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To reduce the energy consumption level of electric vehicles, the working range of the regenerative braking system will gradually expand to the high state of charge of the battery. The time delay in the control signal transmission path of the high state of charge regenerative braking control process will affect the regenerative braking. At the same time, regenerative braking under a high state of charge puts forward higher requirements for the control accuracy of regenerative current. In the research of this paper, the motor model, battery model, and vehicle dynamics model are firstly established by using MATLAB/Simulink, and the dynamic relationship between regenerative current and regenerative braking torque is analyzed at the same time. Considering the system time delay, this paper proposes a high-charge regenerative braking control strategy (SPPC) that combines Smith prediction and prescribed performance control.

The study of vehicle coupling state estimation accuracy especially in observer-based vehicle chassis control for improving road handling and ride comfort is a challenging task for vehicle industry under various driving conditions. Due to a large amount of life safety arising from vehicle roll behavior, how to precisely acquire vehicle roll state and rapidly provide for the vehicle control system are of great concern. Simultaneously, uncertainty is unavoidable for various aspects of a vehicle system, e.g., varying sprung mass, moment of inertia and position of the center of gravity. To deal with the above issues, a novel dual observer approach, which combines adaptive Unscented Kalman Filter (AUKF) and Takagi-Sugeno (T-S), is proposed in this paper. A full-car nonlinear model is first established to describe vehicle lateral and vertical coupling roll behavior under various road excitation.

This paper presents a road classifier based on the system response with consideration of the tire enveloping. The aim is to provide an easily applicable yet accurate road classification approach for automotive engineers. For this purpose, tire enveloping effect is firstly modeled based on the flexible roller contact (FRC) theory, then transfer functions between road input and commonly used suspension responses i.e. the sprung mass acceleration, unsprung mass acceleration, and rattle space, are calculated for a quarter vehicle model. The influence of parameter variations, vehicle velocity, and measurement noise on transfer functions are comprehensively analyzed to derive the most suitable system response thereafter. In addition, this paper proposes a vehicle speed correction mechanism to further improve the classification accuracy under complex driving conditions.

The control parameter of the semi-active suspension system varies with road profile; therefore, in this study a new algorithm based on cuckoo search (CS) optimization method and road estimation was proposed to investigate the characteristics of the nonlinear parameters and at the same time improve the riding comfort. Based on this, a seven degree of freedom full vehicle model was developed with nonlinear damper and spring. The sprung mass acceleration, pitch acceleration, and tire deflection could be selected as the objective functions, and the control current of semi active suspension was selected as optimization variable. A multi-object CS algorithm was utilized to obtain the optimal parameters under different road profiles, and a road estimation algorithm was used to identify the road level. Then the control parameters could be adjusted adaptively according to the level of the road.

The electric vehicles and the intelligent vehicles put forward to new requirements for the brake system, such as the vacuum-independent braking, automatic or active braking, and regenerative braking, which are the key link for the vehicle’s safety and economy. However, the traditional vacuum brake booster is no longer able to meet these requirements. In this article, a novel integrated power-assisted actuator of brake system is proposed to satisfy the brake system requirements of the electric vehicles and intelligent vehicles. The electronic brake booster system is designed to achieve the function of boosting pedal force of driver, being independent on vacuum source, supplying autonomous or active braking. It is mainly composed of a permanent magnet synchronous motor (PMSM), a two-stage reduction transmission (gears and a ball screw), a servo body, and a reaction disk. The scheme design and power-assisted braking control are the key for the electronic actuator.

The study of controllable suspension properties special in the characteristics of improving ride comfort and road handling is a challenging task for vehicle industry. Currently, since most suspension control requires the observation of unmeasurable state, how to accurately acquire the state of a suspension system attracts more attention. To solve this problem, a novel approach interacting multiple mode Kalman Filter (IMMKF) is proposed in this paper. Suspension system parameters are crucial for the performance of state observers. Uncertain suspension system parameters in various conditions, e.g. due to additional load, have significant effect on state estimation. Simultaneously, state transition among different models may be happened on the condition of varying system parameters.

Light-weighting of vehicles is one of the challenges for transportation industry due to the increasing pressure of demands in better fuel economy and environment protection. Advanced high strength steels (AHSS) are considered as prominent material of choice to realize lightweight auto body and structures at least in near term. Stamping of AHSS with conventional die materials and surface coatings, however, results in frequent die failures and undesired panel surface finish. A chromium nitride (CrN) coating with plasma nitriding case hardened layer on a die material (duplex treatment) is found to offer good wear and galling resistances. The coating failure initiates from fatigue cracking on the coating surface due to cyclic sliding frictions. In this work, cyclic inclined sliding wear test was used to imitate a stamping process for study on development of coating fatigue cracking, including crack length and spacing vs. sliding-cycles and sliding energy densities.

This paper describes a uniform Hardware-In-the-Loop (HiL) test rig for the different types of Electronic Braking System (EBS). It is applied to both modular testing and integrated testing. This test rig includes a vehicle dynamic model, a real-time simulation platform, an actual brake circuit and the EBS system under test. Firstly, the vehicle dynamic model is a highly parameterized commercial vehicle model. So it can simulate different types of commercial vehicle by different parameter configurations. Secondly, multi-types of brake circuit are modeled using brake components simulation library. So, it can test the EBS control unit independently without the influence of any real electro-pneumatic components. And a software EBS controller is also modeled. So it can test the algorithm of EBS offline. Thirdly, all real electro-pneumatic components without real gas inputted are connected to the real-time test platform through independent program-controlled relay-switches.

Brake squeal is a complex dynamics instability issue for automobile industry. Closed-loop coupling model deals with brake squeal from a perspective of structural instability. Friction characteristics between pads and disc rotor play important roles. In this paper, a closed-loop coupling model which incorporates negative friction-velocity slope is presented. Different from other existing models where the interface nodes are coupled through assumed springs, they are connected directly in the presented model. Negative friction slope is taken into account. Relationship between nodes’ frictional forces, relative speeds and brake pressure under equilibrant sliding and vibrating states is analysed. Then repeated nodal coordinate elimination and substructures’ modal coordinate space transformation of system dynamic equation are performed. It shows that the negative friction slope leads to negative damping items in dynamic equation of system.

The dynamic properties of disc rotor play important role in the NVH performance of a disc brake system. Disc rotor in general is a centrosymmetric structure. It has many repeated-root modes within the interested frequency range and they may have significant influence on squeal occurrence. A pair of repeated-root modes is in nature one vibration mode. However, in current complex eigenvalue analysis model and relevant analysis methods, repeated-root modes are processed separately. This may lead to contradictory result. This paper presents methods to deal with repeated-root modes in substructure modal composition (SMC) analysis to avoid the contradiction. Through curve-fitting technique, the modal shape coefficients of repeated-root modes are expressed in an identical formula. This formula is used in SMC analysis to obtain an integrated SMC value to represent the total influence of two repeated-root modes.

The study of mechanical properties special in the characteristics of elastic element is a challenging task for vehicle industry. Since torsion bar spring acts as an important part of elastic element, and improves performance of torsion bar spring is of great concern. The effects of the torsion bar spring pre-setting precision on the presetting performance are presented. Based on elastic-plastic theories, the algebraic model of torsion bar spring is established to analyze the stress, torque and residual stress under the yield and plastic conditions in pre-setting process. Then, the stress and strain states of various torsion bar springs in different conditions are simulated using the validated finite element model in ABAQUS software. The simulation results show the effects of torsion error on the pre-setting performance are less than 5% in the pre-setting process.

Closed-loop coupling model, based on complex eigenvalue analysis, is one of the most popular and effective methods for brake squeal analysis. In the model, imaginary coupling springs are used to represent the normal contacting force between coupled nodes. Unfortunately, the physical meaning of these coupling springs was seldom discussed and there’s no systematic method to determine the value of spring stiffness. Realizing this problem, this paper, based on finite element model and modal synthesis technique, develops a new closed-loop coupling disc brake squeal model without introducing imaginary coupling springs. Different from the traditional model where two nodes at coupling interface are connected through a spring, these node-pairs in the new model are assumed to remain in tight contact during vibration. Details of the model, including force analysis, coordinate reduction and transformation and complex eigenvalue decomposition are given in this paper.

High fidelity mathematical vehicle models that can accurately capture the dynamics of car suspension system are critical in vehicle dynamics studies. System identification techniques can be employed to determine model type, order and parameters. Such techniques are well developed and usually used on linear models. Unfortunately, shock absorbers have nonlinear characteristics that are non-negligible, especially with regard the vehicle's vertical dynamics. In order to effectively employ system identification techniques on a vehicle, a nonlinear mathematical shock absorber model must be developed and then coupled to the linear vehicle model. Such an approach addresses the nonlinear nature of the shock absorber for system identification purposes. This paper presents an approach to integrate the nonlinear shock absorber model into the vehicle model for system identification.

In order to improve the tractive ability, steering capability and directional stability, etc. of automated mechanical transmission (AMT) vehicles running on the wet and slippery road, the anti-slip regulation (ASR) technologies for AMT vehicles are developed. The significance of ASR for AMT vehicles is introduced; a road friction recognition method based on the deceleration of driving wheels is investigated; a fuzzy anti-slip control system based on adjustment of engine torque is developed and the corresponding experimental verification is conducted. The experimental results denote that the proposed method is effective to eliminate the excessive slip when the AMT vehicle travels on the low friction road.

Electric Power-Assisted Steering (EPAS) is a new power steering technology that will define the future of vehicle steering. The assist of EPAS is the function of the steering wheel torque and vehicle velocity. The assist characteristic of EPAS is set by control software, which is one of the key issues of EPAS. The straight-line type assist characteristic has been used in some current EPAS products, but its influence on the steering maneuverability and road feel hasn't been explicitly studied in theory. In this paper, the straight-line type assist characteristic is analyzed theoretically. Then a whole vehicle dynamic model used to study the straight-line type assist characteristic is built with ADAMS/Car and validated with DCF (Driver Control Files) mode of ADAMS/Car. Based on the whole vehicle dynamic model, the straight-line type assist characteristic's influence on the steering maneuverability and road feel is investigated.