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A road test on semi-trailers is carried out, and accelerations of some characteristic points on the braking system,axles,and truck body is measured,also brake pressure and noise around the support frame is acquired.The measured data was analyzed to determine the causes of the brake noise, and the mechanism of the noise of the drum brake of semi-trailers during low-speed braking was investigated. The following conclusions are obtained: (1) Brake noise of the drum brake of the semi-trailer at low-frequency is generated from vibrations of the brake shoes, axle, and body, and the vibration frequency is close to 2nd natural frequency of the axle. (2) Brake noise is generated from stick-slip motion between the brake shoes and the brake drum, where the relative motion between the brake drum and the brake shoes is changed alternately with sliding and sticking, resulting in sudden changes in acceleration and shock vibration.

An experiment is carried out to measure creep groan of a drum brake located in a trailer axle of a truck. The noise nearby the drum brake and accelerations on brake shoes, axle and trailer frame are collected to analyze the occurring conditions and characteristics of the creep groan. A multi-body dynamics model with 1/4 trailer chassis structures is established for analyzing brake component vibrations that generates the creep groan. In the model, the contact force between brake cam and brake shoes, the contact friction characteristics between brake linings and inner circular surface of brake drum, and the properties of chassis structure are included. Dynamic responses of brake shoes, axle and trailer frame during the braking process are estimated using the established model and the responses are compared with the measured results, which validate the model.

In order to study the effects of different factors on the static and dynamic characteristics of air springs, three models were established to calculate the static and dynamic characteristics of air springs, including modeling at the design position, modeling only considering the straight state, and modeling considering the thickness of the bellows in the straight state. Static stiffness of air springs is calculated using three different models and are compared with experiments. In the straight state model considering the thickness of the bellow, the influence of aluminum tube and bellows thickness on the static stiffness are considered, and the modeling with the straight state solved the problem of the change in cord angle after the air spring was inflated and expanded. The established model is then used to calculate static and dynamic characteristics of air springs, such as static stiffness, hysteresis loop, and dynamic stiffness.

The fatigue prediction model of an air spring based on the crack initiation method is established in this study. Taking a rolling lobe air spring with an aluminum casing as the studying example, a finite element model for analyzing force versus displacement is developed. The static stiffness and dimensional parameters of limit positions are calculated and analyzed. The influence of different modeling methods of air springs bellow are compared and analyzed. Static stiffness measurement of an air spring is conducted, and the calculation results and the measured results of the static stiffness are compared. It is shown that the relative error of the measured stiffness and calculated stiffness is within 1%. The Abaqus post-processing stage is redeveloped in Python language.

This paper presents an adaptive H2/H∞ control strategy for a semi-active suspension system with unknown suspension parameters. The proposed strategy takes into account the damping force characteristics of continuous damping control (CDC) damper. Initially, the external characteristics of CDC damper were measured, and a forward model and a back propagation (BP) neural network inverse model of CDC damper were proposed using the measured data. Subsequently, a seven-degree-of-freedom vehicle with semi-active suspension system and H2/H∞ controller was designed. Multiple feedback control matrices corresponding to different sprung mass parameter values were determined by analyzing time and frequency domain performance. Finally, a dual observer system combining suspension state and parameter estimation based on the Kalman filter algorithm was established.

If a car is braked frequently or at high speed, the thermal decay of brake system performance appears, which reduces the braking performance of the car. To compensate brake moment reduction during braking at thermal decay of brake system, a compensation strategy of brake moment is designed by using “feedforward +PID feedback” to pressure at wheel braking cylinder. The trigger and exit conditions of the strategy for the wheel cylinder pressure are proposed based on the threshold. A vehicle model consisting braking system is established if a vehicle runs at straight line, and the braking distance and braking acceleration are estimated, the results shown that the thermal decay compensation control strategy proposed in this paper can reduce the braking distance and braking time.

Taking a closed airbag suspension system as studying objects, the nonlinear dynamic model of the reservoir, compressor, solenoid valve, pipeline and air spring is established. The compressor exhaust volume, solenoid valve flow rate and air spring charging and discharging rate are calculated and compared with experiment to validate the model. Taking pressure difference and height adjustment rate under different working conditions of an airbag suspension as control measures, a control strategy is developed based on the established nonlinear dynamic model. The result indicates that when the vehicle is in curb weight, design weight and GVW (gross vehicle weight), the working time of the compressor can be reduced by 13.6%, 15.1% and 46.5%, respectively, compared with the conventional mode, during a height adjustment cycle. Then a state observer is proposed to estimate the steady-height for reducing the disturbance of measured height from road excitation.

In the manufacturing of battery boxes using the aluminum extruded process, poor consistency of products and a short life of the die for making aluminum structural sections are usually observed. A new method of producing battery boxes is proposed that combines steel stamped and aluminum extruded process. This paper first describes the design requirements for a battery box using a new process, and several important issues such as weld seam arrangement and error proofing in the manufacturing process are discussed. To address the issue of weld seam arrangement, the following three principles should be considered in the design: These principles include that the profile lap angle should be above 90°, three or more beams should not be lapped too closely together, and multiple brackets in close proximity should be designed as one unit.

Air springs with auxiliary chambers (ASAC) are widely used in automotive suspension systems. The introducing of the auxiliary chamber and the connecting flow passage makes the system more complex, especially in which case an additional resonance peak caused by the air inertia in a connecting pipe appears. To characterize the nonlinear dynamic characteristics, this paper proposes a novel physical-neural network hybrid modeling method for ASACs. Firstly, experiments are carried out to measure the dynamic characteristics of ASACs. Then, based on the thermodynamic principle, a nonlinear dynamic characteristic model for the ASAC is developed and a linearized process is performed to obtain a linearized physical model. Due to the amplitude dependence and frequency dependence in the dynamic characteristics of ASACs, the physical model cannot accurately characterize these nonlinearities.

Because autonomous vehicles (AVs) equipped with active front steering have the features of time varying, uncertainties, high rate of fault, and high burden on the in-vehicle networks, this article studies the adaptive robust control problem for improving lateral stability in steer-by-wire (SBW) vehicles in the presence of abrupt nonlinear faults. First, an upper-level robust H∞ controller is designed to obtain the desired front-wheel steering angle for driving both the yaw rate and the sideslip angle to reach their correct values. Takagi-Sugeno (T-S) fuzzy modeling method, which has shown the extraordinary ability in coping with the issue of nonlinear, is applied to deal with the challenge of the changing longitudinal velocity. The output of the upper controller can be calculated by a parallel distributed compensation (PDC) scheme.

The vehicle will produce certain shock and vibration during the braking process, which will affect the driving experience of the driver. Aiming at the problems of pitch vibration, longitudinal vibration and shock during the braking process, this paper proposes a planning and following control method for target longitudinal acceleration in post-braking phase, and designs control trigger strategies. Target longitudinal acceleration planning takes minimizing longitudinal shock as the design goal. The following control takes the brake pressure as the control object, and adopts the “feedforward +PID feedback” method to follow the target longitudinal acceleration. Besides, considering the safety of braking process, the trigger condition of control is designed which utilizes BP neural network method to judge whether the control has to be triggered. Based on Simulink software, the simulation model of straight-line braking is established.

To solve the contradiction between model complexity and the warning accuracy of the algorithm of the vehicle rollover warning, a rollover state warning method based on the secondary predictive zero-moment point position for vehicles is proposed herein. Taking a sport utility vehicle(SUV) as the research object, a linear three-degrees-of-freedom vehicle rollover dynamics model is established. On the basis of the model, the lateral position of the zero-moment point and its primary and secondary rates of change are calculated. Then, the theoretical solution of time-to-rollover of the vehicles is deduced from the lateral position of the secondary predictive zero-moment point. When the rollover warning index, the lateral position of the zero-moment point, is greater than the set threshold, the active anti-rollover control system will be triggered. The active anti-rollover braking control system adopts a hierarchical control strategy.

The fully decoupled brake by wire system is a complex system consisting of mechanical components such as springs and rubber and hydraulic structural components coupled together. Compared to conventional braking systems, it is characterized by the full decoupling of the brake pedal from the brake wheel cylinders in normal braking mode, and the pressure fluctuations in the wheel cylinders do not affect the pedal feel. In order to predict brake pedal feel in a passenger car, a dynamic model was developed for both normal and backup braking modes, taking into account the variation of the volume modulus of the brake fluid and the frictional forces of the master cylinder pistons. The influence of different pedal input speeds on the pedal feel characteristic curve was analyzed using static vehicle tests and the related parameters of the braking system were identified in order to correct the design data.

The decoupling brake-by-wire system controls the key components of the flow path and liquid flow of the whole brake system through the solenoid valve of the bottom control unit. The reference cross-sectional area value at the valve inlet is obtained by calculation, and the valve body structure model is established. The flow channel structure is extracted, and the porous media model is used to replace the fluid area of the filter screen at the entrance of the solenoid valve. The Fluent software is used to analyze the influence on the flow characteristics of the solenoid valve with or without a filter. The accuracy of the model is verified by the experimental results, which also show that the porous medium can effectively and accurately reflect the characteristics of the solenoid valve end filter.

The static characteristics of solenoid valve play an important role in the performance of brake system and can indirectly reflect the response speed of the brake system. The static characteristics of the solenoid valve reflect the electromagnetic characteristics of the solenoid valve itself, revealing the maximum potential of the solenoid valve in the system work, which is one of the important characteristics to characterize the working ability of the solenoid valve. In this paper, a numerical calculation method is used to build a finite element model of the solenoid valve electromagnetic field on the Ansoft Maxwell simulation platform. The model takes into account the nonlinear magnetization characteristics of soft magnetic materials and the air gap.

This paper designs the important components and structure of the integrated electro-hydraulic brake system (I-EHB). Firstly, the simplified linear system is modeled, and the transfer function without considering the nonlinear disturbance such as system friction is derived, and the correctness of the linear system is preliminarily verified by AMESim. Then set up the I-EHB system test bench, and use the Stribeck friction model to identify the friction torque parameters in the static and kinetic friction stages of the system to obtain a more accurate friction model. Finally, based on the I-EHB system model of friction disturbance, a pressure-speed-current three-loop cascade PID controller is designed, and a feedforward controller based on the system model is added to form the control structure of “pressure feedforward compensation + pressure-speed-current closed-loop cascade PID”.

Roll stability is an important attribute which must be accounted for in heavy trucks. In order to analyze the anti-roll performance of the suspension in the early period of development, engineers will generally use Multi Body Dynamics (MBD) simulation software which can save time in the product development cycle. However, air suspension employs levelling valves to adjust the height by charging and discharging air springs. The air spring is typically modeled as a closed container in the simulation; the stiffness change of the air spring caused by the levelling valve is not considered. In this paper, an air suspension with levelling valves model integrated into the multi-body dynamic model of a 6�4 heavy truck is built with a co-simulation technique to investigate the influence of three types of levelling valves arrangement on the roll performance of the suspension under two typical conditions.

In order to improve the ride comfort and road friendliness of heavy commercial vehicles, a lateral interconnected air suspension system is developed. Based on the theory of thermodynamics and vehicle dynamics, a Ten-degree-of-freedom vehicle dynamics model with lateral interconnected air suspension is established. Interconnected pipeline parameters’ influence on characteristics of air suspension system in whole vehicle are calculated and analyzed. Simulation results show that the stiffness of air suspension decreases gradually with the increase of interconnected pipeline diameter. The designed interconnected air spring experiments verify the simulation results. Simulation on vehicle dynamics models is carried out by building random road models with different roughness levels in MATLAB.

A new single-attachment air spring system with a parallel one-way tube is designed as a vibration isolation device for vehicles. The dynamics model of the new two-throttle tube air spring is established first, and the accuracy of the two-tube model is verified experimentally. Finally, the experimental results of the two-throttle tube air spring and the single-tube air spring are compared to analyze the effects of the tube diameter, tube length and additional air chamber volume on the dynamic stiffness of the two-throttle tube air spring. The results show that the combination of throttle tubes of different diameters has a great influence on the stiffness and damping characteristics of the air spring.

A fourth-order mathematical model for I-EHB (integrated electro-hydraulic brake) system was derived from its mechanical and hydraulic subsystems. The model was linearized at equilibrium state and then was verified by AMESIM software. The friction model of the system was analyzed based on static friction and viscous friction. A bench test was designed to identify the parameters of friction model. As the I-EHB system worked at different braking conditions, a PID-based switching controller was designed to track the target servo cylinder pressure. Both simulations and experiments results showed that, the response time of pressure was less than 120ms, and there was no overshoot, which helped handling different braking conditions and improving the braking safety and comfort.