Browse Publications Technical Papers 2019-01-0831

Rapid Optimal Design of a Light Vehicle Hydraulic Brake System 2019-01-0831

Automobile brake system design process is complex and time consuming as there are several components in the system as well as the system has to pass all the conflicting government regulations. With these constraints it is not easy to design an optimal configuration. This paper proposes a simple, intuitive and automated methodology that enables rapid optimal design of light vehicle hydraulic brake systems through an efficient exhaustive search of all the possible designs. Firstly, the system is modeled through cascaded analytical equations for each component. A large design space is then generated by varying the operational parameters of each component in its specific reasonable range. The system components under consideration include the brake pedal, the master cylinder, the vacuum-assisted booster, the brake line and the brake pistons. Successful system configurations are identified by implementing the requirements of the two most relevant safety homologation standards for light vehicle brake systems (US and EU legislations). Ergonomics constraints and the compensation for the fluid losses in the system complete the design requirements. The optimal design identification is carried out based on overall system braking performance and the cost. Particularly, optimal braking performance is based on the defined braking efficiency, while a cost function criterion is developed to quantify the overcapacity of the design. The developed methodology is proved to identify the optimal brake system design in a relatively short period of time by generating and testing about eight million of candidate designs for each vehicle.


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