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Abstract Composite ceramic brake discs are made of ceramic material reinforced with carbon fibers and offer exceptional advantages that translate directly into higher vehicle performance. In the case of an electric vehicle, it could increase the range of the vehicle, and in the case of conventional internal combustion engine vehicles, it means lower fuel consumption (and consequently lower CO2 emissions). These discs are typically characterized by complex internal geometries, further complicated by the presence of drilling holes on both friction surfaces. To estimate the aerothermal performance of these discs, and for the thermal management of the vehicle, a reliable model for predicting the air flowing across the disc channels is needed. In this study, a real carbon-ceramic brake disc with drilling holes was investigated in a dedicated test rig simulating the wheel corner flow conditions experimentally using the particle image velocimetry technique and numerically.

Abstract A Direct Yaw-Moment Control (DYC) logic for a rear-wheel-drive electric-powered vehicle is proposed. The vehicle is a Formula SAE (FSAE) type race car, with two electric motors powering each rear wheel. Vehicle baseline balance is neutral at low speeds, for increased maneuverability, and increases understeering at high speeds (due to the aerodynamic configuration) for stability. A controller that can deal with these yaw response variations, modelling uncertainties, and vehicle nonlinear behavior at limit handling is proposed. A two-level control strategy is considered. For the upper level, yaw rate and sideslip angle are considered as feedback control variables and a cubic-error Proportional Derivative (PD) controller is proposed for the feedback control. For the lower level, a traction control algorithm is used, together with the yaw moment requirement, for torque allocation.

Abstract Aiming to improve the handling performance of heavy tractor semi-trailer during turning or changing lanes at high speed, a hierarchical structure controller is proposed and a hardware-in-the-loop (HIL) test bench of the electronic pneumatic braking system is developed to validate the proposed controller. In the upper controller, a Kalman filter observer based on the heavy tractor semi-trailer dynamic model is used to estimate the yaw rates and sideslip angles of the tractor and trailer. Simultaneously, a sliding mode direct yaw moment controller is developed, which takes the estimated yaw rates and sideslip angles and the reference values calculated by the three-degrees-of-freedom dynamic model of the heavy tractor semi-trailer as the control inputs. In the lower controller, the additional yaw moments of tractor and trailer are transformed into corresponding wheel braking forces according to the current steering characteristics.

Abstract With the introduction of advanced lightweight materials with complex microstructures and behaviors, more focus is put on the accurate determination of their forming limits, and that can only be possible through experiments as the conventional theoretical models for the forming limit curve (FLC) prediction fail to perform. Despite that, CAE engineers, designers, and toolmakers still rely heavily on theoretical models due to the steep costs associated with formability testing, including mechanical setup, a large number of tests, and the cost of a stereo digital image correlation (DIC) system. The international standard ISO 12004-2:2021 recommends using a stereo DIC system for formability testing since two-dimensional (2D) DIC systems are considered incapable of producing reliable strains due to errors associated with out-of-plane motion and deformation.

Abstract The tailpipe zero-emission legislation has pushed the automotive industry toward more electrification. Regenerative braking is the capability of electric machines to provide brake torque. So far, the regenerative braking feature is primarily considered due to its effect on energy efficiency. However, using individual e-machines for each wheel makes it possible to apply the antilock braking function due to the fast torque-tracking characteristics of permanent magnet synchronous motors (PMSM). Due to its considerable cost reduction, in this article, a feasibility study is carried out to investigate if the ABS function can be done purely through regenerative braking using a mid-fidelity model-based approach. An uni-tire model of the vehicle with a surface-mount PMSM (SPMSM) model is used to verify the idea. The proposed ABS control system has a hierarchical structure containing a high-level longitudinal slip controller and a low-level SPMSM torque controller.

Abstract A classical antiskid brake system (ABS) is typically used to control the brake fluid pressure by creating repeated cycles of decreasing and increasing brake force to avoid wheel locking, causing the fluctuation of the brake hydraulic pressure and resulting in vibration during wheel rotation. This article proposes a new approach of skid control for ABS by controlling the disk pad position. This new approach involves using a modest control method to determine the optimal skid that allows the wheel to exert maximum friction force for decelerating the vehicle by shifting the brake pad position instead of modulating the brake fluid pressure. This pad position control (PPC) method works in a continuous manner. Therefore, no rapid changes are required in the brake pressure and wheel rotation speed. To identify the PPC braking performance, braking test simulations and experiments have been carried out.

Abstract Brake squeal reduces comfort for the vehicle occupants, damages the reputation of the respective manufacturer, and can lead to financial losses due to cost-intensive repair measures. Mode coupling is mainly held responsible for brake squeal today. Two adjacent eigenfrequencies converge and coalesce due to a changing bifurcation parameter. Several approaches have been developed to suppress brake squeal through structural changes. The main objective is to increase the distance of coupling eigenfrequencies. This work proposes a novel approach to structural modifications and sizing optimization aiming for a start at shifting a single component eigenfrequency. Locations suitable for structural changes are derived such that surrounding modes do not significantly change under the modifications. The positions of modifications are determined through a novel sensitivity calculation of the eigenmode to be shifted in frequency.

Abstract Nowadays, with the great advancement of automobile intellectualization, vehicle integrated dynamic control is increasingly becoming a hot research field. For vehicle stability, this article focuses on the coordinated control of Direct Yaw-moment Control (DYC) and Active Front Steering (AFS). First of all, the nominal control variables (yaw rate and sideslip angle) are designed based on the linear two Degrees of Freedom (2 DOF) vehicle model, in which the phase difference between the actual and nominal variables has been pointed out due to the approximate substitution with first-order time-delay transfer function. Secondly, considering the uncertainty of cornering stiffness per axle, and increasing robustness of the system, the Optimal Guaranteed Cost Control (OGCC) theory is adopted to design the coordinated controller.

Abstract The braking phenomenon is an aspect of vehicle stopping performance where with kinetic energy due to the speed of the vehicle is transformed into thermal energy produced by the brake disc and its pads. The heat must then be dissipated into the surrounding structure and into the airflow around the brake system. The thermal friction field during the braking phase between the disc and the brake pads can lead to excessive temperatures. In our work, we presented numerical modeling using ANSYS software adapted in the finite element method (FEM), to follow the evolution of the global temperatures for the two types of brake discs, full and ventilated disc during braking scenario. Also, numerical simulation of the transient thermal analysis and the static structural analysis were performed here sequentially, with coupled thermo-structural method.

Abstract Electromagnetic forming (EMF) is a high-speed impulse forming process developed during the 1950s and 1960s to acquire shapes from sheet metal that could not be obtained using conventional forming techniques. In order to attain required deformation, EMF process applies high Lorentz force for a very short duration of time. Due to the ability to form aluminum and other low-formability materials, the use of EMF of sheet metal for automobile parts has been rising in recent years. This review gives an inclusive survey of historical progress in EMF of continuum sheet metals. Also, the EMF is reviewed based on analytical approach, finite element method (FEM) simulation-based approach and experimental approach, on formability of the metals.

Abstract In order to improve the safety and dynamic performance of electric vehicles equipped with four in-wheel electric motors, and prevent the wheels from locking or slipping when braking or accelerating, a new longitudinal control strategy which combines ASR traction and ABS braking control is proposed using an observation algorithm of effective radius for four wheel of electric vehicle. Using the electric motor torques as the unique actuator signal sources, this combined ASR/ABS can act as acceleration slip regulation (ASR) by preventing the wheels from slipping during acceleration and as an antilock braking system (ABS) by preventing the wheels from getting locked during braking. A variation of effective radius of the wheel’s tire can have an incidence on the longitudinal and lateral control.

Abstract An automatic emergency braking (AEB) adaptive control algorithm based on the emergency braking behavior of professional drivers fitting (PDF) model is proposed, which can simultaneously take into account safety and ride comfort on different friction roads. Three typical AEB control algorithms are selected for comparative analysis, namely, AEB control algorithms based on the safety distance (SD) model, time-to-collision (TTC) model, and PDF model, respectively. The simulation results of the European New Car Assessment Programme (Euro-NCAP) test scenarios show that the AEB control algorithm based on the PDF model can ensure both safety and ride comfort. In order to overcome the defect that the original AEB control algorithm based on the PDF model does not consider the variation of road friction, the corresponding optimization and improvement are carried out.

Abstract This article presents a survey on active safety control of X-by-wire electric vehicles. The steer-by-wire (SBW) system, brake-by-wire (BBW) system, and electric drive system are three critical techniques for X-by-wire electric vehicles. As to the three systems, the structure comparison and performance analysis of existing products and prototypes are conducted. Then two kinds of X-by-wire chassis configuration, i.e., the centralized type and the distributed type, are introduced. For active safety control, various control models are summarized, including vehicle dynamics model, single-track model, path tracking model, and wheel dynamics model. Based on the proposed model, different active safety control algorithms are introduced involving longitudinal dynamics control, handling stability control, rollover prevention control, path tracking control, and active fault-tolerant control.

Abstract An innovative analysis approach to evaluate heavy-duty vehicle downhill engine brake performance was developed. The vehicle model developed with GT-Drive simulates vehicle downhill control speeds with different engine brake retarding powers, transmission gears, and vehicle weights at sea level or high altitude. The outputs are then used to construct multi-factor parametric design charts. The charts can be used to analyze the vehicle-level engine brake capabilities or compare braking performance difference between different engine brake configurations to quantify the risk of engine retarding power deficiency at both sea level and high altitude downhill driving conditions.

Abstract An improved control method of automatic emergency braking (AEB) for rear-end collision avoidance is proposed, which combines the advantages of a time-to-collision (TTC) control algorithm and professional driver emergency braking behavior. The TTC control algorithm mostly adopts phased braking, and although it can avoid collision effectively, the braking process is radical and brake comfort is poor. The emergency braking system with professional driver fitting (PDF) has good comfort and can also avoid collision successfully. However, its brake trigger time is too early, which leads to the stopping distance being too large under high-speed conditions and affects the road utilization. By combining the advantages of the two control methods, an improved control algorithm for AEB is proposed. When the TTC value is not greater than a predetermined limit, the PDF control switch will be closed to avoid collision.

Abstract In this article, an improved brake cooling simulation method is introduced. By this method, the vehicle parameters, such as weight, height of the center of gravity, wheelbase, and the like can be included to calculate the braking thermal load under different operating conditions. The effect of the brake kinetic energy regeneration (BKER) on the braking thermal load can also be calculated by this method. The calculated braking thermal load is then input to a coupled 3D simulation model to conduct flow and thermal simulation to calculate brake disc temperature. It is demonstrated that by this simulation method, the difference between the brake disc temperatures obtained from simulation and vehicle test can be controlled below 5%.

Abstract Metal Pick-Up (MPU) is a problematic phenomenon in automotive disc brakes. MPU generally forms as some metal lumps on the surface of the brake pad. If brake pads have MPU, during braking they would cause grooving of the disc rotor, generating brake noise and deteriorating the performance of the brake. The previous literature has so far reported that the source of the MPU is an Fe component from a disc rotor or brake pads. However, only a few of the generation mechanisms of MPU have been proven. We investigate MPU to completely elucidate the mechanism of MPU generation by using different analyses than the previous literature. First, to find out the source of MPU generation, we focus on the chemical reaction of a certain component with wear debris during braking, and some of the verification experiments are conducted under the conditions of simulated friction interface.

Abstract The mechanical properties of tires are critical to the driving performance of vehicles. Currently, the tire pressure control system (TPCS) has been applied to achieve different control objectives by adjusting the tire pressure and then changing the mechanical properties of tires. To reveal the influence of inflation pressure variation on vehicle lateral dynamics under combined slip situations, Firstly, the effects of inflation pressure on tire mechanical characteristics under combined slip conditions and the UniTire model considering inflation pressure are introduced. Then, the influence of inflation pressure variation on vehicle handling and stability under both pure and combined situations is investigated by means of an analytical method as well as a handling diagram and phase plane.

Abstract New analytical structural stress solutions for a rigid inclusion in a finite square thin plate with clamping edges under opening loading conditions are developed. The new solutions are used to derive new analytical structural stress and stress intensity factor solutions for similar and dissimilar spot welds in cross-tension specimens. Three-dimensional finite element analyses are conducted to obtain the stress intensity factor solutions for similar spot welds and dissimilar magnesium/steel spot welds in cross-tension specimens of equal thickness with different ratios of half-specimen width-to-weld radius. A comparison of the analytical and computational solutions indicates that the analytical stress intensity factor solutions for similar spot welds in cross-tension specimens of equal thickness are accurate for large ratios of half-specimen width-to-weld radius.

Abstract With the increase of electric vehicles on the roads, there is also an increase with vehicles that use regenerative braking (RB). This novel braking method differs from traditional service braking (SB) because RB decelerates the moment the driver releases the accelerator pedal and continues to actively brake if neither pedal is depressed. Since the vehicle actively decelerates when neither pedal is depressed in a vehicle with RB, we hypothesized that this would result in a difference in driver foot behavior. There were two pieces to explore this potential difference. The first piece was to explore time-based measures. The first measure was the time period from when the lead vehicle brake lights illuminate, to when the driver releases the accelerator pedal. The second measure was the time period from when the driver releases the accelerator pedal, to when the driver presses the brake pedal.