Search Results (24)

Differential planetary roller lead screw (DPRS) serves as a quintessential actuating mechanism within the electromechanical braking (EMB) systems of vehicles, where its operational reliability is paramount to ensuring braking safety. Considering different braking intensities, how assembly errors affect the contact stress in DPRS was analyzed via the finite element method. Firstly, the braking force of the EMB system that employed DPRS was verified by the braking performance of legal provisions. Secondly, a rigid body dynamics model of DPRS was established to analyze the response time, braking clamping force, and axial contact force of DPRS under varied braking intensities. Finally, a finite element model of DPRS was constructed. The impact of assembly errors in the lead screw and rollers on the contact stress were investigated within the DPRS mechanism based on this model. The results indicate that as braking intensity increases, the deviation of the lead screw exerts a greater influence on the contact stress generated by the engagement between the lead screw and rollers compared to that between the nut and rollers. The skewness of the rollers also affects the contact stress generated by the engagement of both the lead screw with rollers and the nut with rollers. When assembly errors reach a certain threshold, the equivalent plastic strain is induced to exceed the critical value. This situation significantly impairing the normal operation of DPRS. This study provides guidance for setting the threshold of assembly errors in DPRS mechanisms. It also holds significant implications for the operational reliability of EMB systems. Full article

Currently, the need for resource efficiency and CO₂ reduction is growing in industrial production, particularly in the automotive sector. To address this, the industry is focusing on lightweight components that reduce weight without compromising mechanical properties, which are essential for passenger safety. Hybrid designs offer an effective solution by combining weight reduction with improved mechanical performance and functional integration. This study focuses on a one-step manufacturing process that integrates forming and bonding of hybrid systems using compression molding. This approach reduces production time and costs compared to traditional methods. Conventional Post-Mold Assembly (PMA) processes require two separate steps to combine fiber-reinforced plastic (FRP) structures with metal components. In contrast, the novel In-Mold Assembly (IMA) process developed in this study combines forming and bonding in a single step. In the IMA process, glass-mat-reinforced thermoplastic (GMT) is simultaneously formed and bonded between two metal belts during compression molding. The GMT core provides stiffening and load transmission between the metal belts, which handle tensile and compressive stresses. This method allows to produce hybrid structures with optimized material distribution for load-bearing and functional performance. The process was validated by producing a lightweight hybrid brake pedal. Demonstrating its potential for efficient and sustainable automotive production, the developed hybrid brake pedal achieved a 35% weight reduction compared to the steel reference while maintaining mechanical performance under quasi-static loading Full article

The automotive brake piston component is an important part of the automotive brake system, and the concentricity detection of the first piston component is crucial to ensure driving safety. In this paper, an improved Canny algorithm is proposed for non-contact detection of spring concentricity of the first piston component. Firstly, the traditional Canny algorithm is improved by replacing the Gaussian filter with a bilateral filter to fully retain the edge information, and accurate edge detection results are obtained by constructing a multi-scale analysis. After obtaining the edge images, a sub-pixel edge detection method with gray moments is introduced to optimize these edges; secondly, a circle is fitted to the extracted edge points by using the RANSAC algorithm to determine the center position and radius of the circle; and finally, the concentricity of the first piston part is calculated based on the fitting results. The experimental results are compared with those of the CMM and the traditional Canny algorithm, and the results show that the improved Canny algorithm reduces the coaxiality error by 4% and enables effective measurement of the concentricity of the first piston assembly spring. Full article

This study proposes an in-wheel assembly with a variable speed-reduction device designed to maximize torque and vehicle speed, enabling high-performance vehicle-level driving characteristics in front-engine, rear-wheel drive (FR), internal combustion engine (ICE) vehicles, where conventional EV motors cannot facilitate e-4WD. The proposed system integrates a motor and speed reducer within the wheel while avoiding interference from braking, steering, and suspension components. Through various innovative approaches, concepts for an integrated wheel-bearing planetary reducer and a variable speed planetary reducer were derived. The developed system achieved twice the maximum torque and a 35% increase in top speed compared to previously developed in-wheel systems, all without altering the front hard points. Multi-body dynamic analysis and component testing revealed wheel lock-up issues during reverse driving, and instability in the one-way clutch at high speeds. To address these issues, the power transmission structure was improved, and the type of one-way clutch was modified. Additionally, deficiencies in lubrication supply to the friction surface of the one-way clutch were identified through flow analysis and visualization tests, leading to design improvements. The findings of this study demonstrate that even in in-wheel systems where the application of large and complex transmission devices is challenging, it is possible to simultaneously enhance both maximum torque and top vehicle speed to achieve high-performance vehicle-level driving dynamics. Consequently, implementing an in-wheel e-4WD system in ICE FR vehicles is expected to improve fuel efficiency, achieve high-performance vehicle capabilities, and enhance market competitiveness. Full article

Assessing the effects that nonstationary dynamic processes have on the durability of structural elements belongs to an important trend in modern dynamics and technical diagnostics of machines. Normally, fatigue strength calculations are performed taking into account only periodically variable stresses, as steady operating modes of machines are much longer in comparison with transient modes. However, a significant role in fatigue failure in machines and engineering structures is also played by nonstationary loads. This is explained by emerging intensive oscillations in the mechanical system during accelerating, braking, or changing the operation mode of a machine unit, which often lead to the accumulation of fatigue damages in the materials of parts in heavy loaded assemblies. The combination of stationary and nonstationary dynamic loads manifests itself, particularly in drilling rigs, where technological cycles include steady motion modes, starts, and stops. This paper represents a generalized mathematical model describing nonstationary processes in the lift system of a drill rig, which considers the relationship between electromagnetic processes in asynchronous motors and mechanical oscillatory phenomena, with the purpose of determining dynamic loads and stresses in structural elements of the rigs. Nonlinear physical systems include mechanical members with both concentrated and clearly expressed distributed parameters. The durability of structural elements is evaluated by means of a computer algorithm for analysis of crack growth rates using the NASGRO equation obtained with the presence of plastic deformation zones. An example of the crown block axis illustrates the influence of nonstationary dynamic processes in drill rigs on the durability of structural elements. Full article

The elevator industry is constantly expanding creating an increased demand for the integration of high technological tools to increase elevator efficiency and safety. Towards this direction, Additive Manufacturing (AM), and especially metal AM, is one of the technologies that could offer numerous competitive advantages in the production of industrial parts, such as integration of complex geometry, high manufacturability of high-strength metal alloys, etc. In this context, the present study has 3D designed, 3D printing manufactured, and evaluated novel bioinspired structures for elevator safety gear friction pads with the aim of enhancing their dynamic friction performance and eliminating the undesired behavior properties observed in conventional pads. Four different friction pads with embedded bioinspired surface lattice structures were formed on the template of the friction surface of the conventional pads and 3D printed by the Selective Laser Melting (SLM) process utilizing tool steel H13 powder as feedstock material. Each safety gear friction pad underwent tribological tests to evaluate its dynamic coefficient of friction (CoF). The results indicated that pads with a high contact surface area, such as those with car-tire-like and extended honeycomb structures, exhibit high CoF of 0.549 and 0.459, respectively. Based on the acquired CoFs, Finite Element Models (FEM) were developed to access the performance of braking pads under realistic operation conditions, highlighting the lower stress concentration for the aforementioned designs. The 3D-printed safety gear friction pads were assembled in an existing emergency progressive safety gear system of KLEEMANN Group, providing sufficient functionality. Full article

The production of high-quality castings without foundry defects at minimal production costs is a constant priority for foundries. Innovation and optimization of production processes are key to achieving this goal. Computer simulation of foundry processes offers a modern alternative to expensive and time-consuming experiments in real foundries and provides a reliable representation and analysis of casting and solidification processes. A detailed analysis of the casting and solidification simulation results allows the prediction of various risks that can cause defects in cast castings, thereby reducing their quality and, last but not least, the cost of their production. This paper deals with the analysis of a computer simulation of the casting of a brake disc in a Slovak foundry. This brake disc has had shrinkages and micro shrinkages that reduce the internal quality of the casting. These defects occurred in the ribs in the upper part of the casting under the feeders. A computer simulation of the casting and solidification of this casting was made according to the real conditions. It turned out that the designed gating system with a system of feeders was not sufficient to eliminate the emerging defects. A new layout for the feeders was proposed, which ultimately eliminated the occurrence of defects based on the results of the computer simulation. The input parameters were set to be as close as possible to the actual needs of the foundry. Moreover, 3D models of the assemblies were designed in SolidWorks Premium 2015 x64 Edition CAD software, and the filling and solidification simulations were performed using the NovaFlow & Solid CV 4.6r42 simulation program. Full article

The optimization of the brake systems is crucial for vehicle performance and safety of Formula SAE (FSAE) race cars. This study introduces a specialized brake test bench designed to enhance the understanding and testing of these systems. The bench integrates a rotating mechanical system mounting a brake disc-caliper group, which is driven by an electric motor, a pneumatic brake pedal assembly to simulate real braking conditions, and a comprehensive array of sensors that facilitate the measurement of critical parameters, such as rotation speed, braking torque, oil pressure, and disc temperature. Its structure, sensor integration, and control electronics are fully described, demonstrating the capability to replicate on-track scenarios in a controlled environment. The results underscore the utility of the bench in providing precise and consistent testing conditions essential for analyzing the efficiency, durability, and safety of the braking systems of FSAE race cars. Full article

Research on systems that imitate the gaze function of human eyes is valuable for the development of humanoid eye intelligent perception. However, the existing systems have some limitations, including the redundancy of servo motors, a lack of camera position adjustment components, and the absence of interest-point-driven binocular cooperative motion-control strategies. In response to these challenges, a novel biomimetic binocular cooperative perception system (BBCPS) was designed and its control was realized. Inspired by the gaze mechanism of human eyes, we designed a simple and flexible biomimetic binocular cooperative perception device (BBCPD). Based on a dynamic analysis, the BBCPD was assembled according to the principle of symmetrical distribution around the center. This enhances braking performance and reduces operating energy consumption, as evidenced by the simulation results. Moreover, we crafted an initial position calibration technique that allows for the calibration and adjustment of the camera pose and servo motor zero-position, to ensure that the state of the BBCPD matches the subsequent control method. Following this, a control method for the BBCPS was developed, combining interest point detection with a motion-control strategy. Specifically, we propose a binocular interest-point extraction method based on frequency-tuned and template-matching algorithms for perceiving interest points. To move an interest point to a principal point, we present a binocular cooperative motion-control strategy. The rotation angles of servo motors were calculated based on the pixel difference between the principal point and the interest point, and PID-controlled servo motors were driven in parallel. Finally, real experiments validated the control performance of the BBCPS, demonstrating that the gaze error was less than three pixels. Full article

Emissions of brake-wear particles are commonly associated with vehicular traffic. We investigated the feasibility of quantifying brake-wear particle emissions under realistic vehicle driving and braking conditions with a currently used regenerative friction brake coordination system. We used a braking system installed in commercially available plug-in hybrid electric vehicles and found that it reduced emissions by 85% for PM₁₀, 78% for PM₂.₅, and 87% for particle numbers (PNs) compared with the system installed in vehicles with internal combustion engines. Brake friction work showed a linear relationship with PM₁₀ and PM₂.₅. Nanoparticle PM emissions tended to increase slightly with regenerative braking but did not contribute significantly to the overall PM percentage. The emission events of high concentrations of nuclei-mode particles (<20 nm in diameter) in electric vehicle brake assemblies designed for regenerative braking use under high-temperature, high-load braking conditions with full-friction brakes. The nuclei-mode particles amplified the PN emissions and led to high variability. In strict regulatory certification tests where measurement reproducibility and stability are required, it is appropriate to measure PNs under brake conditions appropriate for the actual use of electric vehicles rather than under full-friction brake conditions or to remove particle measurements smaller than 20 nm. Full article

The brake system requires careful attention for continuous monitoring as a vital module. This study specifically focuses on monitoring the hydraulic brake system using vibration signals through experimentation. Vibration signals from the brake pad assembly of commercial vehicles were captured under both good and defective conditions. Relevant histograms and wavelet features were extracted from these signals. The selected features were then categorized using Nested dichotomy family classifiers. The accuracy of all the algorithms during categorization was evaluated. Among the algorithms tested, the class-balanced nested dichotomy algorithm with a wavelet filter achieved a maximum accuracy of 99.45%. This indicates a highly effective method for accurately categorizing the brake system based on vibration signals. By implementing such a monitoring system, the reliability of the hydraulic brake system can be ensured, which is crucial for the safe and efficient operation of commercial vehicles in the market. Full article

Particularly crucial throughout the mode transition procedure is the transmission properties of hydro–mechanical composite transmission devices. This paper describes a multipurpose power transmission device that integrates hydrostatic, hydro-mechanical, and mechanical transmission and mainly discusses the transmission characteristic optimization problem from the perspective of speed regulation characteristics, shift strategy, and efficiency characteristics. The kinematic and dynamic analysis of the transmission system, the assembly scheme, and relevant parameters of the power transmission device are analyzed, and the speed regulation characteristic curve is obtained. The shift strategy of power transmission devices involving clutches and brakes during the whole speed regulation process and the best switch time of each component are found. The efficiency expression of the static pressure system is obtained from the efficiency model of the pump-control-motor system, and the efficiency of the multi-purpose power transmission device is obtained using the efficiency definition method. The fitting curves of hydrostatic system efficiency are determined using experimental data, and the efficiency of the hydro–mechanical composite power transmission system is obtained using the conversion mechanism method. The results show that the shift quality of power transmission devices can be improved greatly by controlling the switch sequence of clutches and brakes reasonably. Full article

Matching analysis is a key step in the process of verifying the adaptation of carbon-ceramic brake discs to high-speed trains’ braking system. Relevant research on matching analysis tends to be carried out only on a single parameter of the brake disc. Due to this lack of comprehensive analysis, a data-driven, parametric method is proposed to address the problem. We have summarised the matching parameters of carbon-ceramic brake discs in three dimensions: assembly interface, physical characteristics, and braking performance. The method is based on the feasibility of modelling the parameters, completing the analysis of non-modelled parameters through a comparative conformity check, and modelling parameters through a statistical analysis of the experimental data. Conformity comparison results show that the example carbon-ceramic brake disc is well suited to high-speed trains and is better matching than the example cast-steel brake discs in terms of mass and average frictional coefficient. Analysis of the simulated experimental data shows that under high-speed braking conditions, the maximum disc surface temperature and wear of the example carbon-ceramic disc is higher than that of the cast-steel disc, trains equipped with carbon-ceramic discs have shorter emergency braking distances and higher average braking deceleration, and the carbon-ceramic discs exhibit better matching performance. Full article

Modern direct-driven and high-speed rotary tables with torque motor are optimally suited for all handling and assembly applications that require the shortest indexing times and flexible positioning. The following paper is devoted to the study, the design, and the optimization of an innovative table clamping system (brake for accurate positioning) actuated by pneumatic energy, working at a maximum clamping pressure of 6 bar. The challenge for the aforementioned application is related to developing a solution able to provide a maximum tangential torque (with clamping actuated) in the range of thousands of Nm without leveraging the use of high-pressure hydraulic energy. The optimization of the proposed solution is based on the precise calculation of the stresses in order to perform a fatigue assessment and on the elastic deformation of the clamps in order to set the correct tolerances between the mating parts. Eventually, an experimental campaign is carried out in order to tune the numerical model, which is then used to validate the proposed design solution. Full article

A mathematical model of the gas-delayed blowback operation firearm action is presented in the paper. Mathematical equations and relations describing the action of this automatic weapon system are shown. Results of theoretical calculations are analyzed from the point of view of the influence of system (weapon) parameters (factors) on braking the recoiling assembly movement. In the analysis of computer simulation results, the design of experimental methods are used. The significance of the effects of individual parameters on output characteristics are estimated. This enables us to eliminate insignificant parameters and to assess the character of the dependence on significant parameters. The obtained results serve as a basis for the design of a new laboratory stand and for planning experiments which significantly reduce the time and cost of experimental tests. The stand will be used for a detailed verification and validation of the proposed model. Full article