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Key Technologies on New Energy Vehicles Donghai Hu Design and Control of Hybrid Brake-by-Wire System for Autonomous Vehicle Key Technologies on New Energy Vehicles KeyTechnologiesonNewEnergyVehiclespublishesthelatestdevelopmentsinnew energyvehicles-quickly,informallyandwithhighquality.Theintentistocoverall the main branches of new energy vehicles, both theoretical and applied, including butnotlimited: (cid:129) ControlTechnologyofDrivingSystem (cid:129) HybridElectricVehicleCouplingTechnology (cid:129) CrossDisciplinarydesignoptimizationtechnology (cid:129) SingleandGroupBatteryTechnology (cid:129) EnergyManagementTechnology (cid:129) LightweightTechnology (cid:129) NewEnergyMaterialsandDevice (cid:129) InternetofThings(IoT) (cid:129) CloudComputing (cid:129) 3DPrinting (cid:129) VirtualRealityTechnologies Withinthescopesoftheseriesaremonographs,professionalbooksorgraduatetext- books,editedvolumes,andreferenceworkspurposelydevotedtosupporteducation inrelatedareasatthegraduateandpost-graduatelevels. Tosubmitaproposalorrequestfurtherinformation,pleasecontact: Dr.MengchuHuang,SeniorEditor,AppliedSciences Email:[email protected] Tel:+86-21-24225094 Moreinformationaboutthisseriesathttps://link.springer.com/bookseries/16377 Donghai Hu Design and Control of Hybrid Brake-by-Wire System for Autonomous Vehicle DonghaiHu SchoolofAutomotiveandTraffic Engineering JiangsuUniversity Zhenjiang,Jiangsu,China ISSN2662-2920 ISSN2662-2939 (electronic) KeyTechnologiesonNewEnergyVehicles ISBN978-981-16-8945-1 ISBN978-981-16-8946-8 (eBook) https://doi.org/10.1007/978-981-16-8946-8 ©TheEditor(s)(ifapplicable)andTheAuthor(s),underexclusivelicensetoSpringerNature SingaporePteLtd.2022 Thisworkissubjecttocopyright.AllrightsaresolelyandexclusivelylicensedbythePublisher,whether thewholeorpartofthematerialisconcerned,specificallytherightsoftranslation,reprinting,reuse ofillustrations,recitation,broadcasting,reproductiononmicrofilmsorinanyotherphysicalway,and transmissionorinformationstorageandretrieval,electronicadaptation,computersoftware,orbysimilar ordissimilarmethodologynowknownorhereafterdeveloped. Theuseofgeneraldescriptivenames,registerednames,trademarks,servicemarks,etc.inthispublication doesnotimply,evenintheabsenceofaspecificstatement,thatsuchnamesareexemptfromtherelevant protectivelawsandregulationsandthereforefreeforgeneraluse. Thepublisher,theauthorsandtheeditorsaresafetoassumethattheadviceandinformationinthisbook arebelievedtobetrueandaccurateatthedateofpublication.Neitherthepublishernortheauthorsor theeditorsgiveawarranty,expressedorimplied,withrespecttothematerialcontainedhereinorforany errorsoromissionsthatmayhavebeenmade.Thepublisherremainsneutralwithregardtojurisdictional claimsinpublishedmapsandinstitutionalaffiliations. ThisSpringerimprintispublishedbytheregisteredcompanySpringerNatureSingaporePteLtd. The registered company address is: 152 Beach Road, #21-01/04 Gateway East, Singapore 189721, Singapore Preface The autonomous vehicle is a complex electromechanical integration system. With the development trend of electric and intelligent vehicles, the braking system of it will gradually develop to brake-by-wire in order to achieve a more precise and controllable braking effect. At present, autonomous cars are equipped with hybrid brake-by-wiresystems,suchasacompositebrakesystemformotorandfrictionand anintegratedbrakesystemforelectromagneticandfriction.Asaresearcherinthe fieldofautonomousvehicles,Ihavefrequentlyfeltthatweneedamonographthat givesacomprehensiveanddetailedintroductiontothehybridbrake-by-wiresystem forautonomousvehicles. This book focuses on the hybrid brake-by-wire system for autonomous vehi- clesandpresentsacomprehensiveintroductionandresearchonthebrakesystem’s modeling, design, and control. This book is composed of six chapters. The first chapter introduces the industry status of hybrid brake-by-wire system, the second chapter introduces the research status of hybrid brake-by-wire system, the third chapter models hybrid brake-by-wire system, and the fourth chapter designs the hybrid brake-by-wire system based on the principles of safety and energy-saving, Thefifthchapterputsforwardthebrakingforcedistributioncontrolmethodofhybrid brake-by-wiresystem,andthesixthchapterintroducesthemodeswitchingcontrol ofhybridbrake-by-wiresystem. Thebookiswrittenforengineersofhybridbrake-by-wiresystemforautonomous vehicle,teachersandstudentsmajoringinautomobileandautomation.Wehopethat this selection of materials can provide readers with some guidance in the future designandcontrolofhybriddrive-by-wiresystemsforautonomousvehicles. ThisbookissponsoredbytheNationalkeyresearchanddevelopmentprogramof China“Integratedtransportationandintelligenttransportation”(2018YFB1600303). Zhenjiang,Jiangsu,China DonghaiHu v Contents 1 IndustryStatusofHybridBrake-By-WireSystem ................. 1 1.1 MotorBrake ............................................... 1 1.2 ElectromagneticBrake ...................................... 2 1.3 Electro-HydraulicBrake ..................................... 3 1.4 Electro-PneumaticBrake .................................... 5 1.5 CompositeBrakeSystemforMotorandFriction ................ 6 1.6 IntegratedBrakeSystemforElectromagneticandFriction ........ 8 References ..................................................... 9 2 ResearchStatusofHybridBrake-By-WireSystem ................ 11 2.1 BrakingForceDistributionControlofHybridBrake-By-Wire System .................................................... 11 2.2 ModeSwitchingControlofHybridBrake-By-WireSystem ....... 14 2.2.1 Mode Switching Control Under Non-emergency Braking ............................................. 14 2.2.2 ModeSwitchingControlUnderEmergencyBraking ...... 16 References ..................................................... 18 3 ModelingofHybridBrake-By-WireSystem ...................... 21 3.1 MotorBrakeModel ......................................... 21 3.1.1 DrivingMotorModel ................................. 21 3.1.2 EnergyStorageModel ................................ 22 3.2 ElectromagneticBrakeModel ................................ 24 3.2.1 NonlinearAnalysisofSoftMagneticMaterials ........... 24 3.2.2 CalculationofElectromagneticBrakingTorque .......... 26 3.3 Electro-HydraulicBrakeModel .............................. 27 3.3.1 AirbagAccumulator .................................. 27 3.3.2 MotorPump ......................................... 28 3.3.3 BrakeMasterCylinder ................................ 29 3.3.4 Low-SpeedSolenoidValve ............................ 30 3.3.5 High-SpeedSolenoidValve ............................ 31 3.3.6 BrakeLine .......................................... 32 vii viii Contents 3.3.7 BrakeWheelCylinder ................................ 33 3.4 Electro-PneumaticBrakeModel .............................. 34 3.4.1 SeriesDouble—ChamberBrakeValve .................. 34 3.4.2 RelayValve ......................................... 36 3.4.3 BrakeChamber ...................................... 37 3.4.4 DrumBrake ......................................... 38 3.5 VehicleBrakeDynamicModel ............................... 39 3.5.1 VehicleLongitudinalDynamicModel ................... 39 3.5.2 VehicleSingle-WheelBrakingModel ................... 40 3.6 HybridBrake-By-WireSystemModel ......................... 42 3.6.1 Model of Composite Brake System for Motor andFriction ......................................... 42 3.6.2 ModelofIntegratedBrakeSystemforElectromagnetic andFriction ......................................... 44 References ..................................................... 46 4 DesignofHybridBrake-By-WireSystem ......................... 47 4.1 Safety Design of Composite Brake System for Motor andFriction ............................................... 47 4.1.1 SafetyDesignofPowerSupplyDevice .................. 47 4.1.2 SafetyDesignofSpareBrakeCircuits .................. 49 4.1.3 SafetyDesignofInlet/OutletValve ..................... 51 4.2 Energy-Saving Design of Integrated Brake System forElectromagneticandFriction .............................. 52 4.2.1 EnergyConsumptionAnalysisofElectro-Hydraulic Brake .............................................. 52 4.2.2 EnergyConsumptionAnalysisofElectromagnetic Brake .............................................. 61 4.2.3 Energy-SavingDesignofIntegratedBrakeSystem forElectromagneticandFriction ....................... 70 5 BrakingForceDistributionControlofHybridBrake-By-Wire System ........................................................ 79 5.1 Braking Force DistributionControl ofComposite Brake SystemforMotorandFriction ................................ 79 5.1.1 AnalysisofInfluencingFactorsonBrakingForce DistributionControl .................................. 79 5.1.2 DesignandSimulationofBrakingForceDistribution Control ............................................. 82 5.2 Braking Force Distribution Control of Integrated Brake SystemforElectromagneticandFriction ....................... 86 5.2.1 Braking Force Distribution Control in Friction BrakingMode ....................................... 86 5.2.2 BrakingForceDistributionControlinElectromagnetic BrakingMode ....................................... 94 Contents ix 5.2.3 BrakingForceDistributionControlinCombined BrakingMode ....................................... 100 References ..................................................... 103 6 ModeSwitchingControlofHybridBrake-By-WireSystem ......... 105 6.1 ModeSwitchingControlofHybridBrake-By-WireSystem UnderNon-emergencyBraking ............................... 105 6.1.1 StabilityAnalysisofBrakingModeSwitchingProcess .... 105 6.1.2 ControllerDesignofBrakingModeSwitchingProcess .... 109 6.1.3 ModeSwitchingControlofCompositeBrakeSystem forMotorandFriction ................................ 115 6.1.4 ModeSwitchingControlofIntegratedBrakeSystem forElectromagneticandFriction ....................... 125 6.2 ModeSwitchingControlofHybridBrake-By-WireSystem UnderEmergencyBraking ................................... 129 6.2.1 AntilockBrakingModeling ........................... 129 6.2.2 AntilockBrakingCoordinatedController ................ 132 6.2.3 AntilockBrakingHardware-In-The-Loop ............... 138 6.2.4 AntilockBrakingHardware-In-The-LoopSimulation ..... 144 References ..................................................... 149 Chapter 1 Industry Status of Hybrid Brake-By-Wire System The system integration of brake by wire and standard hydraulic brake or electro- hydraulicbrakehasbecomeatrendindevelopingautomobilebrakesystemsinthe future.Therearetwotypicalautomobileintegratedbrakesystems:compositebrake systemformotorandfrictionandintegratedbrakesystemforelectromagneticand friction.Thischapteralsodescribesthestructureandworkingprincipleoffourkinds ofbrakes. 1.1 MotorBrake AsshowninFig.1.1[1],regenerativemotorbrake(RB)includesdrivemotor,motor controller, power battery, and battery management system. The drive motor has a four-quadrant working capacity. The x-axis represents the direction of the motor rotatingmagneticfield,andthey-axisrepresentsthedirectionofmotorloadtorque. Whenthedrivingmotorworksatthefirstandthirdimagelimits,thedrivingpoweris output,thefirstquadrantisforwarddriving,andthethirdquadrantisreversedriving: Whenthedrivingmotorworksatthesecondandfourthquadrants,thebrakingpower isoutput.Thesecondquadrantisforwardbraking,andthefourthquadrantisreverse braking. Whenthevehicleisbraked,thewheelwilldrivethedrivemotortorotatethrough the transmission device, and the whole vehicle controller will send a regenerative brakingcommandtothedrivemotor.Atthistime,thedrivemotorwillimplement motor regenerative braking. On the one hand, the vehicle braking energy will be recoveredandstoredinthepowerbattery,andontheotherhand,thebrakingtorque will be applied to the wheel. As a non-contact braking mode, motor regenerative brakingcansaveenergyconsumption,improvevehicledrivingrange,andhaveno brakingdustandnoiseinthebrakingprocess.Itisanenvironment-friendlybraking mode. However, the implementation of motor regenerative braking is affected by ©TheAuthor(s),underexclusivelicensetoSpringerNatureSingaporePteLtd.2022 1 D.Hu,DesignandControlofHybridBrake-by-WireSystemforAutonomousVehicle, KeyTechnologiesonNewEnergyVehicles, https://doi.org/10.1007/978-981-16-8946-8_1