Search Results (48)

The throughput of the pneumatic brake valve is a key parameter in ensuring fast and safe vehicle braking. The instantaneous value of this parameter determines the short response time of the system to an operator’s force. The scientific objective of this paper was to determine the throughput of brake valve tracts using numerical and experimental methods. These tracts are supposed to provide the tracking and acceleration function of the valve depending on the setting of the correction system. The first numerical method was based on polyhedral meshes using computational fluid dynamics (CFD) and Ansys Fluent software. The second research method—experimental tests on the author’s bench using the reservoir method—consisted of identifying throughputs based on pressure waveforms in the measurement tanks. The determined throughputs were averaged over the range of pressure differences tested and allowed the final calculation of the mass flow rate. The analysis of the obtained results showed an average discrepancy between the two research methods for both tracts, in which the flow in both directions was considered to be 9.43%, taking into account the use of a polyhedral numerical mesh ensuring high-quality results with an optimal simulation duration. The analysis of the pressure distribution inside the working chambers showed local areas of increased pressure and negative pressure resulting from the acceleration of the flow in narrow flow channels and the occurrence of the Venturi effect. Full article

Adaptive vehicle control systems are crucial for enhancing safety, performance, and efficiency in modern transportation, particularly as vehicles become increasingly automated and responsive to dynamic environments. This review explores the advancements in bio-inspired actuators and their potential applications in adaptive vehicle control systems. Bio-inspired actuators, which mimic natural mechanisms such as muscle movement and plant tropism, offer unique advantages, including flexibility, adaptability, and energy efficiency. This paper categorizes these actuators based on their mechanisms, focusing on shape memory alloys, dielectric elastomers, ionic polymer–metal composites, polyvinylidene fluoride-based electrostrictive actuators, and soft pneumatic actuators. The review highlights the properties, operating principles, and potential applications for each mechanism in automotive systems. Additionally, it investigates the current uses of these actuators in adaptive suspension, active steering, braking systems, and human–machine interfaces for autonomous vehicles. The review further outlines the advantages of bio-inspired actuators, including their energy efficiency and adaptability to road conditions, while addressing key challenges like material limitations, response times, and integration with existing automotive control systems. Finally, this paper discusses future directions, including the integration of bio-inspired actuators with machine learning and advancements in material science, to enable more efficient and responsive adaptive vehicle control systems. Full article

Open-pit mining involves the use of vehicles with high load capacity and satisfactory mobility. As experience shows, these requirements are fully met by pneumatic wheeled dump trucks, the traction drives of which can be made using thermal or electric machines. The latter are preferable due to their environmental friendliness. Unlike dump trucks with thermal engines, which require fuel to be injected into them, electric trucks can be powered by various options of a power supply: centralized, autonomous, and combined. This paper highlights the advantages and disadvantages of different power supply systems depending on their schematic solutions and the quarry parameters for all the variants of the power supply of the dumper. Each quantitative indicator of each factor was changed under conditions consistent with the others. The steepness of the road elevation in the quarry and its length were the factors under study. The studies conducted show that the energy consumption for dump truck movement for all variants of a power supply practically does not change. Another group of factors consisted of electric energy sources, which were accumulator batteries and double electric layer capacitors. The analysis of energy efficiency and the regenerative braking system reveals low efficiency of regeneration when lifting the load from the quarry. In the process of lifting from the lower horizons of the quarry to the dump and back, kinetic energy is converted into heat, reducing the efficiency of regeneration considering the technological cycle of works. Taking these circumstances into account, removing the regenerative braking systems of open-pit electric dump trucks hauling soil or solid minerals from an open pit upwards seems to be economically feasible. Eliminating the regenerative braking system will simplify the design, reduce the cost of a dump truck, and free up usable volume effectively utilized to increase the capacity of the battery packs, allowing for longer run times without recharging and improving overall system efficiency. The problem of considering the length of the path for energy consumption per given gradient of the motion profile was solved. Full article

Agricultural tractors are equipped with air braking systems to supply and control the braking systems of towed vehicles. This system’s functional and operational characteristics significantly impact the compatibility and speed of the braking system of the tractor–trailer combination and are therefore checked during approval tests. This paper presents a test methodology and a description of the instrumentation and apparatus used to test the air braking systems of tractors under stationary conditions, as required by EU Regulation 2015/68. Sample test results of the trailer air supply system are included, such as checking the system for leaks, checking the pressure at the coupling heads, checking the compressor flow rate and air reservoir capacity, and checking the response time of the tractor control line. Approval authorities and tractor manufacturers can use the work results for quality control or product qualification tests. Full article

The normalized operation of 30,000-ton heavy-haul trains is of significant importance for enhancing the transportation capacity of heavy-haul railways. However, with the increase in train formation size, traditional braking strategies result in excessive longitudinal impulse when combined pneumatic and electric braking is applied on long, steep gradients. This presents a serious challenge to the braking safety of the train. To this end, this paper establishes a longitudinal dynamic model of a 30,000-ton heavy-haul train based on vehicle system dynamics theory, and validates the model’s effectiveness through line test data. On this basis, the influence of two braking parameters, namely, the distribution of the magnitude of the electric braking force and the matching time of pneumatic braking and electric braking, on the longitudinal dynamic behavior of heavy-haul trains is studied. Thereby, an optimized combined pneumatic and electric braking strategy is formulated to reduce the longitudinal impulse of the trains. The results show that setting reasonable braking parameters can effectively reduce the longitudinal impulse, with the braking matching time having a significant impact on the longitudinal impulse. Specifically, when using a strategy where the electric braking forces of three locomotives are set to 90 kN, 300 kN, and 300 kN, with a 30 s delay in applying the electric braking force, a better optimization effect is achieved. The two proposed braking strategies reduce the maximum longitudinal forces by 20.27% and 47.83%, respectively, compared to conventional approaches. The research results provide effective methods and theoretical guidance for optimizing the braking strategy and ensuring the operational safety of 30,000-ton heavy-haul trains. Full article

This study presents the design and analysis of a proportional solenoid used in electro-pneumatic brake systems for heavy vehicles. The solenoid was designed using a traditional method, and its static and dynamic characteristics were investigated both theoretically and experimentally. ANSYS 2024 R1 Maxwell was employed for theoretical static analysis, focusing on the effects of the geometric dimension parameters in the fixed and moving pole contact regions on the force–displacement characteristics. The optimal dimensions for proportionality were determined under constraint parameters. The static analysis results provided the magnetization curve data, which were used to create Look-Up Tables for a dynamic model in MATLAB R2024b-Simulink, and this method reduced the simulation time and increased the dynamic simulation accuracy. Following static analysis, a prototype electromagnet was manufactured and tested. The solenoid achieved a constant magnetic force of 45 ± 3 N with a current of 1.3 A over a working range of 1–3 mm. The dynamic model, incorporating data from ANSYS, yielded results that closely matched the experimental findings. Full article

Purpose: To assess the applicability of computational fluid dynamics (CFDs) in determining the flow parameters of inter-chamber nozzle openings in the differential section of a trailer air brake valve. Methodology: Numerical calculations were performed using SolidWorks Flow Simulation (SW-FS) and Ansys Fluent (A-F) with defined boundaries and initial conditions. The results were validated experimentally using the reservoir method and the lumped method for throughput identification. Results: CFD calculations determined the functional dependence of the mass flow rate on the nozzle diameter for a range of control nozzle bore diameters. The SW-FS 2024 and A-F 2023 software showed a mean difference of 4.66% in the total characteristics. The experimental validation resulted in differences of 6.31% (SW-FS) and 5.79% (A-F) compared to the CFD results. Theoretical contribution: This study fills a research gap in applying CFDs to brake valve performance analyses, providing a foundation for developing more complex numerical models to evaluate individual valve sections. Practical implications: The findings suggest that CFDs can be used to accurately determine the flow parameters of control nozzle orifices, with an average of a 6.05% difference from experimental tests. This approach can potentially streamline the design and optimization process for pneumatic brake valves. Full article

Currently, most electromechanical brake (EMB) schemes are only suitable for passenger cars, and their maximum clamping force is insufficient to satisfy the braking demands of commercial vehicles. Additionally, previous studies on clamping force control are largely based on an EMB equipped with sensors. Due to constraints in installation space and cost, sensorless EMBs are gradually gaining attention. Furthermore, accurately identifying the contact point between the friction lining and the brake disc is the promise of clamping force control for sensorless EMBs. Hence, a sensorless EMB scheme suitable for commercial vehicles is proposed in this study. Secondly, a dynamics model of the EMB actuator is established. After a comprehensive analysis of the proposed EMB actuator, a clamping force control strategy considering the contact points between the friction lining and the brake disc is proposed. Finally, simulation analyses of the strategy are carried out. The results show that the axial length of the proposed EMB actuator is shortened by 17.6% compared with a mainstream pneumatic disc brake. Furthermore, the proposed method can accurately identify the contact points between the friction lining and the brake disc, and the proposed control strategy enables the EMB actuator to achieve the fast response, accurate tracking, and stable maintenance of the target clamping force. Full article

The present study aimed to enhance the efficiency and efficacy of the Al/Cu joint production process implemented by the company VEMID Ltd., Jagodina, Serbia, by attaining sound joints within a very short welding time. For this purpose, the present study aimed at investigating the accuracy and the quality of the continuous drive friction welding (CDFW) process, as well as the optimum combination of CDFW parameters with highest joint efficiency in terms of investigated properties. The accuracy was estimated through an analysis of temperature–time curves recorded during CDFW using an infrared camera. The quality was evaluated through an investigation of the properties of Al/Cu joints produced using different friction (66.7, 88.9, and 133.3 MPa) and forging (88.9, 222.2, and 355.6 MPa) pressures and a constant total welding time (4 s) and rotational speed (2100 rpm). Thermal imaging with an infrared camera demonstrated that the actual total welding time was 15% longer compared to the nominal value. This was attributed to the slow pressure response of the pneumatic brake system. The relative changes in the maximum surface temperature (T_MS) during the CDFW process corresponded to changes in welding pressures, indicating the potential of the thermal imaging method for monitoring and assessing this process. A preliminary investigation demonstrated that Al/Cu joints produced using welding pressures less than 88.9 MPa often displayed the presence of non-joined micro-regions at the Al/Cu interface and a significant thickness of interfacial Al₂Cu (up to 1 µm). However, when friction pressure was set at 66.7 MPa, an increase in the forging pressure to 222.2 MPa eliminated the presence of non-joined micro-regions and reduced the thickness of Al₂Cu to 0.5 µm on the average level. These Al/Cu joints achieved the highest joint efficiencies in terms of strength (100%) and ductility (61%). They exhibited an electrical conductivity higher than 92% of the theoretical value. A further increase in any welding pressure produced similar or deteriorated properties, accompanied by an increase in the consumption of raw materials and energy. Such turn of events was counterproductive to the original goal of increasing the efficiency and efficacy of the CDFW process. Full article

With the development of safety technologies for intelligent commercial vehicles, electronic pneumatic braking systems (EBSs) have been widely used. However, EBS actuators may fail during vehicle operation and thus create safety problems. For this reason, we propose a path-tracking fault-tolerant control strategy under EBS actuator failure in intelligent commercial vehicles. First, in order to be able to characterize different types of brake actuator faults during the EBS differential braking process of a vehicle, a comprehensive fault coefficient for calculating the degree of fault is designed, and a BES generalized fault model is established. Second, the faults are introduced into the fault-tolerant controller through the comprehensive fault coefficients for braking torque calculation and braking pressure allocation. Thus, a vehicle path model with the complete fault coefficients as variable parameters is established. Then, based on the LPV system gain scheduling, a path-tracking LPV/H∞ fault-tolerant controller under EBS actuator faults in commercial vehicles is designed, which is used to solve the safety problem arising from sudden EBS actuator faults. Finally, we conducted experimental validation through hardware-in-the-loop tests. The results demonstrate that the control strategy designed in this paper redistributes the braking torque and synergizes with the steering system to enhance vehicle stability, thereby improving vehicle safety in the EBS failure mode. 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

In the electronic brake system (EBS) of commercial vehicles, due to the compressibility of gas, it is difficult to achieve accurate control in the pneumatic pipeline. To address this issue, a vertical load estimator based on unscented particle filtering (UPF) was designed, which can estimate vertical load during the running of the vehicle. Then, the EBS dynamics model was established based on software, including a brake signal sensor, single-channel bridge control module, ABS solenoid valve, and dual-channel bridge control module. Finally, based on the characteristics of the EBS valve, the control algorithm of the valve was studied, and the algorithm was tested using a hardware-in-the-loop experiment. The experiment results showed that the designed algorithm could improve braking performance. Full article

Fast and precise pressure control for an electropneumatic brake system is essential for ensuring the safe operation of trains. However, the nonlinearity and uncertainties of the system make controller design challenging. This paper proposes a prescribed performance control method integrating an extended state observer to address this issue. A thermodynamical model of the brake cylinder is first built based on the pneumatic characteristics of the braking system, considering multiple modes, coupling effects, and input saturation. Then, an extended state observer is designed to estimate model uncertainty due to temperature variation and disturbances and to achieve online compensation of the model. A feedback control law with a specified prescribed performance function is developed based on the updated thermodynamic model to guarantee the transient and steady-state performance of the pressure control. A parameter adaptive method is also utilized to handle input saturation. The observer’s bounded convergence and stability analysis of the closed-loop control system is given using the Lyapunov theory. Compared experimental results are provided to verify the effectiveness of the proposed method. Full article

Currently, braking control systems used in regional railways are open-loop systems, such as metro and tramways. Given that the performance of braking can be influenced by issues such as wheel sliding or the properties of the friction components present in brake systems, our study puts forward a novel closed-loop mechanism to autonomously stabilize braking performance. It is able to keep train deceleration close to the target values required by the braking control unit (BCU), especially in terms of the electrical–pneumatic braking transform process. This method fully considers the friction efficiency characteristics of brake pads and encompasses running tests using rolling stock. The test results show that the technique is able to stabilize the actual deceleration at a closer rate to the target deceleration than before and avoid wheel sliding protection (WSP) action, especially during low-speed periods. Full article

This review examines compressed air receiver tanks (CARTs) for the improved energy efficiency of various pneumatic systems such as compressed air systems (CAS), compressed air energy storage systems (CAESs), pneumatic propulsion systems (PPSs), pneumatic drive systems (PDSs), pneumatic servo drives (PSDs), pneumatic brake systems (PBSs), and compressed air vehicles (CAVs). The basic formulas and energy efficiency indicators used in a CART calculation and selection are included. New scientific research by the authors on measurements based on tank methods, numerical solutions in the process of charging and discharging, the valve-to-tank-to-valve system and pneumatic propulsion system was presented. The numerical model of the valve-tank-valve system takes into account CART polytropic charging and discharging processes, the mass flow balance equation, and the sound (choked) and subsonic mass flow rate in the inlet and outlet valves. Future research directions to improve the energy efficiency of a CART charging and discharge are highlighted. The effective density of energy storage in CART was compared to that of other renewable energy sources and other fuels. Economic and environmental issues were also considered by adopting various energy performance indicators. The discussion also focused on the design concept and computational model of the hybrid tricycle bike (HTB) pneumatic propulsion system. Full article