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.
In this paper, the principle of a test bench for real-time simulation of vehicular braking of 1/4 vehicle is proposed. The proposed test bench consists of a hardware system, including a motor, rollers, a torque controller, a pair of flywheels, a signal acquisition and processing system, and a control system. The wheel speed and vehicle speed are simulated by the roller speed and flywheel speed, respectively. The translational kinetic energy of 1/4 vehicle is simulated by the rotational kinetic energy of the flywheels. The signal acquisition and processing system is used to acquire and process the signals, such as speeds and torques in the test bench. A magnetic powder clutch in the test bench is controlled by the control system to achieve the purpose of simulating the vehicular braking. Based on the proposed test bench and the theory of vehicle dynamics, the simulation method of the translational kinetic energy of 1/4 vehicle is investigated. The mathematical models of the real-time simulation about road adhesion coefficient based on the magnetic powder clutch and 1/4 vehicular braking system based on test bench are established. The feasibility of the test bench is verified through the test benchbased and road-based simulation results.
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