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Full-Scale Testing of A Novel Slip Control Braking System For Heavy Vehicles
Full-Scale Testing of A Novel Slip Control Braking System For Heavy Vehicles
Full-Scale Testing of A Novel Slip Control Braking System For Heavy Vehicles
Abstract
This paper summarises the measured emergency braking performance of a tri-axle heavy goods vehicle semitrailer fitted
with a novel pneumatic slip control braking system developed by the Cambridge Vehicle Dynamics Consortium.
Straight-line braking tests were carried out from 40 km/h in order to compare a commercially electro-pneumatic
available anti-lock braking system and the Cambridge Vehicle Dynamics Consortium system, which has bi-stable valves
coupled with a sliding-mode slip controller. On average, the Cambridge Vehicle Dynamics Consortium system reduced
the stopping distance and the air use by 15% and 22% respectively compared with those for the conventional anti-lock
braking system. The most significant improvements were seen on a wet basalt-tile surface (with similar friction proper-
ties to ice) where the stopping distance and the air use were improved by 17% and 30% respectively. A third perfor-
mance metric, namely the mean absolute slip error, is introduced to quantify the ability of each braking system to track a
wheel slip demand. Using this metric, the bi-stable valve system is shown to improve the wheel slip demand tracking by
62% compared with that of the conventional anti-lock braking system. This improvement potentially allows more accu-
rate control of the wheel forces during extreme manoeuvres, providing scope for the future development of advanced
stability control systems.
Keywords
Anti-lock braking system, slip control, heavy vehicle, straight-line braking, brake system design, vehicle testing, pneumatic
actuator, electro-pneumatic
Introduction and literature review systems (EBSs) and the change from drum brakes to
disc brakes, the stopping distances of HGVs are typi-
Motivation cally 40% longer than those of passenger cars.7,8
In the UK, heavy goods vehicles (HGVs) were involved
in 272 fatal traffic accidents in 2011. This equates to
8.4% of all fatal vehicle accidents. This is considerably Anti-lock braking systems
higher than the number statistically expected, as HGVs Wheel lock-up during a harsh braking manoeuvre is an
make up only around 3% of the vehicle fleet.1,2 The event that can result in both an increased stopping dis-
Department for Transport1 estimated that the average tance and a loss of directional stability. In articulated
value of the prevention of these fatal accidents per vehicles, this loss of stability can result in jackknifing or
casualty and per accident is £1.88 3 106. In the USA, rollover. Anti-lock braking systems (ABSs) have been
one in nine traffic fatalities was found to involve an developed for both passenger cars and heavy vehicles
HGV in 2008.3,4 Of these accidents, rear-end collisions to prevent the occurrence of wheel lock-up.
were the most common type (21%), followed by roll-
over (16%).5
The over-representation of HGVs in fatal crash data
can be attributed to several undesirable attributes of Department of Engineering, University of Cambridge, Cambridge, UK
their dynamics. These include the following: rearward
Corresponding author:
amplification during transient manoeuvres, lateral off- David Cebon, Department of Engineering, University of Cambridge,
tracking6 and their long emergency stopping distances. Trumpington Street, Cambridge CB2 1PZ, UK.
Even with the recent introduction of electronic braking Email: dc@eng.cam.ac.uk
Figure 1. Heavy-vehicle ABS performance on a wet pebble Figure 2. Sample adhesion–slip curves, showing the slip-curve
surface (mpeak = 0.28). peak, plotted using the model presented by Fancher.11
and following the sliding-mode controller derivation by oscillatory throughout the stop. This is due to the
Slotine and Li31, gives the expression for the brake low control bandwidth of these valves. By contrast,
chamber pressure demand Pdem as the bi-stable 3 ms valves can theoretically track the
peak of the slip curve for the majority of the stop
Rr Rb Fx (1 l)v_x J s (Figure 5(b)).
Pdem = ks Fs s ð3Þ
KBG Rr jsj + d
where ks, Fs and d are the tuneable gains, J is the rota-
Performance metrics
tional inertia of the lumped wheel–tyre mass and vx is
the vehicle speed. A differentiation is made here Preliminary tuning of the main slip control loop was
between Rr (the rolling radius) and Rb the radius discussed in previous simulation studies.12,21,30 Two
through which the braking force acts. performance metrics were used in these simulations: the
Two bi-stable valves are used to modulate the brake stopping distance and the air consumption.
pressure at each wheel. These are arranged in an inlet The stopping distance can be easily measured in both
and outlet configuration (as shown in Figure 3). Pulse simulation and field tests. It provides a quantitative
width modulation (PWM) is used to control the air measure of how well the available adhesion is utilised by
flow through each of the valves. A simple proportional different systems on the same surface. The stopping dis-
pressure controller is used to define the desired PWM tance (together with the mean fully developed decelera-
mark-to-space ratio RMS for the inlet and outlet valves, tion) is used in European and US legislation to specify
using the relationship the minimum braking requirements for road vehicles.7,34
The air consumption increases as the brake system
RMS = kp ðPdem Pc Þ ð4Þ performs more ‘fill-and-exhaust’ cycles and therefore
provides a measure of controller action. The amount of
where positive RMS values corresponded to an inlet
air available to the braking system is limited by the size
valve demand, with negative RMS corresponding to an
of the air reservoirs on the vehicle. A system that uses
outlet valve demand. kp is a tuneable gain and was set
considerably more air than existing systems is therefore
to 1.5 3 1025 Pa21 for the CVDC bi-stable valves used
undesirable as it requires larger heavier air tanks to be
in this work. This value was selected by Miller et al.21
fitted to the vehicle.
to achieve a control bandwidth larger than the expected
The mean absolute slip error (MSE) is introduced in
wheel-hop frequency (12.5 Hz). A 0.05 bar deadzone
this work as a third performance metric. The MSE is
was also included to prevent limit cycling (see the thesis
defined as
by Miller33 for a thorough limit-cycling analysis).
Sample simulation results of the slip control system 1X
discussed above with two different valve models, one MSE = jl ldem j ð5Þ
N
corresponding to conventional ABS valves (switching
delay, 20 ms) and the other representing the prototype where N is the total number of data points.
bi-stable valves (switching delay, 3 ms), are shown in The MSE is used to quantify how well a slip control-
Figure 5(a) and Figure 5(b) respectively. The non-linear ler can track a specified wheel slip level. This metric is
quarter-vehicle and the actuator model used in these applicable to stability control systems, where a precise
simulations are the same as those presented by Miller braking force (requiring a specific slip level) may be
et al.21 As can be seen in Figure 5(a), the wheel speed demanded from individual wheels.
and slip traces for the slip controller using conventional The values of the stopping distance, the air use and
ABS hardware (but using the slip-control strategy) are the MSE are displayed in Figure 5(a) and Figure 5(b)
Figure 5. HGV quarter-vehicle braking simulation results corresponding to a straight-line braking event from 80 km/h (22.2 m/s) on
a smooth dry asphalt road: (a) sliding-mode slip controller with the existing ABS modulator valves; (b) sliding-mode slip control with
3 ms bi-stable modulator valves.
MSE: mean absolute slip error.
for comparison. In this simulation case the difference the air consumption increases significantly. The pre-
between the stopping distance for a slip controller with ferred gain for the system is therefore selected at the
conventional ABS hardware and the stopping distance ‘knee’ of this conflict plot (shown in the figure). The
for a slip controller with high-speed pneumatic valves is other slip control gains Fs and d were found to have
only 6.2%; the performance improvement in terms of less influence on the stopping distance than ks does and
slip point tracking is, however, highlighted by the MSE were fixed at constant values of 100 kPa and 0.05
value, which is reduced by 56% when high-speed valves respectively throughout all the simulation results and
are used. the experimental results presented in this paper. The
The air consumption and the stopping distance are ‘ideal-stop’ test case shown in Figure 6 represents a
often displayed as a conflict plot, which can be used to braking event where the instantaneous adhesion–slip
compare visually the performances of different braking curve peak is followed perfectly throughout the stop.
systems and can be employed to tune the various As can be seen in the figure, the simulated slip control
sliding-mode controller gains. Figure 6 shows one such system achieves a stopping distance very close to the
conflict plot for a simulated slip-controlled stop with a ideal case.
sliding-mode switching gain ks ranging from 10 kPa to
10 MPa. As can be seen in Figure 6, as the controller
System design for implementation on a
gain ks is increased, the stopping distance is first
reduced and the air consumption remains relatively tri-axle semitrailer
constant. Beyond a certain level of ks, however, A 12.5 m tri-axle semitrailer was used as the test bed
improvements in the stopping distance decrease and for the sliding-mode slip controller and the bi-stable
Figure 7. Test vehicle and CVDC bi-stable modulator valve installed at the wheel end.
Figure 8. Slip control braking system fitted in parallel to the existing Haldex EBS-ABS for back-to-back braking tests (details of the
existing Haldex system are not shown) (not to scale).
ABS: anti-lock braking system; CAN: controller area network; CVDC: Cambridge Vehicle Dynamics Consortium; EBS: electronic braking system;
ECU: electronic control unit.
A failure mode and effect analysis was carried out to controllers shown in Figure 8 were mounted on the
ensure the safety of the test vehicle set-up. This analysis trailer chassis and housed the valve drive electronics as
indicated that, owing to the bi-stable nature of the well as a microcontroller which performed the slip con-
valves, the prototype valve system cannot be easily trol and pressure control calculations. A schematic dia-
arranged such that it always fails in a safe predictable gram showing the functions carried out by the local
manner. The chosen system was therefore installed in controllers, and how they interfaced with the rest of the
parallel to the conventional braking system, as shown vehicle, is given in Figure 9. The braking demands and
in Figure 8. Shuttle valves fitted at each wheel station the vehicle states (such as the vehicle speed and the
were connected to both braking systems, allowing the vehicle deceleration) were sent from a MATLAB XPC
driver to override the slip control system by applying computer in the tractor cab to the local slip controllers
the conventional footbrake. A ‘3–2’ solenoid valve and via controller area network (CAN) buses.
pneumatic relay valves were also fitted upstream of the The conventional ABS fitted to the vehicle included
slip control in order to isolate it from the trailer’s air three Haldex EB + generation 1 electronic control
supply in the event of a failure. The local slip units (ECUs), as shown in Figure 8. Each ECU
monitored two wheel speeds and included two pres- Straight-line emergency braking
sure control channels. This layout is often referred to comparisons
as a 6S–6M system as it senses six wheel speeds in
total and has six pressure modulator channels. The Straight-line braking tests were carried out at the
system therefore allowed individual ABS control of MIRA35 testing facility, near Nuneaton, Warwickshire,
each wheel. The brake pressure demands can be sent UK. A Volvo tractor unit (FH12, 6 3 2) provided by
to the Haldex ECUs either from the tractor by the Haldex Brake Products Ltd was used to tow the test
tractor’s footbrake (via the standard pneumatic ser- trailer presented in the previous section. The vehicle
vice brake connections), or from the XPC computer parameter values for the tractor–trailer combination
via a separate CAN bus. are listed in Table 1. The wheel slip was calculated
using the wheel speed sensor signals and a velocity esti-
mate from the VBOX GPS logger. Pre-processed
adhesion–slip look-up tables were then used to estimate
Additional sensors and hardware the magnitude of Fx in real time, for the current level
A VBOX II Global Positioning System (GPS) logger of the wheel slip. Fx, the wheel slip and the vehicle
(fitted within the tractor cab) was used to provide mea- deceleration (once again measured using the VBOX
surements of the following vehicle states: logger) were passed to the main slip control equation
(equation (3)) in order to calculate the individual brake
(a) the position (longitude and latitude); pressure demands Pdem. Constant slip demands were
(b) the velocity; sent to all local wheel stations when slip control was
(c) the heading; active. These demands were chosen to match approxi-
(d) the acceleration (longitudinal and lateral); mately the peak of the relevant adhesion–slip curve at
(e) the distance covered since reset. 30 km/h (8.33 m/s).
Tests were carried out on three different wet sur-
As the GPS antenna was located on the roof of the faces. These were as follows:
tractor unit, its readings were affected by the movement
of the suspended tractor cab. It was, however, still (a) a ‘Delugrip’ test surface (an asphalt surface with a
found to provide reasonable estimates of the distance nominal tyre–road adhesion coefficient of 0.75);
(for calculations of the stopping distance) in straight- (b) a ‘Bridport Pebble’ test surface (a pebble surface
line braking tests and the longitudinal speed for slip with a nominal tyre–road adhesion coefficient of
control in the low-adhesion tests presented in this work. 0.40);
The trailer reservoir pressure was measured using (c) a basalt-tile test surface (a tiled surface with a
pressure transducers included within the Haldex EB + nominal tyre–road adhesion coefficient of 0.30).
brake ECUs on the trailer. These measured the line
pressure at the ECU’s reservoir connection. The trailer
reservoirs were isolated from the tractor’s compressor The adhesion coefficients quoted here are those sup-
feed during braking tests via a manual valve. The plied by MIRA as nominal values for passenger car
change in the reservoir pressure was then employed to tyres. It should be noted that those actually observed
calculate the mass of air used during the stop by utilis- for the HGV trailer tyres used in this study were 23%,
ing an equation which assumes adiabatic behaviour for 30% and 60% less than the nominal values for a wet
the short-duration tests and is given by21 Delugrip surface, a Bridport Pebble surface and a
basalt-tile surface respectively (see mpeak in Table 1).
DPTank VTank Because of the limited length of the straight-line
Dmair = ð6Þ braking facility the initial speed of the braking tests
gRTTank
was limited to 40 km/h (11.11 m/s) to prevent the vehi-
where Dmair is the total mass of air used, DPTank is the cle from over-running the end of the surface. All tests
change in the tank pressure, VTank is the tank volume, were carried out with the trailer unladen; this consti-
TTank is the average tank temperature, R is the specific tuted a worst-case loading condition for the vehicle
gas constant for air and g is the ratio of specific heats where substantial ABS cycling is expected on all com-
for air. mon test surfaces. Only the trailer brakes were applied
Thermocouples were fitted to each brake disc to during these tests.
monitor the brake temperature throughout the vehicle
tests. The brake gain is known to vary with the brake
disc temperature; it was therefore necessary to run all Brake gain measurement
the braking tests in a specified brake temperature range The brake gain KBG appears in the denominator of the
in order to obtain reproducible results. Monitoring the main slip control equation (equation (3)) and, as was
brake temperature can also alert the test driver of highlighted by Miller and Cebon,12 can vary depending
potential brake overheating which can cause compo- on the vehicle’s operating conditions. Miller et al.
nent damage. showed through simulations that 20% errors in the
Table 1. Vehicle parameter values and adhesion–slip model coefficients for straight-line braking tests at the MIRA testing facility,
Nuneaton, Warwickshire, UK.
Figure 12. Free-body diagram for straight-line braking of a tractor–semitrailer combination used for dynamic load transfer
calculations with the tractor unit brakes disabled (the corresponding inertial properties are given in Table 1).
It should be noted that the tyre–road adhesion para- 7. The brakes are automatically activated by
meters in Table 1 represent the average values and were the ‘global controller’ computer at 40 km/h
only applicable for the specific operating conditions of (11.11 m/s).
the vehicle; they did not take into account changes in 8. The braking is continued until the vehicle reached
the parameters such as the vehicle speed and the lateral standstill.
slip and variations in the adhesion along the length of 9. The data logging is stopped.
the test track. In future implementations of the slip 10. The air isolation valve is opened (to recharge the
control system, these characteristics will need to be esti- trailer reservoirs).
mated online in real time, e.g. using the methods
described by Miller.33 Repeated tests were performed with both braking sys-
tems on each surface. Slip control tests were carried out
with increasing controller gain ks to produce conflict
Straight-line braking test method plots of the air consumption versus the stopping dis-
The straight-line braking test procedure followed in this tance, similar to that presented in Figure 6.
work differs slightly from the standard procedure An upper limit for the brake disc temperature of 120
described in Regulation 13 of the United Nations °C was recommended by Haldex, as brake fade typi-
Economic Commission of Europe (UNECE) for mea- cally begins beyond this point, making the brake gain
suring the ABS performance. In the UNECE regula- data potentially incorrect above this temperature. A
tion, the braking performance metrics are measured lower limit of 80 °C was also used in early test runs to
from when fully developed deceleration has been ensure that the tyres were warm. Data gathered from
reached;34 for the comparative tests carried out in this the tests with initial brake disc temperatures less than
work it was seen as important also to include the initial 80 °C were discarded.
signal delays and the transient response of the braking Tests on each surface were performed on the same
system in calculations of the stopping distance, as these day, to reduce the effects of the environmental condi-
can differ significantly for different systems. The testing tions on the test results. All surfaces were tested in the
procedure followed for each individual straight-line wet condition, using the water spray system that is part
braking test was as follows. of the straight-line wet-grip facility at MIRA.
Table 2. Straight-line braking test performance summary, for braking from 40 km/h (11.11 m/s) (the percentages show the relative
change from the value for a conventional ABS).
ABS: anti-lock braking system; CVDC: Cambridge Vehicle Dynamics Consortium; N/A: not applicable; MSE: mean absolute slip error.
the MSE) compared with those of the conventional slip control system pressurises the brake chamber more
HGV ABS. quickly at the beginning of the event. This results in a
Figure 13 shows the sample test results for the con- more rapid rise in adhesion utilisation than for the
ventional ABS and the slip control system on the wet ABS. The periodic drop in adhesion utilisation seen in
Delugrip surface (mpeak = 0.58). The oscillatory nature Figure 13(a) during exhaust cycles with the conven-
of the ABS can be clearly seen in this figure. The tional ABS also contributes to the system’s relatively
approximate peak of the slip curve (l = 0.12) is also long stopping distances.
shown on the wheel slip plots for both systems. The slip The results of the wet Delugrip tests are also pre-
control system is able to control the wheel slip success- sented in Figure 14, this time in the form of a probabil-
fully around this point. The slip controller demands ity distribution. This figure shows the proportion of
only small changes in the brake pressure throughout time spent by the two braking systems at different lev-
the stop, whereas ABS has many full fill-and-exhaust els of wheel slip, normalised by the time taken to stop
cycles. This difference results in a reduction in the air the vehicle. The area under any section of this figure
consumption for the slip control system. The bottom represents the proportion of time spent in that wheel
subplots in Figure 13(a) and Figure 13(b) show the slip range. The approximate peak of the adhesion–
instantaneous adhesion utilisation of the wheel during wheel slip curve is also superimposed on this figure.
the course of the stop. This represents the ratio of the The shapes of the wheel slip distributions for both sys-
estimated adhesion force achieved Fx to the maximum tems are relatively similar, but the slip control system
adhesion force available (i.e. the slip curve peak). The has a narrower taller distribution, centred about the
Figure 13. Experimental test results corresponding to straight-line braking tests with an initial speed of 40km/h on a wet Delugrip
surface (mpeak = 0.58): (a) conventional trailer ABS (6S–6M); (b) slip control system.
GPS: Global Positioning System; MSE: mean absolute slip error.
approximate slip curve peak, indicating that the system shown in Table 2. The MSE of the slip control system
spends more time in this slip range than does the con- for the wet basalt-tile results (0.087) was higher than
ventional ABS. that observed for the other two test cases presented in
Figure 15 shows the sample test results for the wet Table 2 (0.057 and 0.062 for the Delugrip surface and
basalt-tile surface (mpeak = 0.12). The low level of adhe- the Bridport Pebble surface respectively). The low
sion on this test surface is similar to that of ice. The chamber pressures required for the wet basalt-tile sur-
conventional ABS clearly struggles on this surface, with face may partially explain the reduction in the slip
the brake chamber pressure regularly dropping to tracking performance. As can be seen in Figure 15(b),
atmospheric pressure (noting that the pressures shown the brake chamber pressure required is around 2 bar
in Figure 15 are absolute). The adhesion utilisation can absolute pressure; this was lower than the chamber
be seen to drop to 0% during these parts of the ASB pressures used to tune the pressure control loop in pre-
braking cycle. In contrast, the adhesion utilisation of vious studies (which involved tests centred around 4
the slip control system is consistently near 100% for bar absolute pressure).21 Because of this, the chamber
the first half of the stop. This difference is also obvious pressure often overshot the demand pressure, resulting
in the large reduction in the stopping distance achieved in a subsequent overshoot in the wheel slip (this can be
by the bi-stable valve system for this test case: 17% in seen in Figure 15(b)). Despite this observation, the per-
comparison with that for a conventional ABS, as formance improvements achieved on the wet basalt-tile
Figure 15. Experimental results corresponding to straight-line braking tests with an initial speed of 40 km/h (11.11 m/s) on a wet
basalt-tile surface (mpeak = 0.12): (a) conventional trailer ABS (6S–6M); (b) slip control system.
GPS: Global Positioning System; MSE: mean absolute slip error.
Figure 18. Experimental results corresponding to a straight-line braking test from 60 km/h (16.67 m/s) to 42 km/h (11.67 m/s) on a
wet basalt-tile surface (mpeak = 0.12): (a) conventional trailer ABS (6S–6M); (b) slip control system.
GPS: Global Positioning System; MSE: mean absolute slip error.
cost inertial sensors; such sensors are already present in For the raw data used in the production of this
modern vehicle motion control systems such as elec- paper, see the information given by Henderson and
tronic stability control (ESC). Integrating the slip con- Cebon.39
trol system presented in this work with a vehicle speed
observer potentially allows a commercially viable sys-
tem to be developed. Conclusions
In this work, the brake gain KBG at each wheel was
measured using a rolling road dynamometer prior to the 1. An HGV trailer braking system incorporating bi-
straight-line braking tests. The brake gain incorporates stable pneumatic ABS modulator valves and a
friction conditions between the brake pad and the disc, sliding-mode slip controller was tested for the
the radius at which the braking torque is applied and straight-line emergency braking performance on
the mechanical advantage achieved through the brake low-adhesion surfaces.
calliper. The value of KBG varies significantly depending 2. The system was found to reduce the stopping
on the operating conditions of the vehicle. In a commer- distance, the air consumption and the MSE by
cial system this parameter, therefore, needs to be esti- 15 6 2%, 22 6 9% and 62 6 3% respectively,
mated during normal driving. The present authors relative to those for an existing HGV trailer ABS.
suggest using a brake pulsing method, similar to that 3. Improvements seen in the stopping performance
demonstrated by Miller,33 to estimate KBG in real time. metrics may allow HGVs to meet tighter legislation
Funding
The author(s) disclosed receipt of the following finan-
cial support for the research, authorship, and/or publi-
cation of this article: This work was supported by
Haldex Brake Products Ltd, the New Zealand Tertiary
Education Commission (grant number TAD3264) and
the CVDC. At the time of writing the CVDC consisted
of the following members: Anthony Best Dynamics,
Figure 19. Probability distribution functions of the wheel slip Camcon, Denby Transport, Firestone Industrial
measured during a straight-line braking event on a wet basalt-tile Products, Goodyear Tyres, Haldex Brake Products,
surface (mpeak = 0.12) between 60 km/h (16.67 m/s) and 42 km/h MIRA, SIMPACK, SDC Trailers, Tinsley Bridge,
(11.67 m/s). Tridec, Volvo Trucks and Wincaton.
ABS: anti-lock braking system; CVDC: Cambridge Vehicle Dynamics
Consortium.
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