This paper proposes a new brake-by-wire system for intelligent/unmanned vehicles. Magnetorheological fluid clutch (MRC) with the characteristics of simple structure, fast response and large range of controllable transmission torque is employed for the brake-by-wire system to realize continuous and fast braking force output of the electro-mechanical brakes (EMBs). The proposed brake-by-wire actuator is mainly composed of an AC servo motor, a planetary gear set, a MRC and a screw set. The planetary gear set amplifies the output torque of the AC servo motor, through controlling the current in the excitation coil of the MRC to realize the real-time control of the braking force at the end of the screw set. Specifically, the structure of the MRC is designed and verified by magnetic simulation. The optimization for structural design of the MRC is carried out via Mechanical APDL and the prototype is manufactured. The mechanical properties of the MRC are calibrated, and the real-time braking force tracking experiment based on PID control is conducted and analysed.
Magnetorheological brakes (MRBs) have the characteristics of simple structure, fast response and large controllable range, which would effectively improve the vehicular braking efficiency and stability. They have been utilized in the intellectualization and electrification of vehicles. A brake-by-wire actuator namely MRB, is designed, optimized, manufactured in this paper. It is composed of an input shaft, brake discs, fixed discs, an excitation coil, and shells. A hardware-in-the-loop test bench is established and the anti-lock braking system (ABS) experiment is conducted. Specifically, the braking torque of MRB is matched to a minicar and a multi-disc MRB is designed. In order to improve the mechanical properties and lightweight design of MRB, the magnetic circuit design and multi-objective structural optimization are carried out by ANSYS/ADPL programming. The prototype development and calibration of MRB mechanical properties are conducted according to the optimized parameters. The test bench of the braking system is established, and the single-wheel ABS tests for the MRB is implemented and evaluated.
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