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Investigation of Advanced Brake-By-Wire Systems for Electric Vehicles Wenfei Li University of Wollongong

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Investigation of Advanced Brake-By-Wire Systems for Electric Vehicles Wenfei Li University of Wollongong University of Wollongong Research Online University of Wollongong Thesis Collection 2017+ University of Wollongong Thesis Collections 2019 Investigation of Advanced Brake-by-Wire Systems for Electric Vehicles Wenfei Li University of Wollongong Unless otherwise indicated, the views expressed in this thesis are those of the author and do not necessarily represent the views of the University of Wollongong. Recommended Citation Li, Wenfei, Investigation of Advanced Brake-by-Wire Systems for Electric Vehicles, Doctor of Philosophy thesis, School of Electrical, Computer and Telecommunication Engineering, University of Wollongong, 2019. https://ro.uow.edu.au/theses1/572 Research Online is the open access institutional repository for the University of Wollongong. For further information contact the UOW Library: [email protected] Investigation of Advanced Brake-by-Wire Systems for Electric Vehicles Wenfei Li A thesis in fulfilment of the requirements for the degree of Doctor of Philosophy School of Electrical, Computer and Telecommunication Engineering Faculty of Engineering and Information Sciences The University of Wollongong 2019. 1 CERTIFICATE OF ORIGINALITY I, Wenfei Li, hereby declare that all the works presented in this thesis is original and was carried out at School of Electrical, Computer and Telecommunications Engineering (SECTE), Faculty of Engineering and Information Sciences (EIS), University of Wollongong. This thesis, submitted in fulfilment of the requirements for the award of Doctor of Philosophy, is wholly my own work unless otherwise referenced or acknowledged. This document has not been submitted for qualifications at any other academic institution. Wenfei Li (Signature) ________________ 2 ABSTRACT Brake-By-Wire (BBW) technology is the ability to control brakes through electrical means. A BBW system implemented with one micro-controller and actuator per wheel can provide more precise braking. The BBW system is considered to be one of the most significant innovations among X-By-Wire technologies that will revolutionize the automotive industry. The BBW system has the advantages of fast response speed and high braking torque control precision that can potentially replace the traditional hydraulic braking system (HBS). This thesis aims to investigate advanced BBW systems and solve their related issues. There are many forms of BBW systems such as the motor braking system (MBS) and the blended BBW system. The MBS as a form of BBW can not only achieve high precision braking torque control but also achieve the function of regenerative braking. Usually, the relationship between brake pedal position and vehicle deceleration is linear for MBS. However, this strategy does not take motor electrical characteristics and braking energy recovery into consideration. The recovered braking energy is limited. In this thesis, a new braking strategy based on the driver's braking intention and motor working characteristics is proposed for a pure MBS. This strategy is able to achieve as much braking energy recovery as possible, without violating the driver's braking intention. Pure MBS is suitable for low speed and light electric vehicles (EVs). However, in order to guarantee effective braking performance, the blended braking system (BBS) is usually adopted for heavy vehicles or high speed vehicles. The blended BBW system which combines MBS and one conventional BBW system (such as the electro-mechanical brake (EMB) or electro hydraulic braking (EHB)) not only has fast response and large braking torque capability, but is also able to achieve braking energy recovery. However, the coordinated control of blended BBW is a challenging task, especially when the input time-delay and output braking torque of one of the brake actuators cannot be directly measured in the blended BBW system. In order to solve this problem, a new observer is proposed and designed in this thesis. The designed observer is able to simultaneously estimate the input time-delay and output braking torque of the brake actuator in a blended BBW system. In addition, there are two important indicators for the blended BBW system. One is braking performance. Another one is braking energy recovery. Braking performance is 3 an important indicator of the efficacy of the vehicle braking system. Braking performance especially needs to be guaranteed in emergency braking conditions. Anti-lock braking systems (ABS) play an important role in improving vehicle braking performance during emergency braking. One challenge of ABS, however, is that the optimal slip ratio is difficult to obtain in real time and the optimal slip ratio can be different under different road conditions. To solve this problem, a modified extremum seeking based adaptive fuzzy sliding mode control strategy is proposed to seek and track the optimal slip ratio for improving the braking performance. In addition to ensuring braking performance, there is still room to improve braking energy recovery by adjusting braking torque distribution. Consequently, a new braking torque distribution strategy is designed for the blended BBW system. The proposed braking torque distribution strategy adjusts the braking torque distribution ratio according to the command braking torque signal, the braking actuators’ dynamic characteristics and the motor’s electrical characteristics. The simulation results show that the proposed braking torque distribution strategy is able to recover more braking energy without affecting the braking performance. In order to further improve the braking performance of the blended BBW system, the conventional BBW system used in the blended BBW system can be replaced by a magneto-rheological brake system (MRB). However, the problem of heat generated by the MRB’s zero-applied field friction torque during vehicle cruising exists in conventional MRB. The heat generated by zero-applied field friction torque when the vehicle is cruising can seriously affect the braking capacity of MRB and even lead to the failure of the Magneto-rheological fluid (MRF) and cause traffic accidents. In order to overcome this problem, a new MRB is designed in this thesis. It is able to achieve zero friction torque during vehicle cruising. A comprehensive literature review of various BBW systems and control methods is the focus of the introduction. Then a new braking strategy is designed for a pure MBS. In addition, a new observer, a modified extremum seeking and tracking algorithm and a new braking torque distribution strategy are designed for a blended BBW system. Finally, a new type of MRB is designed to solve the problems existing in conventional MRBs and to replace the conventional BBW system. 4 ACKNOWLEDGEMENTS This thesis would not have been possible without the guidance and the help of several individuals who in one way or another contributed and extended their valuable assistance in the preparation and completion of this study. First and foremost, I wish to thank my supervisor, Prof. Haiping Du, for his enthusiastic support and constant encouragement that inspired me to overcome the challenges on my wonderful journey of PhD. His patience, motivation and immense knowledge has helped me during the research and writing of this thesis. He was not only a research supervisor but more importantly a life coach. His hard-working attitude always encouraged me to move forward. He gave me the freedom to pursue my own ideas and it was certainly a pleasure working with him. A sincere appreciation to my co-supervisor Prof. Weihua Li for his constant support and help. Without his help, I had no chance to start my journey of PhD. I also would like to acknowledge support from Australian Research Council’s Discovery Projects for funding this research. Particular thanks are also extended to my colleagues, Shuaishuai Sun, Donghong Ning and Zhong Ren, Chao huang, Xinxin Shao, Dan Yuan, Wenxing Li, Qianbin Zhao for their kind assistance, discussion, and encouragement to finish the experiment. I also would like to express my sincere gratitude to my friends, Xuankai Jia, Yang Wang, Xinmo Wu and Huan Zhang. It was your company that brought me through when I was anxious. I want to especially thank Gaofeng Wang for gave me a lot of guidance about graduate studies. Finally, and most importantly, I would acknowledge the ones closest to my heart, my family. Words cannot express my gratitude to my parents for providing me an opportunity to pursue my studies. I could not have achieved this without your encouragement. Many thanks to my parents and wish them happiness every day. Finally, I express my sincere appreciation to all the people who have given me a hand during the last four years. Thank you! 5 TABLE OF CONTENTS CERTIFICATE OF ORIGINALITY ............................................................................ 2 ABSTRACT ..................................................................................................................... 3 ACKNOWLEDGEMENTS ............................................................................................ 5 CHAPTER 1 Introduction ........................................................................................... 19 1.1 X-By-Wire systems ......................................................................................... 19 1.2 Brake-By-Wire system .................................................................................... 19 1.3 Motor braking system ..................................................................................... 20 1.4 Braking systems .............................................................................................
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