Brake Valve Timing and Fuel Injection: a Unified Engine Torque Actuator for Heavy-Duty Vehicles

A unified engine torque actuator for heavy-duty vehicles is developed in this paper. Based on averaging and identification of the instantaneous torque response for changes in brake valve timing and fuel flow, we derive a control oriented engine model of a six cylinder, 350 Hp turbocharged diesel engine, equipped with a compression brake. This work bridges the gap between the detailed compression crank angle based models developed in the engine design community, and the first order lag representation of diesel engine torque response used in the vehicle dynamics community. Moreover, we integrate the compression brake actuator with the service brakes and design a PI-controller that emulates the driver's actions during long descends on grades. The controller simply uses the engine speed measurement to activate the service brakes only when needed.     

Heavy-duty vehicle modelling and longitudinal control

This paper addresses modelling, longitudinal control design and implementation for heavy-duty vehicles (HDVs). The challenging problems here are: (a) an HDV is mass dominant with low power to mass ratio; (b) They possess large actuator delay and actuator saturation. To reduce model mismatch, it is necessary to obtain a nonlinear model which is as simple as the control design method can handle and as complicated as necessary to capture the intrinsic vehicle dynamics. A second order nonlinear vehicle body dynamical model is adopted, which is feedback linearizable. Beside the vehicle dynamics, other main dynamical components along the power-train and drive-train are also modelled, which include turbocharged diesel engine, torque converter, transmission, transmission retarder, pneumatic brake and tyre. The braking system is the most challenging part for control design, which contains three parts: Jake (engine compression) brake, air brake and transmission retarder. The modelling for each is provided. The use of engine braking effect is new complementary to Jake (compression) brake for longitudinal control, which is united with Jake brake in modelling. The control structure can be divided into upper level and lower level. Upper level control uses sliding mode control to generate the desired torque from the desired vehicle acceleration. Lower level control is divided into two branches: (a) engine control: from positive desired torque to desired fuel rate (engine control) using a static engine mapping which basically captures the intrinsic dynamic performance of the turbo-charged diesel engine; (b) brake control: from desired negative torque to generate Jake brake cylinder number to be activated and ON/OFF time periods, applied pneumatic brake pressure and applied voltage of transmission retarder. Test results are also reported.     

Heavy-duty vehicle modelling and longitudinal control

This paper addresses modelling, longitudinal control design and implementation for heavy-duty vehicles (HDVs). The challenging problems here are: (a) an HDV is mass dominant with low power to mass ratio; (b) They possess large actuator delay and actuator saturation. To reduce model mismatch, it is necessary to obtain a nonlinear model which is as simple as the control design method can handle and as complicated as necessary to capture the intrinsic vehicle dynamics. A second order nonlinear vehicle body dynamical model is adopted, which is feedback linearizable. Beside the vehicle dynamics, other main dynamical components along the power-train and drive-train are also modelled, which include turbocharged diesel engine, torque converter, transmission, transmission retarder, pneumatic brake and tyre. The braking system is the most challenging part for control design, which contains three parts: Jake (engine compression) brake, air brake and transmission retarder. The modelling for each is provided. The use of engine braking effect is new complementary to Jake (compression) brake for longitudinal control, which is united with Jake brake in modelling. The control structure can be divided into upper level and lower level. Upper level control uses sliding mode control to generate the desired torque from the desired vehicle acceleration. Lower level control is divided into two branches: (a) engine control: from positive desired torque to desired fuel rate (engine control) using a static engine mapping which basically captures the intrinsic dynamic performance of the turbo-charged diesel engine; (b) brake control: from desired negative torque to generate Jake brake cylinder number to be activated and ON/OFF time periods, applied pneumatic brake pressure and applied voltage of transmission retarder. Test results are also reported.     

具有迟滞模拟记忆功能的奥迪盘式制动器可变线性模型

本文以奥迪１００盘式制动器为研究对象，建立了一种可模拟制动压力－力矩响应迟清点特性的可变线性模型，首先，介绍在ＪＦ－１３２型汽车制动器试验台上进行防抱制动器模拟试验的方法，其次，在获得大量试验数据的基础上，运用曲线拟合和优化技术，建立制动压力－力矩关系的线性模型，心滞模型为线笥模型，最后，在相同制动压力输入的前提下，把模型的理论计算民试验结果进行对比分析了模型的有效性和精确性。     

发动机制动、排气制动与缓速器联合作用时的非连续线性控制系统的研究

针对客车发动机制动、排气制动的制动扭矩比较小的问题,提出采用发动机制动、排气制动与缓速器联合作用的持续制动方式,并且针对汽车在山区道路下坡行驶过程中对稳定车速的要求,进行了相应的控制系统设计。模拟分析结果表明:该控制系统可以保证汽车在不采用行车制动器的条件下,利用发动机制动、排气制动与缓速器联合作用的持续制动方式,在各种坡度的坡道上以希望的车速稳定下坡行驶,为汽车在山区道路连续下坡行驶的制动安全性提供了一个合理的解决方案。     

Longitudinal Oscillations of Vehicle/Trailer Combinations Induced by Overrun Braking

A mathematical model for the representation of longitudinal oscillations which can occur in car/trailer systems in braking, when the trailer brakes are applied through compression of the towing hitch, is described. The model is used to show how the trailer braking system parameters affect the steady deceleration performance of the vehicle combination, and the stability, in the linear system sense, of the steady motions. The sensitivity of the stability to other system design parameters is also examined.

Digital simulation of the motions occurring in response to a step input of car braking torque is reported, with the results confirming the predictions of the linear stability analysis, and also showing the influence of backlash in the trailer brake actuating mechanism.

The system is shown to be capable of self-excitation in a “shunting” mode, in which the car and trailer motions are in antiphase, with the stability/damping property critically dependent on drawbar damping, and only weakly dependent on other system parameters. The characteristic frequency of the “shunting” mode oscillations is shown to be controllable via the stiffness of the trailer brake linkage, but this frequency is closely related to the steady drawbar deflection which occurs in uniform deceleration.

The model behaviour described provides a basis for the design of relevant systems whose longitudinal dynamic characteristics will be satisfactory.     

Coordinated vehicle traction control based on engine torque and brake pressure under complicated road conditions

Vehicle traction control system has been developed to enhance the traction capability and the direction stability of the driving wheels through the tyre slip ratio regulation. Under normal situations, if the tyre slip ratio exceeds a certain threshold, the slip ratio of the driving wheel is regulated by the coupled interaction of the engine torque and the active brake pressure. In order to obtain the best driving performance on a road under complicated friction conditions, the driving torque and the active brake pressure, need to be decoupled and adjusted to avoid penalisation of each other. In this paper, a coordinated cascade control method with two sliding-mode variable structure controllers is presented. In this control method, the driving wheel slip ratio is regulated by adjusting the engine torque and the wheel brake pressure. Through the sliding-mode controller, the engine torque is tuned to achieve the maximum driving acceleration and then the active brake pressure is applied to the slipped wheel for further modification of the wheel slip ratio. The advantage of this control method is that through proper regulation, the conflict between the two control inputs could be avoided. Finally, the simulation results validate the effectiveness of the proposed method.     

Novel coordinated algorithm for Traction Control System on split friction and slope road

A Traction Control System (TCS) is used to avoid excessive wheel-slip via adjusting active brake pressure and engine torque when vehicle starts fiercely. The split friction and slope of the road are complicated conditions for TCS. Once operated under these conditions, the traction control performance of the vehicle might be deteriorated and the vehicle might lack drive capability or lose lateral stability, if the regulated active brake pressure and engine torque can’t match up promptly and effectively. In order to solve this problem, a novel coordinated algorithm for TCS is brought forward. Firstly, two brake controllers, including a basic controller based on the friction difference between the two drive wheels for compensating this difference and a fuzzy logic controller for assisting the engine torque controller to adjust wheel-slip, are presented for brake control together. And then two engine torque controllers, containing a basic PID controller for wheel-slip control and a fuzzy logic controller for compensating torque needed by the road slope, are built for engine torque control together. Due to the simultaneous and accurate coordination of the two regulated variables the controlled vehicle can start smoothly. The vehicle test and simulation results on various road conditions have testified that the proposed method is effective and robust.     

气压制动系统储能装置容量特性研究

建立了气压制动系统的简化模型，研究了和储能装置容量特性相关的制动器促动刚度、气室推力和容积以及制动过程中气体的热力学特性，介绍了计算储能装置容量特性的方法。最后讨论了储能装置容量的法规适应性检验、制动系统设计参数协调性、制动问隙对制动力影响和变型车制动系统设计等问题。     

钳盘式和片式制动器设计计算

针对钳盘式制动器和片式制动器各自的优点,详细介绍了它们的制动力矩的设计计算,以及对制动器摩擦片进行耐压、耐磨损的温升等验算.     

谈摩托车液压盘式制动器的结构设计

随着国内对摩托车液压盘式制动器需求量的不断加大,国内很多企业在模仿国外制动器的基础上开始自行研发,一些企业在没有完全理解制动器设计原理的情况下,没有经过充分试验便更改国外制动器的一些设计尺寸,从而造成设计上的一些不合理,其中最普遍的问题就是制动器的制动抱死现象.     

Design and use of an eddy current retarder in an automobile

In this study, the structure and working principles of an eddy current retarder acting as an auxiliary brake set is introduced in detail. Based on the principle of energy conservation, a mathematical model was developed to design a retarder whose nominal brake torque is 1, 900 N·m. According to the characteristics of the eddy current retarder, an exclusive test bed was developed and used for brake performance measurements. The main technical parameters, such as the brake characteristics, temperature characteristics and power consumption, were measured with the test bed. The test data show that the brake torque of the eddy current retarder obviously decreased in the continuous braking stage and that there is a certain amount of brake torque in the normal driving state because of the remnant magnetism of the rotor plate. The mathematical model could be used to design an eddy current retarder. The exclusive test bed could be used for optimization of an eddy current retarder as well as for R&D of a series of products.     

制动器力学模型对其制动效能的影响

本文通过动力学数值仿真，研究制动器力学型的选取对其制动效能的影响问题，讨论了制动器动态特性与制动效能之间的关系，指出了在制动器动态设计存在的不足之处，给出若干动态设计的指导性准则和依据。     

新型电控机械制动系统制动效能分析

在建立了汽车制动过程的动态分析模型、传统的液压制动器模型和新型的电控机械制动器模型基础上,通过计算机仿真对比分析了它们的制动效能。研究结果表明新型电控机械制动器比传统液压制动器具有响应速度快、制动效能高等优点。     

Pneumatic train brake simulation method

The design of new pneumatic brakes for rail vehicles or improvements of existing ones can be made better or more efficient by the use of a simulation method. This paper gives a general presentation of the author’s modelling methods used for solving problems relating to railway pneumatic brakes. The brake models in this paper (slightly different from those of other authors) take into account air-wave phenomena including air viscosity, the influence of the brake pipe branches, heat transfer in the brake pipes and reservoirs, air flows in the brake valves and the dynamics of moving mechanical parts. For various simulation purposes, separate partial models with different levels of accuracy were created. Various verifications and identifications of the models were performed with the use of train brake testing facilities, including both in-house and other test stands. A variety of examples of simulation results are presented here.     

两种新型汽车制动器惯性测功机

本文介绍了两种新型汽车制动器惯性测功机，一种是高模拟式，一种是多功能式，前者可准确模拟汽车的制动工况和测定各项性能参数，特别适用于产品研究与开发；后者是专为执行国内外制动器及衬片试验法规和标准而研制的，它除了具有制动器惯性测功机功能外，尚具有ＫＲＡＵＳＳ和ＣＨＡＳＥ两种衬片材料试验机功能。     

Control of Wheel Slip Ratio Using Sliding Mode Controller with Pulse Width Modulation

For the control of anti-lock brake system (ABS), a longitudinal four-wheel vehicle model with brake actuator is described and a sliding mode controller with pulse width modulation (PWM) method has been developed for passenger vehicles. In our research, we introduce actuator dynamics of solenoid-solenoid valve type in system equation and derive the sliding mode control input theoretically. We propose using PWM method to compensate for the discrete nature of actuator dynamics by duty control. The effectiveness of the proposed control algorithms was confirmed by vehicle test on an in-door test bench that was specially constructed for the purpose concerned.     

Direct tire force generation algorithm based on non-iterative nonlinear inverse tire model

The function of vehicle dynamics control system is adjusting the yaw moment, the longitudinal force and lateral force of a vehicle body through several chassis systems, such as brakes, steering and suspension. Individual systems such as ESC, AFS and 4WD can be used to achieve desired performance by controlling actuator variables. However, integrated chassis control systems that have multiple objectives may not simply achieve the desired performance by controlling the actuators directly. Usually those systems determine the required tire forces in an upper level controller and a lower level controller regulates the tire forces through the actuators. The tire force is controlled in a recursive way based on vehicle state measurement, which may not be sufficient for fast response. For immediate force tracking, we introduce a direct tire force generation method that uses a nonlinear inverse tire model, a pseudo-inverse model of vehicle dynamics and the relationship between longitudinal force and brake pressure.     

Structural optimization of a circumferential friction disk brake with consideration of thermoelastic instability

This research suggests a new disk brake design using circumferential friction on the disk of a front-wheel-drive passenger car. The paper compares mechanical performance between the conventional and suggested disk brakes under dynamic braking conditions. Thermoelastic instability is considered in simulation of the test condition. An optimization technique using a metamodel is introduced to minimize the weight of the suggested disk brake. To achieve this goal, the response defined in the optimization formulation is expressed in a mathematically explicit form with respect to the design variables by using a kriging surrogate model, resulting in a simple optimization problem. Then, the simulated annealing algorithm is utilized to find the global optimum. The design results obtained by the kriging method are compared with those obtained from ANSYS analysis.     

Control of Wheel Slip Ratio Using Sliding Mode Controller with Pulse Width Modulation

For the control of anti-lock brake system (ABS), a longitudinal four-wheel vehicle model with brake actuator is described and a sliding mode controller with pulse width modulation (PWM) method has been developed for passenger vehicles. In our research, we introduce actuator dynamics of solenoid-solenoid valve type in system equation and derive the sliding mode control input theoretically. We propose using PWM method to compensate for the discrete nature of actuator dynamics by duty control. The effectiveness of the proposed control algorithms was confirmed by vehicle test on an in-door test bench that was specially constructed for the purpose concerned.