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In the hybrid brake system of electric vehicle, due to the limitation of the motor braking force when the motor is at high speed and the failure of the regenerative braking force when the motor is at low speed, there are three transitional conditions in hybrid braking: the hydraulic brake system intervenes the braking, the hydraulic brake system withdraws the braking and the regenerative braking force withdraws the braking. Due to the response speed of the hydraulic system is slower than that of the motor, there is a large braking impact (the derivative of braking deceleration) in the transitional conditions of hybrid braking, which deteriorates the smoothness and comfort in braking. Aiming at the impact caused by the poor cooperation between the hydraulic braking force and the motor braking force, a coordinated strategy of double closed-loop feedback and motor force correction is proposed in this paper.

In the process of ABS control, the Anti-lock braking system (ABS) of the vehicle adjusts the wheel cylinder brake pressure through the hydraulic actuator so as to control the movement of the wheel. The high-speed on-off valve (HSV) is the key components of the Anti-lock braking system. HSV affects the performance of the hydraulic actuator and the valve response characteristics affects the Anti-lock braking system pressure response as well as braking effect. In this paper, the electromagnetic field theory and flow field theory of HSV are analyzed, and simulation analysis of electromagnetic field characteristics of HSV is done by ANSYS. Combined with the ANSYS analysis results, a precise physical model of HSV is constructed in AMESim. Meanwhile, the valve response characteristics are analyzed. Moreover, the influence of different wheel cylinder diameter and PWM carrier frequency on hydraulic braking force characteristics are analyzed.

In order to establish the correlation between objective and subjective evaluation of brake pedal feel for passenger cars, road tests of brake pedal feel were carried out and an evaluation method was proposed. In the road tests, subjective scores and objective measurements were obtained under the conditions of uniform and emergency braking. The objective measurements include pedal preload, low deceleration pedal force and travel, moderate deceleration pedal force and travel, brake response time and brake linearity. Using the theory of analytic hierarchy process (AHP), the design process of the evaluation method was established. Key setups including the hierarchical structure model, the judgement matrix and the score calculation method of objective measurements were described in detail. Then, the correlation between subjective and objective scores was analyzed. It can be concluded that the evaluation method is effective and it can be applied to brake pedal feel assessment and adjustment.

In order to explore the generation mechanism of hot-spots on the automotive brake disc, disc tests under non-frictional thermal loads are carried out on the brake dynamometer test bench. In the tests, the oxy-acetylene flame is used as the heat source, and the distribution characteristics of the disc temperature and displacement are measured and analyzed. To confirm the mechanism of the disc deformation, a disc thermal buckling model using finite element method is established, and the key factors for the disc thermal buckling under thermal loads are further analyzed. It is found that the temperature circumferential gradient is small but the temperature radial gradient is large. The disc presents waviness deformation mode with 5th order in circumferential direction, which is the first thermal buckling mode of the disc. A method using spatial frequency spectrum has been proposed to find the critical time and load of thermal buckling.

Automatic lane change of intelligent vehicles is a complex process. Besides of safety, feelings of the driver and passengers during the lane change are also very important. In this paper, a lane change trajectory planner is designed to generate an ideal collision-free trajectory to satisfy the driver’s preference. Various lane changing modes, gentle lane change, general lane change, radical lane change and personalized lane change, are designed to meet the needs of different passengers on vehicles simultaneously. In this paper, the condition of the two-lane change is studied. One vehicle is in front of the ego vehicle at the same lane and one is at the rear of the ego vehicle at the target lane. A trajectory planning method is then established based on constant speed offset and sine curve, vehicle distances and speed difference, etc. The key factors which can reflect drivers’ lane change characteristics are then acquired.

After obtaining the optimal trajectory through the lane change decision and trajectory planning, the last key technology for the automatic lane change assist system is to carry out the precise and rapid steering actuation according to the front wheel angle demand. Therefore, an automatic lane change system model including a BLDCM (brushless DC motor) model, a steering system model and a vehicle dynamics model is first established in this paper. Electromagnetic characteristics of the motor, the moment of the inertia and viscous friction etc. are considered in these models. Then, a SMC (Sliding Mode Control) algorithm for the steering system is designed to follow the steering angle input. The control torque of the steering motor is obtained through the system model according to steering angle demand. After that, the control current is calculated considering of electromagnetic characteristics of the BLDCM. Debugging and optimization of the control algorithm are done through simulations.

The automatic lane change assist system is an intelligent driving assistance technology oriented to traffic safety, which requires trajectory planning of the lane change maneuver based on the lane change decision. A typical scene of lane change for overtaking is selected, where the front vehicle in the same lane and the rear vehicle in the left lane are deemed to be potential dangerous vehicles through the lane change. Lane change trajectory equation is first established according to the general law of steering wheel angle through lane changes. Based on the relative position, velocity and acceleration information of the dangerous vehicles and the lane change vehicle, motions of these surrounding dangerous vehicles are predicted. At the same time, a multi-objective optimization function is established based on the relative longitudinal safety boundary. The objectives are the minimum safety distance, the lane change time and the front wheel angle.

Downsizing gasoline direct injection engine with turbo boost technology is the main trend for gasoline engine. However, with engine downsizing and ever increasing of power output, a new abnormal phenomenon, known as pre-ignition or super knock, occurs in turbocharged engines. Pre-ignition will cause very high in-cylinder pressure and high oscillations. In some circumstances, one cycle of severe pre-ignition may damage the piston or spark plug, which has a severe influence on engine performance and service life. So pre-ignition has raised lots of attention in both industry and academic society. More and more studies reveal that the auto-ignition of lubricants is the potential source for pre-ignition. The auto-ignition characteristics of different lubricants are studied. This paper focuses on the ignition delay of different lubricants in Controllable Active Thermo-Atmosphere (CATA) combustion system.

Research studies have suggested that changes to the ignition system are required to generate a more robust flame kernel in order to secure the ignition process for the future advanced high efficiency spark-ignition (SI) engines. In a typical inductive ignition system, the spark discharge is initiated by a transient high-power electrical breakdown and sustained by a relatively low-power glow process. The electrical breakdown is characterized as a capacitive discharge process with a small quantity of energy coming mainly from the gap parasitic capacitor. Enhancement of the breakdown is a potential avenue effectively for extending the lean limit of SI engine. In this work, the effect of high-power capacitive spark discharge on the early flame kernel growth of premixed methane-air mixtures is investigated through electrical probing and optical diagnosis.

A novel compound power-split hybrid transmission based on a modified Ravigneaux gear set is presented. The equivalent lever diagrams are used to investigate the electric operating modes for the hybrid powertrain, and then its dynamic and kinematic characteristics as well as efficiency characteristics are described in equations. A brake clutch mounted on the carrier shaft is proposed to enhance the electric driving efficiency for the hybrid transmission. Three types of electric operating mode are analyzed by the simplified combined lever diagrams and the system efficiency and torque characteristics for these electric operating modes are compared. A major influence on output torque of the hybrid transmission derived from the torque capability of motors and brake clutch is depicted.

An ion current sensor is employed in a 4 cylinder production SI engine for combustion diagnosis during combustion process, knock, and low speed pre-ignition (LSPI) detection. The results show that the ion current peak value and ion current peak phase have strong correlation with the cylinder pressure and pressure peak phase respectively. The COV of ion current integral value is greater than the COV of IMEP at the same operating condition. Results show that the ion current signal is sensitive to different lambdas. Using ion current signal, the knock in any given cylinder can be detected. Importantly, the ion sensor successfully detected the low speed pre-ignition (LSPI) about more than 20 °CA before spark ignition.

Gasoline Direct Injection (GDI) engines have attracted interest as automotive power-plants because of their potential advantages in down-sizing, fuel efficiency and in emissions reduction. However, GDI engines suffer from elevated unburned hydrocarbon (HC) emissions during start up process, which are sometimes worsened by misfires and partial burns. Moreover, as the engine is cranked to idle speed quickly in HEVs (Hybrid Electric Vehicle), the transients of quick starts are more dramatically than that in traditional vehicle, which challenge the optimization of combustion and emissions. In this study, test bench had been set up to investigate the GDI engine performances for ISG (Integrated Starter and Generator) HEVs during start up process. Based on the test system, cycle-controlled of the fuel injection mass, fuel injection timing and ignition timing can be obtained, as well as the cycle-resolved measurement of the HC concentrations and NO emissions.

The present work discusses a novel oxyfuel combustion method named internal combustion rankine cycle (ICRC) used in reciprocating engines. Water is heated up through heat exchanger by exhaust gas and engine cooling system, and then injected into the cylinder near top dead center to control the combustion temperature and in-cylinder pressure rise rate, meanwhile to enhance the thermo efficiency and work of the combustion cycle. That is because injected water increases the mass of the working fluid inside the cylinder, and can make use of the combustion heat more effectively. Waste heat carried away by engine coolant and exhaust gas can be recovered and utilized in this way. This study investigates the effect of water injection temperature on the combustion and emission characteristics of an ICRC engine based on self-designed test bench. The results indicate that both indicated work and thermal efficiency increase significantly due to water injection process.

In this paper, by analyzing multiple electro-hydraulic brake system schemes in detail, the idea of dual-motor electro-hydraulic brake system is proposed. As a new solution, the dual-motor electro-hydraulic brake system can actively simulate pedal feel, make the most of pedal power (from the driver), and reduce the maximum power output of each active power source remarkably, which is a distinctive innovation compared to most current electro-hydraulic brake systems. Following the proposed concept, a general research thought and method is conceived, and then a dual-motor electro-hydraulic brake system is designed. Finally, the simulation model is set up in AMESim software and its feasibility is simulated and verified.

Disc brake squeal has always been a great challenge to the automotive industry. Based on the pin-on-disc system, a series of frictional squeal bench tests are carried out, which show significant time-varying characteristics on occurrence, sound pressure and frequency of frictional squeal. To investigate the generation mechanism of time-varying characteristics of frictional squeal, a four-degree-of-freedom (4DOF) lumped parameter model considering the time-varying tangential contact stiffness, the normal contact stiffness and the friction coefficient is established in this paper. Through both the system stability analysis and the transient response analysis, the time-varying frictional squeal is predicted successfully, and the generation mechanism and the key impact factors are also investigated in depth.

Brake pedal feel characteristic is determined by the structural and kinetic parameters of the components of the brake system. As the servo power component of the brake system, vacuum booster has a significant influence on the brake pedal feel. In this paper, a brake system model for brake pedal feel which has a detail vacuum booster mathematical description is established in the software MATLAB/Simulink. The structure gaps, spring preload, friction force and reaction disc characteristics of vacuum booster are considered in this model. A brake pedal feel bench test under different input velocity and vacuum pressure is completed in order to validate the prediction of the model.

The Forming limit diagram (FLD) is a powerful tool for describing the formability of sheet materials in the automobile industry, which provides fundamental data for die design and Finite Element (FE) simulation. However, traditional FLD testing is typically conducted at quasi-static strain rates from 0.001/s to 0.01/s, which are much lower than the industrial stamping process with strain rates about 1-10/s. In this research, FLDs at various punch speeds (from 1mm/s to 100mm/s or 120mm/s) were obtained for three kinds of AHSS, Quenched and Partitioned steel, Dual Phase 980 and Dual Phase 590 and three kinds of conventional steels, Low Alloy High Strength steel, Bake Hardening steel and IF steel. The results show that FLDs at a typical industrial stamping speed (100mm/s or 120mm/s) are considerably lower than the quasi-static test speed for the Advanced High Strength Steels (AHSS).

The control in transient conditions when hydraulic brake and regenerative brake switch mutually is the key technical issue about electric vehicle hybrid brake system, which has a direct influence on the braking feel of driver and vehicle braking comfort. A coordination control system has been proposed, including brake force distribution correction module and motor force compensation module. Brake force distribution correction module has fixed the distribution results in hydraulic brake force intervention condition, hydraulic brake force evacuation condition and regenerative brake force low speed evacuation condition. Motor compensation module has compensated hydraulic system with motor system, which has fast and accurate response, thus the response of whole hybrid system has been improved.

Brake squeal shows a significant uncertainty characteristic. In this paper, a series of bench tests were carried out to study the uncertainty of brake squeal on a multi-function brake inertia dynamometer test bench. Then based on time-frequency analysis results, a creative squeal confirmation and determination method was presented, which can show the squeal variations in the domains of time, frequency and amplitude together. An uncertainty analysis method was also established, in which the statistical parameters of squeal frequency and sound pressure level (SPL), and probability density evaluation of frequency based on Quantile-Quantile Plot (QQ plot) were given. And a judgment method of the frequency doubling was devised based on numerical multiple and occurrence concurrence, as well as the uncertainty statistical analysis method considering frequency doubling. All the methods established were applied to the uncertainty analysis of brake squeal.

Similar laser welded blanks with same material and same gauge have been extensive applied in automobile body for improving the material utilization and extending maximum coil size. It is known that, for TWBs with dissimilar material and thicknesses, the difference of material properties and/or thickness of the welded blanks, change of the material properties in the weld seam and heat-affected zones (HAZ) as well as location and orientation of the weld seam are reasons for reduced formability. However, the plastic deformation capacity of TWBs is reduced even when the material and thickness are the same. The aim of this paper is to evaluate the deformation behaviors of similar laser welded joints. Uniaxial tensile of five laser welded joints, with 90°,60°,45°,30°and 0°weld orientations, were tested by using optical measurement-DIC (Digital Image Correlation). Strain /strain ratio distribution and evolution of each joint was analyzed and compared with base material.