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EuroBrake is organised by FISITA, the international membership organisation that supports the automotive and mobility systems sector in its quest to advance technological development. Having delivered against this mission for every generation of engineers since 1948, we are uniquely placed to promote excellence in mobility engineering and the development of safe, sustainable and affordable mobility solutions.

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EB2013-ABT-006

Paper

Wurth, Sebastian, Mehlan, Dr.-Ing. Andreas; -Faiveley Transport Witten GmbH

Detail

Actual axle mounted brake discs for high speed trains are made by casting with a subsequent heat treatment to generate the required mechanical properties. The casting process is connected with a number of disadvantages. From the technical point of view, there is a high scrap rate of approximately 40% which is mainly caused by casting defects, like hot cracks, non metallic inclusions, porosities or cavities generated during solidification of the moulding mass. The scrap rate as well as the heat treatment of the brake disc lead to high total manufacturing costs (TMC). Moreover, the reproducibility of the casting process is poor, which results in high differences in the quality of the brake discs. Finally, the development of new or modified brake disc designs is a long-term process since first samples have to be produced. To avoid these commercial and technical disadvantages, Faiveley Transport developed an innovative ventilated, modular axle mounted brake disc. This disc is built by steel sheets, which are the friction layers, with spacers in between. The contour of the friction layers is produced by laser cut. By applying electron beam welding, all single parts are joined in a hybrid structure. By using materials for the friction layers and the spacers, which are produced as bulk good, TMC as well as the delivery time can be significantly reduced. Furthermore, another advantage of the innovative concept is the high flexibility of the design. Referring to the friction layers and spacers a wide range of materials can be used in order to fulfil specific requirements of different applications. In order to evaluate the wear behaviour of the friction layers under equal conditions, different steel grades have been selected and were tested on a scale rig. Compared to standard brake disc cast steel grades, a number of materials with a significant reduced specific wear rate could be identified. In addition to this, full scale prototypes have been tested on a test bench in order to evaluate the performance under emergency and service conditions on high speed route profiles.

EuroBrake 2013

Advanced Brake Technologies (ABT)

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Development of an Innovative Ventilated, Modular Axle Mounted Disc, EB2013-ABT-006, EuroBrake 2013

EB2013-ABT-008

Paper

Farshizadeh, Emad; Steinmann, David; - DMecS Development of Mechatronic
Systems GmbH & Co. KG

Detail

This paper describes a concept for an electrohydraulic brake system for electric vehicles. The concept offers the possibility to generate about any brake pedal feedback for the driver, so that the perception of the brake pedal can be influenced and adapted to actual driving conditions. The brake system is particularly suitable for vehicles with recuperative braking, as combined recuperative and friction-based braking can be accomplished with minimal influence on the brake pedal feedback. Two examples are presented to show how different brake pedal feedback characteristics can be implemented. The developed control concept is analyzed in a simulation with a detailed nonlinear model of the brake system in an electric vehicle environment. The simulation results show a very good performance for recuperative together with friction-based braking without negatively affecting the pedal feedback.

EuroBrake 2013

Advanced Brake Technologies (ABT)

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A Concept For An Electrohydraulic Brake System With Adaptive Brake Pedal 
Feedback, EB2013-ABT-008, EuroBrake 2013

EB2013-ACC-001

Paper

Kanarachos, Stratis*; Alirezaei, Mohsen; Scheepers, Bart; Jansen, Sven;
Maurice, Jan-Pieter,

Detail

Developing and implementing vehicle active safety systems, e.g. electronic stability control (ESC), can significantly reduce the number of crashes, despite the increasing traffic density. However, any failure of a component or instrument of the electronic safety systems, e.g. sensor reading or motor failure, affects the vehicle’s dynamic response. In x-bywire and especially in braking-by-wire systems the performance degradation due to a failure becomes even more critical due to the lack of mechanical connection between driver’s pedal input and tires. In this study the fault tolerance of a hybrid braking system consisting out of an electric regenerative braking system –an electric motor installed at the front axle- and an electrohydraulic braking system acting on all wheels is considered. The main subject of the present paper is the development of a fault tolerant integrated Vehicle Dynamics Control (VDC) system based on the State Dependent Riccati Equation (SDRE) technique. In SDRE the nonlinear dynamics of the system is factorized into the state vector and the product of a matrix valued function that depends on the state itself. In doing so, the nonlinearities of the system are fully captured bringing the nonlinear system to a linear like structure having state-dependent coefficient (SDC) matrices. The nonlinear regulator is derived by minimizing an objective function which is formulated as a weighted integral of the system response and the actuators effort. By following an augmented penalty approach the method allows to implement adaptive terms in the objective function which can be used to improve system performance against failures. The proposed optimized VDC system is based on a 3 DOF vehicle model with a nonlinear combined slip Pacejka tire model and the SDRE technique. An extended linearization scheme of the system’s state space equations on the basis of the Pacejka tire model is developed and a suboptimal controller is computed at each time increment by solving efficiently an Algebraic Riccati Equation. The proposed control strategy has been evaluated in simulation utilizing a 14 Degrees Of Freedom nonlinear vehicle model in Matlab/Simulink environment. The simulation analysis later is validated experimentally by implementing the control system on a real time dSpace platform in a driving car. The performance of the controller will be shown for the mu-split braking manoeuvre considering three controller configurations. In the first configuration the VDC performance is evaluated for the nominal condition (no failure). In the second configuration the controller is tested in case of a failure without failure detection by the supervisory controller. In the third coniguration the controller is tested in case of failure with failure detection by the supervisory controller. The results show that the proposed controller can optimally stabilize the vehicle in nominal condition. In the case of failure the results demonstrate that if the fault detection and diagnosis module provides appropriate feedback for the supervisory controller the performance of the proposed VDC system is close to the nominal one and in the case of no failure detection, the system is still robust enough to stabilize the vehicle however at the cost of slower response. Last but not least it is shown that recuperation of energy is possible even in critical for safety situations. The main limitation of the proposed method is that it uses a very simple fault diagnosis module. Furthermore, it is assumed that the failure is isolated and doesn’t affect the reliability and performance of other system’s components. The SDRE method allows to design integrated vehicle dynamic controllers using a detailed description of the vehicle’s nonlinear state dynamics. Furthermore, as the objective function in the SDRE technique can be function of the state of the system, it is possible to systematically design a reconfigurable and robust controller in case of a system’s component failure. For the first time the application of SDRE using a penalty augmented approach in case of a failure is presented and proven to be effective. The problem of designing an optimal and fault tolerant vehicle dynamic control system based on the SDRE technique has been presented. The proposed system has been tested in simulation and experimentally and has been proven capable to stabilize the vehicle with an optimized braking force distribution.

EuroBrake 2013

Braking within Advanced Chassis Control Systems (ACC)

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Design And Evaluation Of A Fault Tolerant Brake By Wire System Based On The 
State Dependent Riccati Equation Technique, EB2013-ACC-001, EuroBrake 2013

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Technical Programme

EuroBrake 2012 in Dresden was a huge success, attracting 675 delegates from 37 countries. With more than 100 technical presentations and 50+ exhibitors, it was the largest dedicated braking conference in the world, bringing together experts from the passenger car, commercial vehicle, motorcycle, rail, aerospace and wider industrial fields. Participating in EuroBrake is your opportunity to connect with a powerful, international network of braking specialists from every corner of the industrial and research communities.

Added to this, advanced integrated chassis control systems increasingly call for sophisticated braking mechatronics, from brake preconditioning to autonomous emergency braking. Meanwhile the trend towards hybridisation and electrification of vehicle powertrains poses major challenges for brake system designers. How to recover the maximum available energy, whilst preserving a natural intuitive feel for the driver? Then there is the important task of engineering effective braking systems for the emerging breed of compact, ultra-low cost vehicles aimed at first-time purchasers in developing markets. How do we think differently to make safe braking affordable for every driver in every market?


These are the challenges which inspired us to create the EuroBrake conference, and the world’s braking community responded enthusiastically.

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Braking technology is an area of renewed focus for the automotive and transportation industries world-wide. The pressure to conserve energy while improving safety and driving pleasure is leading to exciting developments in foundation braking systems from NVH tools and solutions to new materials like carbon ceramic rotors and other lightweight design concepts.

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