high pressure compaction and pressure sintering. The process so developed in the present investigations is much simpler and easy to adopt by existing P/M industries. Hot powder pre-form forging technique for making heavy duty brake pads offers better opportunity for pore free material with better bonding between various metallic and non-metallic constituents. After conducting an initial characterization such as hardness, density and Pin-on Disc tests, the samples were tested for high energy (32,933kgfm) on Sub-scale dynamometer under Rejected Take Off conditions. The results have also been compared with respect to brake pads employed in heavy duty Military aircraft tested under identical laboratory conditions. The present work indicates that the newly developed materials compare better than the one being currently employed in heavy duty aircraft. The reasons for better performance are improved processing technique and resulting higher levels of density and improved binding of the product.
基金Supported by the National Natural Science Foundation of China （50875252）
文摘A mathematical model and finite element model for analysis of temperature rise of the hoisting machine brake sys- tem was constructed, limit conditions were defined, and the law of temperature rise of brake shoes during emergent brake course was analyzed and calculated by using finite element software. By analyzing the calculation results, the law of tempera- ture change of surface of brake disk and shoes during the braking process was found. The law of brake shoes surface tempera- ture distribution and the law of temperature change along with thickness of brake shoes at brake time 0.5 s, 1.0 s and 1.5 s was analyzed. A hoisting machine emergent braking test was carried out. Finally, the author concluded that velocity rebound in the process of hoisting machine emergent brake is due to decreased friction coefficient caused by the temperature rise of the brake shoes surface.
文摘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.
基金supported by the China Academy of Railway Sciences Foundation[Grant No.2021YJ244].
文摘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.
