Contactless Magnetic Brake for Automotive
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CONTACTLESS MAGNETIC BRAKE FOR AUTOMOTIVE APPLICATIONS A Dissertation by SEBASTIEN EMMANUEL GAY Submitted to the Office of Graduate Studies of Texas A&M University in partial fulfillment of the requirements for the degree of DOCTOR OF PHILOSOPHY May 2005 Major Subject: Electrical Engineering CONTACTLESS MAGNETIC BRAKE FOR AUTOMOTIVE APPLICATIONS A Dissertation by SEBASTIEN EMMANUEL GAY Submitted to Texas A&M University in partial fulfillment of the requirements for the degree of DOCTOR OF PHILOSOPHY Approved as to style and content by: _____________________________ _____________________________ Mehrdad Ehsani Hamid Toliyat (Chair of Committee) (Member) _____________________________ _____________________________ Shankar Bhattacharyya Mark Holtzapple (Member) (Member) _____________________________ Chanan Singh (Head of Department) May 2005 Major Subject: Electrical Engineering iii ABSTRACT Contactless Magnetic Brake for Automotive Applications. (May 2005) Sebastien Emmanuel Gay, Dipl. of Eng., Institut National Polytechnique de Grenoble; M.S., Texas A&M University Chair of Advisory Committee: Dr. Mehrdad Ehsani Road and rail vehicles and aircraft rely mainly or solely on friction brakes. These brakes pose several problems, especially in hybrid vehicles: significant wear, fading, complex and slow actuation, lack of fail-safe features, increased fuel consumption due to power assistance, and requirement for anti-lock controls. To solve these problems, a contactless magnetic brake has been developed. This concept includes a novel flux-shunting structure to control the excitation flux generated by permanent magnets. This brake is wear-free, less-sensitive to temperature than friction brakes, has fast and simple actuation, and has a reduced sensitivity to wheel-lock. The present dissertation includes an introduction to friction braking, a theory of eddy- current braking, analytical and numerical models of the eddy-current brake, its excitation and power generation, record of experimental validation, investigation and simulation of the integration of the brake in conventional and hybrid vehicles. iv To my parents, my family, my friends, my many professors and my few mentors. v ACKNOWLEDGMENTS Thanks go to Mr. Philippe Wendling of Magsoft Corporation for his patience and diligence to answer my questions about Flux 3D. Many problems were solved and much time was saved thanks to his help. vi TABLE OF CONTENTS Page ABSTRACT.............................................................................................................. iii DEDICATION .......................................................................................................... iv ACKNOWLEDGMENTS......................................................................................... v TABLE OF CONTENTS.......................................................................................... vi LIST OF FIGURES................................................................................................... x LIST OF TABLES .................................................................................................... xx CHAPTER I INTRODUCTION................................................................................... 1 1 Friction braking of vehicles and its disadvantages............................... 1 2 The concept of an integrated brake ...................................................... 5 3 Fundamental physics of eddy-current braking ..................................... 8 4 Review of existing eddy-current brake concepts ................................. 9 5 Novel eddy-current brake concepts...................................................... 14 6 Research plan....................................................................................... 19 II THEORETICAL ANALYSIS OF EDDY-CURRENT BRAKING ....... 21 1 Method of theoretical analysis of the eddy-current brake.................... 21 2 Theoretical analysis derivations........................................................... 22 2.1 Modeling of the excitation field............................................ 25 2.2 Distribution of the excitation flux ......................................... 28 2.3 Distribution of eddy-currents and associated fields .............. 34 2.4 Computation of the braking force ......................................... 40 3 Investigation of eddy-current braking using the analytical model....... 43 3.1 Implementation of the analytical model................................ 43 3.2 Fundamental physics of eddy-current brakes........................ 45 3.2.1 Eddy-current brake torque-speed curve ................. 45 3.2.2 Distribution of the flux and current densities......... 47 3.3 Impact of design parameters on the brake’s performance..... 53 3.3.1 Impact of mean disc radius..................................... 53 vii CHAPTER Page 3.3.2 Impact of disc area ................................................. 57 3.3.3 Impact of disc thickness ......................................... 60 3.3.4 Impact of airgap width ........................................... 63 3.3.5 Impact of stator pole width..................................... 66 3.3.6 Impact of stator pole number ................................. 68 3.3.7 Impact of electrical conductivity............................ 71 3.3.8 Impact of magnetic permeability............................ 73 3.3.9 Impact of permanent magnet properties................. 75 4 Limitations of theoretical analysis ....................................................... 78 III FINITE ELEMENT ANALYSIS OF EDDY-CURRENT BRAKING .. 81 1 Fundamentals of finite element analysis .............................................. 81 2 Selection of finite-element analysis method ........................................ 82 3 Comparison of analytical and finite-element results............................ 90 4 Analysis of the impact of design parameters on performance ............. 95 4.1 Similarities with theoretical analysis..................................... 95 4.2 Impact of disc area ................................................................ 96 4.3 Impact of disc thickness ........................................................ 99 4.4 Impact of airgap width .......................................................... 103 4.5 Impact of electrical conductivity........................................... 106 4.6 Impact of ferromagnetic properties ....................................... 114 4.7 Impact of permanent magnet properties................................ 123 5 Conclusions on numerical analysis ...................................................... 124 IV EXPERIMENTAL VALIDATION........................................................ 125 1 Objective and experimental procedure................................................. 125 2 Test-bed design .................................................................................... 127 3 Measurement of the disc’s properties................................................... 140 4 Comparison of experimental and finite-element data .......................... 145 5 Conclusions on experimental validation .............................................. 150 V INTEGRATION OF THE BRAKE IN VEHICLE SYSTEMS.............. 152 1 Braking with eddy-current brakes........................................................ 152 1.1 Pure eddy-current braking with unlimited force ................... 154 1.1.1 Brake with constrained critical speed..................... 154 1.1.2 Brake with optimized critical speed....................... 160 1.2 Integrated braking with limited force.................................... 163 1.2.1 Brake with constrained critical speed..................... 164 viii CHAPTER Page 1.2.2 Brake with optimized critical speed....................... 167 2 Integrated braking of automobiles........................................................ 176 2.1 Braking performance requirements....................................... 176 2.2 Conceptual design of an automobile integrated brake .......... 179 2.3 Integrated braking in conventional drive trains..................... 193 2.3.1 Braking system control strategy............................. 193 2.3.2 Performance in the FTP 75 Urban drive cycle....... 194 2.3.3 Performance in the FTP 75 Highway drive cycle .. 198 2.4 Integrated braking of series hybrid drive trains .................... 203 2.4.1 Braking system control strategy............................. 204 2.4.2 Performance in the FTP 75 Urban drive cycle....... 210 2.4.3 Performance in the FTP 75 Highway drive cycle .. 213 2.4.4 Performance in the NREL drive cycle ................... 215 2.5 Impact of temperature on braking performance.................... 225 2.6 Impact of eddy-current braking on friction brake wear ........ 226 2.7 Power assistance energy consumption of integrated brake... 229 2.8 Anti-lock control of the integrated brake .............................. 230 2.9 Traction control with the integrated brake ............................ 235 2.10 Dynamic stability control with the integrated brake ........... 238 3 Integrated braking of heavy duty road vehicles ................................... 251 3.1 The integrated braking of commercial trucks and trailers..... 251 3.1.1 Braking system architecture................................... 252 3.1.2 Dynamic stability control of commercial trucks .... 260 3.1.3 Anti-lock control of commercial trucks ................. 262 3.1.4 The integrated brake as a backup brake ................. 263 3.2 Integrated braking of urban buses ........................................