Yes / An examination of the heat partition ratio between the friction surfaces of a disc braking system is presented using finite element analysis (FEA). This includes a 2D static analysis of two semi-infinite bodies in contact with and without an interface layer which represents the interface tribo-layer (ITL). An analytical approach with a finite difference solution was used for cross-comparison with the static FE models. Results from the static model have provided the boundary conditions for a 2D dynamic model, where one rectangular block slides on another (fixed) rectangular block. The effects of normal loads and real contact area have also been studied. / Institution of Mechanical Engineers

This thesis presents an investigation of braking system characteristics, brake system performance and brake system component design parameters that influence brake pedal force / displacement characteristics as ‘felt’ by the driver in a passenger car. It includes detailed studies of individual brake system component design parameters, operation, and the linear and nonlinear characteristics of internal components through experimental study and simulation modelling. The prediction of brake pedal ‘feel’ in brake system simulation has been achieved using the simulation modelling package AMESim. Each individual brake system component was modelled individually before combining them into the whole brake system in order to identify the parameters and the internal components characteristics that influence the brake pedal ‘feel’. The simulation predictions were validated by experimentally measured data and demonstrated the accuracy of simulation modelling. Axisymmetric Finite Element Analysis (using the ABAQUS software) was used to predict the behaviour of nonlinear elastomeric internal components such as the piston seal and the booster reaction disc which was then included in the AMESim simulation model. The seal model FEA highlighted the effects of master cylinder and caliper seal deformation on the brake pedal ‘feel’. The characteristics of the brake booster reaction disc were predicted by the FEA and AMESim simulation modelling and these results highlighted the importance of the nonlinear material characteristics, and their potential contribution to brake pedal ‘feel’ improvement. A full brake system simulation model was designed, prepared, and used to predict brake system performance and to design a system with better brake pedal ‘feel’. Each of the brake system component design parameters was validated to ensure that the braking system performance was accurately predicted. The critical parameter of brake booster air valve spring stiffness was identified to improve the brake ‘pedal ‘feel’. This research has contributed to the advancement of automotive engineering by providing a method for brake system engineers to design a braking system with improved pedal ‘feel’. The simulation model can be used in the future to provide an accurate prediction of brake system performance at the design stage thereby saving time and cost.

This work is engaged in the confrontation of the existing braking system of Formula SAE project. From made confrontations is selected the best solution and make his dimension and own construct design. It is verify through analyse of tension and analyse of heat transfer.

Active safety systems for road vehicles have been improved considerably in recent years along with technological advances and the increasing demand for road safety. In the development route of active safety systems which started with introduction of digital controlled ABS in the late seventies, vehicle stability control systems have been developed which today, with an integration approach, incorporate ABS and other previously developed active safety technologies. ABS, as a main part of this new structure, still maintains its importance. In this thesis, a design methodology of an antilock braking system controller for four wheeled road vehicles is presented with a detailed simulation work. In the study, it is intended to follow a flexible approach for integration with unified control structure of an integrated active safety system. The objective of the ABS controller, as in the previous designs in literature, is basically to provide retention of vehicle directional control capability and if possible shorter braking distances by controlling the wheel slip during braking. iv A hierarchical structure was adopted for the ABS controller design. A high-level controller, through vehicle longitudinal acceleration based estimation, determines reference slip values and a low-level controller attempts to track these reference slip signals by modulating braking torques. Two control alternatives were offered for the design of the low-level controller: Fuzzy Logic Control and PID Control. Performance of the ABS controller was analyzed through extensive simulations conducted in MATLAB/Simulink for different road conditions and steering maneuvers. For simulations, an 8 DOF vehicle model was constructed with nonlinear tires.

Durch das I-FAS der TU Chemnitz wurde im Rahmen des AKTIV-Projektes eine Probandenstudie zur Akzeptanz von Systemausprägungen einer Aktiven Gefahrenbremsung (AGB) bei PKW durchgeführt. Unter Verwendung eines stehenden Hindernisses wurden sechs Systemausprägungen verglichen, die von den AGB-Partnern in zwei Versuchsträger implementiert wurden. Die sechs Systemausprägungen werden nahezu identisch bewertet, solange Probanden keine Vergleichsmöglichkeit zu anderen Systemausprägungen haben. Wenn es zu einem Fahrereingriff kommt, ist der Eingriffszeitpunkt des Fahrers unabhängig von der gefahrenen Systemausprägung.

Design of braking system for the formula student car. Calculation of basic forces acting in the braking system, including the design of hydraulic circuits. Mechanical analysis of the most important parts of the braking system and pedal assembly. Thermal analysis of the brake discs. Manufacturing and total cost calculation.

Design of braking system for the formula student car. Calculation of basic forces acting in the braking system. Mechanical analysis of the most important parts of the braking system. Manufacturing of brake pedal. Assembly brake components to brake system.

This thesis deals with a conceptual design of small utility vehicle with three axles. The aim is to devise a suitable type of frame along with construction of all axles and a steering system, implementation of a drive train, a braking system and other basic equipment. Own solution is preceded by elaboration of a survey dealing with small utility vehicles produced nowadays as well as in the past together with a description of all variants of basic assemblies suitable for the construction of the specified vehicle.

Within the safety analysis industry there are a variety of tools used to ensure reliability and security of systems, ranging from mostly qualitative approaches to mostly quantitative. One safety analysis method that lies in between these two is called Layers Of Protection Analysis (LOPA). LOPA is known as a “semi-quantitative” approach that uses a mix of quantitative and qualitative approaches to draw conclusions. In this masters thesis the LOPA approach is demonstrated, in addition to being developed into two alternate LOPA approaches, known as MarkovLOPA and RBDLOPA. These two developed approaches use the concept of Markov chains and Reliability block diagram (RBD) respectively, to extend the applicability of the traditional LOPA methodology. Furthermore, a conventional hydraulic braking system (CHB), which includes ABS/TCS- and ESP functionality was analysed by these three methodologies. The results of the analysis show that in the analysis by LOPA and RBDLOPA 4- and 3 out of 10 scenarios need slight improvements and only 1 scenario for MarkovLOPA. Additionally, the validity of the alternative approaches are analysed by a sensitivity analysis, showing irregularities in the results, leading to the conclusion that further research and development is required prior to industrial applications of the approaches.

Utifrån en problemställning formulerad av Trafikverkets skyltfond har produktutvecklingsföretaget Prodelox drivit ett projekt med syfte att testa kreativa idéer för att minska bromssträckan för personbilar i nödsituationer. Som en del i projektet har ett examensarbete genomförts vilket resulterat i denna rapport. Examensarbetet ämnar sammanställa en mängd idéer på alternativa metoder att bromsa bilar, för att sedan välja ut tre av dessa för praktiska tester. Idén med att korta bromssträckan grundar sig i trafiksäkerhetsarbetet i kombination med introduktionen av nya tekniska system som kan förutspå kollisioner. Om en kollision kan förutses är det av största intresse att kunna bromsa in bilen så mycket som möjligt innan detta sker för att minska skadorna och rädda liv. Ur ett förutsättningslöst perspektiv har kreativa idéer tagits fram. Rapporten tar dessutom upp och sammanfattar friktionsteorier och fordonsdynamiska aspekter att ta hänsyn till vid utvecklingsarbetet. Projektet följer en produktutvecklingsmetodik presenterad av Ulrich och Eppinger (2008) och omfattningen är utvecklingsfasens tidiga steg. Genom två iterationer utvecklas koncept genom framtagande av kravspecifikation, konceptgenerering, och konceptval. Idéer testas löpande genom fysiska såväl som virtuella prototyper under hela processen. Den första utvecklingsiterationen resulterar i 17 konceptidéer innefattande olika typer av bromsmetoder. Koncepten delas in i kategorierna ökad friktion, ökad normalkraft, spjärn mot asfalten, aerodynamik och magnetism. Tre koncept väljs ut och utvecklas vidare: Koncept Ankare, Gummiplatta och Avverkan. Utvecklingen av koncept Ankare resulterar i ett koncept där en infästning i asfalten sker i farten under bilen med hjälp av krutdrivna spikpistoler. Fästet förbinds med bilen med ett textilband kallat Tear Webbing. Det är två sydda remmar som producerar en konstant kraft då remmarna slits isär och sömmarna rivs upp. Bandet testas praktiskt och ger en bromseffekt på uppemot 1,5 g-krafter, medan de krutdrivna spikpistolerna inte kan testas i farten inom ramen för detta projekt. Koncept Gummiplatta bygger på att en stor gummiyta placerad under bilen trycks ner i marken och lyfter framvagnen på bilen. Olika gummibelägg testas med förhoppningen att hitta ett gummibelägg med goda friktionsegenskaper. Ökad area och optimerade materialegenskaper kan i teorin leda till bättre friktion. Konceptet testas på både vått och torrt väglag genom en konstruktion under testbilens framvagn. Fyra olika gummiprover jämförs med bilens vanliga bromsar. Endast ett gummi, naturgummi, presterar bättre än referensen i tester från 50 km/h, medan resten resulterar i längre bromssträcka. Vid tester från 100 km/h presterar samtliga gummiprover sämre än referensbromsningarna. Koncept Avverkan baseras på idén att en större kraft än friktionskraften kan fås ut om ett hårt material trycks ner i asfaltens yta och river upp densamma. Deformationerna av asfalten åstadkommer den bromsande kraften. I test av konceptet höll inte konstruktionen, men retardationen som utvecklades innan konstruktionen gav vika kom upp i 1,2 g-krafter, något som visar på att konceptet har kapacitet att korta bromssträckan. Som fortsättning på detta projekt föreslås flera vägar att gå. Koncepten Ankare och Avverkan visar på stor potential att korta bromssträckan och nya projekt med syfte att fortsatt utveckla och testa dessa koncept föreslås. Även andra projekt som ligger utanför syftet av denna rapport, så som en idé för att minska dubbdäcksanvändningen, föreslås för utredning i framtida studier. / At the request of the Swedish Transport Administration the product development company Prodelox has initiated a project aiming to test creative ideas on reducing the braking distance for passenger cars in emergency situations. As a part of this project a master thesis has been conducted resulting in this report. The thesis aims to compile ideas on alternative methods for braking cars, and thereafter choosing three of them for practical testing. In combination with introduction of new technical innovations that predict collisions, an alternative braking system that could brake more than standard brakes are of great interest. By reducing the braking distance deaths and serious injuries in traffic can be reduced. From this perspective ideas have been impartially generated. The report includes friction theory and vehicle dynamics to consider in the development. The project is following a product development process presented by Ulrich and Eppinger (2008) and focuses on the early stages of the process. In two iterations concepts are developed through the phases target specification, concept generation and concept selection. Ideas are concurrently tested through physical as well as virtual prototypes. The first development iteration resulted in 17 concepts including different kinds of braking methods. The concepts are divided into five categories; increased friction, increased normal load, grabbing of the asphalt, aerodynamics, and magnetism. Three concepts are chosen for further development; concept Anchor, Rubber plate, and Rip up. The development of concept Anchor results in a concept for which an attachment is made in the asphalt on the fly by use of cartridge actuated fastening machine. The attachment is connected to the car by a textile webbing, called Tear Webbing. It consists of two sewn straps that produce a constant force when torn apart. In practical tests, the concept generate a breaking effect of 1.5 g-forces, while the cartridge actuated fastening cannot be tested on the fly within this project. The development of concept Anchor results in a concept for which an attachment is made in the asphalt on the fly by use of cartridge actuated fastening machine. The attachment is connected to the car by a textile webbing, called Tear Webbing. It consists of two sewn straps that produce a constant force when torn apart. In practical tests, the concept generate a breaking effect of 1.5 g-forces, while the cartridge actuated fastening cannot be tested on the fly within this project. Concept Rip up is based on idea that a bigger force than the frictional force can be achieved by pressing a hard material into the surface of the asphalt road and tearing up the same. The deformations of the asphalt generate the braking force. While testing the concept the structure holding the horns broke, but the force achieved before time of collapse was corresponding to a deceleration of 1.2 g-forces. This shows that the concept has potential to reduce the braking distance. To conclude this project several new projects are suggested. The concepts Anchor and Rip up show great potential to reduce the braking distance and new projects aiming to further develop and test these concepts are recommended. Also other further studies outside the frame of this report are suggested, for example an idea on how to reduce the usage of studded tires.