Fault detection and diagnosis of the electromechanical brake based on observer and parity space

In the future, the conventional hydraulic brake system in automobiles will be removed and replaced by an electrically operated brake system called brake-by-wire. The brake-by-wire units, such as the EMB (Electro-Mechanical Brake), provide better braking performance by directly controlling the brake motor and are environmentally friendly because they do not use hydraulic fluid. For implementation of the EMB systems, reliable and robust fault detection and diagnosis methods become increasingly important. In this study, a sensor fault diagnosis method is proposed with parity space and observer approaches to detect faults in the motor current sensor, speed (or position) sensor and clamping force sensor. The proposed method is verified through a closed-loop simulation using Matlab/Simulink, and the simulation result is compared with the HILS bench test results.     

Fault-tolerant braking control with integerated EMBs and regenerative in-wheel motors

This paper presents a fault-tolerant brake torque controller for four-wheel-distributed braking systems with in-wheel motors and Electro-Mechanical Brakes (EMB). Mechanical and electrical faults can degrade the performance of the EMB actuators and, thus, their effects need to be compensated in vehicle dynamics level. In this study, the faults are identified as performance degradation and expressed by the gains of each actuator. Assuming the brake force distribution and the regenerative braking ratios, the over-actuated braking system is simplified into a two-input system. A sliding mode controller is designed to track the driver’s braking and steering commands, even if there exist faults in EMBs. In addition, adaptive schemes are constructed to achieve the fault-tolerant control in braking. The proposed controller and strategies are verified in the EMB HILS (Hardware-in-loop-simulation) unit for various conditions.     

Approach to functional safety-compliant ECU design for electro-mechanical brake systems

In this paper, we propose a design approach to a functional safety-compliant ECU for an electro-mechanical brake (EMB) control system or an electronic wedge brake (EWB) control system. Brake actuators in a brake-by-wire (BBW) system such as EMB or EWB are characterized by the safety-critical functions which are now executed by using many electric and electronic devices with application software. Based on hazard analysis and risk assessments of the automotive functional safety standard ISO 26262, the proposed EMB control system should be ASIL-D-compliant, which is the highest ASIL level. To this end, a hardware and a software design method is introduced to implement functionl safety-oriented monitoring functions which are based on an asymmetric dual-core architecture with an external watchdog processor. It is shown by using EMB hardware-In-the-Loop-Simulation (HILS) that the proposed ECU design approach is very effective when a hardware fault or software execution faults occur in the EMB ECU, moreover, this functional safety-compliant design can be well combiled with the sensor fault-tolerant control logic.     

机电控制CVT电控电动执行机构参数设计方法（双语出版）

为了使机电控制无级变速器（CVT）能够可靠地传递转矩，快速地调节速比，结合某车型的结构性能参数，对机电控制CVT电控电动执行机构的设计方法进行研究。首先，对机电控制CVT电控电动执行机构的结构和工作原理进行分析，说明电控电动执行机构对CVT速比和从动带轮夹紧力的调节方法，从运动学和动力学的角度研究从金属带式无级变速器的传动机理，获得速比与主动带轮可动盘位移的关系以及保证主、从动带轮可靠传递转矩所需要的夹紧力；然后，根据整车的结构性能参数，明确汽车对机电控制CVT的功能需求和性能要求，以电控电动执行机构中直流电动机的负载转矩最小为目标，设计确定各碟形弹簧的参数和组合形式，在此基础上确定电控电动执行机构中电动机械传动系统的结构性能参数；最后，为验证所设计电控电动执行机构参数的正确性，利用所建立的机电控制CVT传动系统模型在ECE工况下对电控电动执行机构的性能进行仿真分析。结果表明：相对传统CVT液压执行机构，在ECE工况下机电控制CVT电控电动执行机构消耗的能量减少52.2%，同时设计的电控电动执行机构在ECE工况下能够实现实际夹紧力和速比对目标值的良好跟随。     

金属带式无级变速器夹紧力控制的研究

介绍了金属带式无级变速器控制系统的主要功能,研究了夹紧力控制阀的工作特性,设计了带有前馈抗回绕的PID控制器。对所设计的夹紧力控制系统模型进行了仿真试验,并对装有该夹紧力控制器的综合控制系统进行了装车试验。结果表明,所设计的控制器能够按照行驶工况的要求控制合适的夹紧力,调节速比,可满足实际需要。     

Analysis of a regenerative braking system for Hybrid Electric Vehicles using an Electro-Mechanical Brake

The regenerative braking system of the Hybrid Electric Vehicle (HEV) is a key technology that can improve fuel efficiency by 20∼50%, depending on motor size. In the regenerative braking system, the electronically controlled brake subsystem that directs the braking forces into four wheels independently is indispensable. This technology is currently found in the Electronic Stability Program (ESP) and in Vehicle Dynamic Control (VDC). As braking technologies progress toward brake-by-wire systems, the development of Electro-Mechanical Brake (EMB) systems will be very important in the improvement of both fuel consumption and vehicle safety. This paper investigates the modeling and simulation of EMB systems for HEVs. The HEV powertrain was modeled to include the internal combustion engine, electric motor, battery and transmission. The performance simulation for the regenerative braking system of the HEV was performed using MATLAB/Simulink. The control performance of the EMB system was evaluated via the simulation of the regenerative braking of the HEV during various driving conditions.     

基于自适应模型预测的智能汽车横向轨迹跟踪控制

当路面附着情况和车辆行驶状态不断变化时,基于恒定侧偏刚度的模型预测控制(MPC)不能考虑轮胎非线性特性的影响,难以保证车辆轨迹跟踪的适应性。为此,提出一种考虑轮胎侧向力计算误差的自适应模型预测控制(AMPC),以提高智能汽车在不确定工况下的轨迹跟踪性能。分析了路面附着系数和垂向载荷对轮胎侧向力的影响,基于平方根容积卡尔曼滤波(SCKF)算法,设计了利用侧向加速度和横摆角速度作为测量变量的前后轮胎侧向力估计器。利用轮胎侧向力线性计算值与估计值的差值计算得到侧偏刚度修正因子,设计了前后轮胎侧偏刚度的自适应修正准则,进而提出了一种基于时变修正刚度的AMPC控制方法。基于CarSim与MATLAB/Simulink联合仿真和硬件在环测试平台,对AMPC控制的有效性和实时性进行了验证。研究结果表明：在不同的路面附着情况和车辆行驶状态下,AMPC控制都能够降低横向位置偏差和航向角偏差,有效提高车辆的轨迹跟踪精度,其控制效果明显优于基于恒定侧偏刚度的标准MPC控制。尤其在低附着工况下,标准MPC控制会因为线性轮胎力的计算误差过大而导致车辆在轨迹跟踪时严重失稳,而AMPC控制通过估计轮胎力修正侧偏刚度依然能够保证车辆稳定有效的跟踪参考轨迹。所提出的AMPC控制在保证控制精度的同时具有良好的实时性,对智能汽车控制系统的设计与优化具有重要参考价值。     

基于LS-SVM模型的无级变速器夹紧力控制系统故障诊断

在不增加硬件成本和过大的运算量的前提下,研究了基于模型的无级变速器夹紧力控制系统故障诊断方法.提出了根据测得的信号以及全局和部分元件诊断模型的输出结果来完成故障隔离与定位的诊断策略;针对系统的非线性特征,采用最小二乘支持向量机建立反映其输入输出关系的非线性预测模型.测试结果表明所建立的故障自诊断系统具有较高的精度和反应速度,可以粗略地实现故障的隔离和定位.     

电子驻车制动卡钳电控性能测试系统的设计与实现

介绍了基于飞思卡尔MC9S12XS128MAL单片机的电子驻车制动卡钳电控性能测试系统,具体阐述了电子驻车制动卡钳无液压夹紧释放功能、有液压夹紧释放功能、电机过载性和电机欠电性测试的实现方法。该测试系统采用完全不同于汽车行业现有团体标准规定的试验方法,以更接近实车工况的方式进行测试,测试方法和测试系统具有一定的创新性。试验结果表明,该系统输入电流、液压控制精准,卡钳夹紧力、液压、电流数据采集实时,试验测得的响应时间、夹紧力及动态关系曲线稳定可靠,可以满足各主机厂及零部件厂商对电子驻车制动卡钳电控性能试验的要求。     

EMB硬件在环仿真试验台

介绍了用于EMB系统研究的硬件在环仿真试验台的搭建方法,对试验台的总体结构设计、机械系统设计、控制电路设计以及用于仿真试验的仿真模型进行了初步的探讨,并通过试验证实了这一技术的可行性和应用前景。     

An alternative approach to automotive ESC based on measured wheel forces

Traditional electronic stability control (ESC) systems act on one or more wheels on the basis of a logic aiming at the control of variables that cannot be directly measured (vehicle sideslip angle and the tyre slip). Hence, a vehicle state estimator capable of evaluating the needed variables from the data of the input sensors is necessary. In the present paper, the authors discuss a different approach to the estimation problem, assuming that the forces acting on the wheels can be directly measured. The ESC feed-forward control logic is designed through a vehicle frequency response analysis in order to obtain a faster active system activation. The variable controlled by the logic is the tyre longitudinal force. Experimental results obtained on an ESC hardware-in-the-loop test bench prove the validity of the approach, showing enhanced dynamic performances, together with the limits due to the delays in the actuation of the ESC motor pump, which needs some time to build the pressure requested for the intervention on the selected callipers. Finally, the tests demonstrate the opportunity of closing the control loop on a variable (i.e. the force) that can be directly measured.     

Experimental study of an electro-mechanical CVT ratio controller

This paper introduces an electro-mechanical, dual acting pulley, continuously variable transmission (EMDAPCVT) and presents its real time ratio controller using a proportional-derivative-plus-conditional-integral (PDPCI) controller. The ratio controller system is developed based on primary (input) and secondary (output) pulley position controllers. Each position controller has two PID parameters, releasing and clamping, which are determined experimentally using a relay feedback method. A PC-based ratio controller system is implemented using Matlab/Simulink® software and a Keithley DAS-1602 data acquisition system card. The experimental results show that the PDPCI controller system can control the CVT ratio adequately.     

Adaptive feedforward control of a steer-by-wire system by online parameter estimator

The tracking control of the steer-by-wire (SBW) system to achevie desired steering motion is the core issue for the design of algorithm. Most of model-based tracking control assumed the constant parameters without the consideration of dynamic characteristics. The external disturbances and model nonlinearities can bring uncertainties of the system parameters. To reduce the influence of parameter uncertainties, an online estimator by output error identification method is proposed to estimate the dynamic parameters of a SBW system. Meanwhile, the parameter gradient projection method is applied to eliminate the parameter drift, while a full order state observer is developed to weaken the effects of noise disturbance during the parameter identification. Since the sensitivity of parameter uncertainties for the feedforward control, the online estimator is incorporated into the control model and improve the controlled robustness. The proposed adaptive feedforward controller is conducted by the real-time experiments to show the tracking performance.     

Customer loads of two-wheeled vehicles

Customer usage profiles are the most unknown influences in vehicle design targets and they play an important role in durability analysis. This publication presents a customer load acquisition system for two-wheeled vehicles that utilises the vehicle's onboard signals. A road slope estimator was developed to reveal the unknown slope resistance force with the help of a linear Kalman filter. Furthermore, an automated mass estimator was developed to consider the correct vehicle loading. The mass estimation is performed by an extended Kalman filter. Finally, a model-based wheel force calculation was derived, which is based on the superposition of forces calculated from measured onboard signals. The calculated wheel forces were validated by measurements with wheel–load transducers through the comparison of rainflow matrices. The calculated wheel forces correspond with the measured wheel forces in terms of both quality and quantity. The proposed methods can be used to gather field data for improved vehicle design loads.     

Vehicle Dynamic Control for In-Wheel Electric Vehicles Via Temperature Consideration of Braking Systems

?Vehicle dynamic control (VDC) systems play an important role with regard to vehicle stability and safety when turning. VDC systems prevent vehicles from spinning or slipping when cornering sharply by controlling vehicle yaw moment, which is generated by braking forces. Thus, it is important to control braking forces depending on the driving conditions of the vehicle. The required yaw moment to stabilize a vehicle is calculated through optimal control and a combination of braking forces used to generate the calculated yaw moment. However, braking forces can change due to frictional coefficients being affected by variations in temperature. This can cause vehicles to experience stability problems due an improper yaw moment being applied to the vehicle. In this paper, a brake temperature estimator based on the finite different method (FDM) was proposed with a friction coefficient estimator in order to solve this problem. The developed braking characteristic estimation model was used to develop a VDC cooperative control algorithm using hydraulic braking and the regenerative braking of an in-wheel motor. Performance simulations of the developed cooperative control algorithm were performed through cosimulation with MATLAB/Simulink and CarSim. From the simulation results, it was verified that vehicle stability was ensured despite any changes in the braking characteristics due to brake temperatures.     

电子机械式制动执行器硬件在环仿真

电子机械制动技术是一种全新的制动理念,极大的提高了汽车的制动安全性.文中介绍了电子机械制动系统的发展、组成及工作原理;搭建了电子机械式制动执行器原理机硬件在环仿真试验平台.以1/4车辆模型为研究对象,对基于模糊控制方法的车辆防抱死制动特性的Matlab/Simulink仿真结果和硬件在环仿真结果进行比较分析.验证了电子机械式制动执行器的合理性和可行性.     

Numerical modeling of journal bearing considering both elastohydrodynamic lubrication and multi-flexible-body dynamics

This study uses an elastohydrodynamic lubrication model coupled with multi-flexible-body dynamics (MFBD) to analyze dynamic bearing lubrication characteristics, such as pressure distribution and oil film thickness. To solve the coupled fluid-structure interaction system, this study uses an MFBD solver and an elastohydrodynamics module. The elastohydrodynamics module passes its force and torque data to the MFBD solver, which can solve general dynamic systems that include rigid and flexible bodies, joints, forces, and contact elements. The MFBD solver analyzes the positions, velocities, and accelerations of the multi-flexible-body system while incorporating the pressure distribution results of the elastohydrodynamics module. The MFBD solver then passes the position and velocity information back to the elastohydrodynamics solver, which reanalyzes the force, torque, and pressure distribution. This iteration is continued throughout the analysis time period. Other functions, such as mesh grid control and oil hole and groove effects, are also implemented. Numerical examples for bearing lubrication systems are demonstrated.     

Clamping performance of fastener in windshield wiper assembly using theoretical and experimental methods

Improper clamping of wiper arms can cause problems in the operation of the wiper. An excessive clamping force can cause damage to the wiper arm head. On the other hand, an insufficient clamping force can cause self-loosening of the nut. Given the lack of direct research on the clamping force of the fastener in wiper assembly, this study verifies the existing clamping performance of the fastener in windshield wiper assembly by theoretical and experimental methods. The theoretical calculation results show that all the clamping performance are satisfied under the general snow load condition. However, under the critical load condition, maximum assembly preload and safety margin against slipping are in disagreement with the standard values. This problem is solved by increasing the strength grade of the bolt. The experimental results show a reducing tendency of the clamping force during the snow durability test. However, this reducing clamping force during the 60,000 test cycles is acceptable. In the case of nut reusing more than two times possibly cause a problem of its loosening because of insufficient clamping force. Therefore, it is recommended that the nut should not be reused more than two times.     

Tire Lateral Force Estimation Using Kalman Filter

As for the tire analysis, lateral tire force is a fundamental factor that describes the stability of vehicle handling. Attempts to analyze the vehicle stability have been made based on various objective test methods and some specific factors such as yaw, lateral acceleration and roll angle. However, the problem to identify which axle is lack of the tire grip at a certain situation still remains. Since indoor tire force measurement system cannot represent a real road and vehicle conditions, tire force measurement through a real vehicle test is inevitable. Due to the high price of the tire force measurement device, tire force estimator can be an alternative toward cost reduction and device failure. In this paper, nonlinear planar full car model combined with tire model is proposed. Then, using discrete-time extended Kalman-Bucy filter (EKBF), individual tire lateral force are estimated with modified relaxation length model.