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The brake-by-wire system (BBW) is better match the new energy vehicle in the future direction of development. The electro-mechanical brake (EMB) is lack of the brake failure backup and need a high 42 V voltage for the power supply. This paper presents a new brake-by-wire hybrid brake system (HBS) with the electro-hydraulic brake (EHB) equipped on the front wheels and the EMB equipped on the rear wheels. The combination of these two brake-by-wire systems has advantages of both the EHB and EMB system. The EMB on the rear wheels totally removing the rear pipes and can be simply mounted. In addition, since the need of brake torque on the rear axle is relatively small, the power supply of EMB can be reduced to 12 V. Meanwhile, the EHB on the front wheels has the failure backup function through the hydraulic line. The HBS can quickly and accurately regulate four wheels brake force of vehicles which can well meet the requirement of antilock brake system (ABS).

This paper presents a unified novel function-based brake control architecture, which is designed based on a top-down approach with functional abstraction and modularity. The proposed control architecture includes a commands interpreter module, including a driver commands interpreter to interpret driver intention, and a command integration to integrate the driver intention with senor-guided active driving command, state observers for estimation of vehicle sideslip, vehicle speed, tire lateral and longitudinal slips, tire-road friction coefficient, etc., a commands integrated control allocation module which aims to generate braking force and yaw moment commands and provide optimal distribution among four wheels without body instability and wheel lock or slip, a low-level control module includes four wheel pressure control modules, each of which regulates wheel pressure by fast and accurate tracking commanded wheel pressure.

With the development of modern vehicle chassis control systems, such as Anti-Lock Brake System (ABS), Acceleration Slip Regulation (ASR), Electronic Stability Control (ESC), and Regenerative Braking System (RBS) for EVs, etc., there comes a new requirement for the vehicle brake system that is the precise control of the wheel brake pressure. The Electro-Hydraulic Brake system (EHB), which owns an ability to adjust four wheels’ brake pressure independently, can be a good match with these systems. However, the traditional control logic of EHB is based on the PWM (Pulse-Width Modulation), which has a low control accuracy of linear electromagnetic valves. Therefore, this paper presents a research of the linear electro-magnetic valve characteristic analysis, and proposes a precise pressure control algorithm of the EHB system with a feed forward and a PID control of linear electro-magnetic valves.

The Electromechanical Brake Booster system (EMBB) integrates active braking and energy recovery and becomes a novel brake-by-wire solution that substitutes the vacuum booster. While the intelligent unmanned vehicle is in unstable state, the EMBB can improve the vehicle yaw stability more quickly and safely. In this paper, a new type of integrated EMBB has been designed, which mainly includes two parts: servo motor unit and hydraulic control unit. Aiming at the dynamic instability problem of intelligent unmanned vehicle, a three-layer vehicle yaw stability control structure including decision layer, distribution layer and execution layer is proposed based on integrated EMBB. Firstly, the decision layer calculates the ideal yaw rate and the side slip angle of the vehicle with the classic 2DOF vehicle dynamics model. The boundary of the stable region is determined by the phase plane method and the additional yaw moment is determined by the feedback PI control algorithm.

Vehicle yaw stability control (YSC) can actively adjust the working state of the chassis actuator to generate a certain additional yaw moment for the vehicle, which effectively helps the vehicle maintain good driving quality under strong transient conditions such as high-speed turning and continuous lane change. However, the traditional YSC pursues too much driving stability after activation, ignoring the difference of multi-objective requirements of yaw maneuverability, actuator energy consumption and other requirements in different vehicle stability states, resulting in the decline of vehicle driving quality. Therefore, a vehicle yaw stability model predictive control strategy for dynamic and multi-objective requirements is proposed in this paper. Firstly, the unstable characteristics of vehicle motion are analyzed, and the nonlinear two-degree-of-freedom vehicle dynamics models are established respectively.