Full-Scale Testing of A Novel Slip Control Braking System For Heavy Vehicles

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Original Article

Proc IMechE Part D:


J Automobile Engineering
1–18
Full-scale testing of a novel slip control Ó IMechE 2015
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DOI: 10.1177/0954407015604804
pid.sagepub.com

Leon Henderson and David Cebon

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

Date received: 11 January 2015; accepted: 7 August 2015

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

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2 Proc IMechE Part D: J Automobile Engineering

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

ABSs on heavy vehicles operate on the same general


principles as those used in passenger cars, the main dif- Alternative braking strategies
ference being the use of pneumatics as opposed to ‘Slip control’ is a broad term used to describe control
hydraulics.9 Because pneumatic brake actuation is strategies that have been developed as an alternative to
slow, the ABSs used on heavy vehicles today cycle at an ABS. In order to achieve the minimum possible
only 1–2 Hz (compared with between 6 Hz and 8 Hz for stopping distance, an ideal slip controller would manip-
passenger cars9,10). A typical heavy-vehicle ABS emer- ulate the braking torque so that wheel slip converges to
gency stop on a wet road is shown in Figure 1. The the peak of the adhesion–slip curve. In order for a con-
ABS algorithm prevents wheel lock-up by releasing the troller to identify this optimal slip point, the tyre force
brake pressure when high levels of wheel deceleration characteristics must be known or estimated. In reality a
are sensed. pre-set optimal slip value is often used, typically
A vehicle state known as the wheel slip l is defined around l = 0.2, to reduce the computation require-
to represent the level of relative speed (i.e. the slip) ments in the controller. More recent controller con-
between the tread band of the tyre and the road accord- cepts fit adhesion–slip curves in real time in order to
ing to estimate the optimal slip point for any operating
conditions.12
vx  Rr v
l= ð1Þ Researchers have investigated slip control using a
vx
range of different linear and non-linear control strate-
where Rr is the rolling radius, v is the angular velocity gies on both passenger cars and HGVs.13–20 In the case
and vx is the longitudinal velocity. The wheel slip varies of HGV slip control, studies have predicted significant
between 0 and 1, where l = 0 corresponds to freewheel- stopping distance reductions in simulations;20–22 how-
ing and l = 1 corresponds to complete lock-up of the ever, only one study was found in which vehicle tests
wheel. were performed.14 In this study, a slip control strategy
The available adhesion force Fx between the road was implemented on a medium-sized rigid HGV with
and the tyre can be related to the wheel slip. Sample an air-over-hydraulic braking system. In these tests, an
adhesion–slip curves for dry asphalt and ice are shown improved steerability of the vehicle was observed in
in Figure 2 plotted using a model devised by Fancher.11 brake-in-turn scenarios. Straight-line braking tests were
As can be seen, the shape of the adhesion–slip curve dif- also carried out. However, comparisons of the stopping
fers greatly depending on the road conditions. The rela- distances with those of conventional systems were not
tionship is additionally dependent on variables such as made.
the vehicle speed, the inflation pressure of the tyre, the Miller and Cebon23 showed, through simulations,
normal tyre load and the lateral slip. Although a con- that slip control would only be advantageous on HGVs
ventional ABS improves the lateral stability by prevent- if fast-acting high-flow-rate pneumatic actuators were
ing lock-up, its oscillatory nature means that the wheel used. They predicted that a slip control system using
slip varies periodically between low levels and high pneumatic valves with a switching delay of 3 ms and an
levels. Consequently, the peak braking force (encircled orifice of diameter 8 mm (compared with using conven-
in Figure 2) is not maintained throughout the braking tional pneumatic ABS modulator valves with a switch-
event, resulting in a suboptimal straight-line braking ing delay of 20–40 ms and an orifice of diameter 8 mm)
performance. could reduce the stopping distances by up to 30%

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Henderson and Cebon 3

compared with those of a conventional ABS.23 Like


many of the existing slip controller designs, Miller and
Cebon23 required accurate measurements of the abso-
lute longitudinal speed of the vehicle and the individual
braking forces. As these are not measured directly on
commercially available vehicles, they need to be
obtained using state estimation techniques.

Novel brake actuators for improved control


bandwidth
Many researchers have investigated completely repla-
cing pneumatic and hydraulic brake components with
electrical actuators.10,24–27 Siemens have presented Figure 3. Cross-section of a valve enclosure incorporating two
working prototypes of an electromechanical wedge- CVDC bi-stable valves, used for brake pressure modulation.
brake concept. Siemens have claimed that these brakes
have one tenth of the energy expenditure of conven-
tional hydraulic brakes.27 Separate simulations carried the Miller et al.21 sliding-mode slip controller, have
out by Emereole10 suggested that using electromechani- achieved reductions in the stopping distance of up to
cal actuators on a passenger car can reduce the stop- 25% compared with that of a commercially available
ping distances by approximately 10% on low-friction HGV ABS.
roads. This reduction, however, was only seen when
the conventional ABS control algorithm was replaced Slip control using bi-stable pneumatic
with a slip controller. Electromechanical brake systems modulator valves
have also been proposed for heavy vehicles.28,29 Haldex
Brake Products carried out a range of straight-line In this paper, the slip control strategy presented by
braking tests using a ‘bobtail’ tractor unit fitted with Miller and Cebon12 is implemented on a full-scale HGV
their own prototype electromechanical disc brake. trailer using prototype bi-stable fast-acting pneumatic
Reductions in the stopping distances of up to 24% on valves (developed from the earlier valve design pre-
low-friction roads were seen in comparison with those sented by Miller et al.21).
with a conventional EBS–ABS (where electric signals The relevant slip control equations are presented
are used to communicate the brake pressure demand briefly in this section; for further detail relating to the
from the driver to the electro-pneumatic regulator controller derivations and the mechanical design of the
valves).29 These trials once again included the use of a bi-stable valves, readers are referred to the publications
slip controller as opposed to the conventional ABS by Miller and Cebon12,30 and Miller et al.21
algorithm.
The Cambridge Vehicle Dynamics Consortium
Overview of the sliding-mode slip control system
(CVDC) has recently developed a high-speed bi-stable
pneumatic valve for use in an electro-pneumatic brak- The slip control system presented by Miller and
ing system.21 This valve is an order of magnitude faster Cebon12,30 and Miller et al.21 can be simplified into the
than existing heavy vehicle ABS modulator valves and flow diagram shown in Figure 4. A pressure control
comparable with electromechanical brake designs, loop is cascaded within a slip control loop, which
which can adjust to small changes in brake torque tracks a prescribed wheel slip demand ldem. As is
demand27 within 10 ms. A schematic diagram of the shown in the figure, some state estimation is required
CVDC valve is shown in Figure 3. The valve includes a to identify the adhesion force Fx at the contact patch
cantilevered steel flexure which is mounted between and the longitudinal vehicle speed vx. In addition to
two permanent magnets. Electrical pulses in a wire coil this, parameters such as the rolling radius Rr of the tyre
are used to switch the flexure from one pole piece to and the brake gain KBG must be known.
the other. The low moving mass of the flexure and its A first-order sliding surface s is defined as
high stiffness allow the valve to switch in approxi-
s = l  ldem ð2Þ
mately 3 ms. The CVDC valve design has an orifice of
diameter 8 mm and can therefore be used directly in where ldem is the demanded slip level. ldem was set to
line (as opposed to the indirect piloted diagram valve the estimated peak of the adhesion–slip curve in this
system used in conventional pneumatic ABS modulator study. Combining the sliding surface definition (equa-
valves). Recent hardware-in-the-loop (HiL) experi- tion (2)) with the equations of motion of a simplified
ments using an HGV disc brake assembly fitted with a single-degree-of-freedom model of a rolling wheel sub-
load cell (to measure the clamping force at the brake ject to a braking torque TB = PcKBG (where Pc is the
disc) and prototype bi-stable valves, controlled using brake chamber pressure and KBG is the brake gain),

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4 Proc IMechE Part D: J Automobile Engineering

Figure 4. Flow diagram of the slip control system.

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)

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Henderson and Cebon 5

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

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6 Proc IMechE Part D: J Automobile Engineering

chance of jackknifing during straight-line braking


(compared with braking the full combination).
3. A semitrailer that had a modern trailer EBS–ABS
fitted was readily available to the present authors.
This braking system had been modified so that it
can be activated via a laptop computer; this was used
as a benchmark braking system for comparison.
4. Once commissioned, the slip control system can be
extended to the tractor unit for full tractor–
semitrailer tests (a subject for future work).

The bi-stable valve design previously presented by


Miller et al.21 was modified before installation on the
trailer. Design improvements included reducing the
Figure 6. Conflict plot of the simulated straight-line braking valves’ overall electrical power requirements, increasing
performance of the sliding-mode slip controller with 3 ms bi- their maximum operating pressure to above 9 bar and
stable pneumatic valves on a smooth icy surface (mpeak = 0.2) improving their reliability (specifically the valve seals
from an initial vehicle speed of 80 km/h (22.22 m/s). and the accompanying power electronics). New bi-
stable modulator valve assemblies (housing both the
inlet valves and the outlet valves) were manufactured
pneumatic valve system (the slip control system). An for each wheel station. As can be seen in Figure 7 and
HGV trailer was used for this prototype installation, as Figure 8, each modulator valve assembly was mounted
opposed to a tractor unit or rigid truck, for the follow- on the axle, as close as possible to the brake chamber,
ing reasons. in order to minimise the propagation delays of the
pneumatic signals. This arrangement differs signifi-
1. Trailers generally have more available space cantly from that common to conventional trailer brak-
around their wheel stations, allowing easier mount- ing systems, where ABS valves are typically mounted
ing of prototype hardware and instrumentation. on the trailer chassis, near the middle of the axle group.
2. Applying the trailer brakes only in a tractor– Figure 8 also shows that the axles on this particular test
semitrailer combination significantly reduces the trailer were steered; this system remained locked in its
central position during the work discussed here.

Figure 7. Test vehicle and CVDC bi-stable modulator valve installed at the wheel end.

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Henderson and Cebon 7

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

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8 Proc IMechE Part D: J Automobile Engineering

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

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Henderson and Cebon 9

Table 1. Vehicle parameter values and adhesion–slip model coefficients for straight-line braking tests at the MIRA testing facility,
Nuneaton, Warwickshire, UK.

Symbol Parameter Value Source

h1 Ground to hitch 1.17 m Cheng32


h2 Ground to trailer centre-of-mass 1.2 m Cheng32
(unladen)
l1 Hitch to trailer centre-of-mass (unladen) 5.8 m Cheng32
l2 Hitch to centre axle (trailer) 7.7 m Cheng32
l3 Axle spacing (trailer) 1.43 m Cheng32
Rr Wheel rolling radius (average, all trailer 0.528 m Calibrated against VBOX
wheels) velocity signal
mtractor Tractor mass (combined sprung and 9400 kg Weigh station, MIRA
unsprung)
mtrailer Trailer mass (combined sprung and 11,700 kg Weigh station, MIRA
unsprung; unladen)
Pcrack Chamber pressure at which the braking 1.29 bar Rolling road dynamometer tests
force becomes non-zero (average; all
trailer wheels)
Fz Static normal load (individual trailer 14.9 kN Weigh station, MIRA
wheel; average)
^Fz Adjusted ‘dynamic’ normal load calculated Delugrip surface: 13.7 kN Equation (8)
for the peak adhesion–slip curve Bridport Pebble surface: 14.3 kN
(individual trailer wheel; average) Basalt surface: 14.6 kN
BG
K Brake gain (average; all trailer wheels) 1.80 kNm/bar Rolling road dynamometer tests
C0 Longitudinal slip stiffness (at zero slip; the 132.5 kN Calculated from the normal
Fancher adhesion–slip model) wheel load, using the Fancher11
relationship
Vf Friction function shaping factor (the Delugrip surface: 5 m/s Constant-brake-pressure tests
Fancher adhesion–slip model) Bridport surface: 5 m/s
Basalt surface: 13.8 m/s
mpeak Peak tyre–road adhesion coefficient Delugrip surface: 0.58 6 0.03 Constant-brake-pressure tests
Bridport Pebble surface: 0.28 6 0.01
Basalt surface: 0.122 6 0.006
m0 Coefficient of static friction (the Fancher Delugrip surface: 0.80 Constant-brake-pressure tests
adhesion–slip model) Bridport Pebble surface: 0.30
Basalt surface: 0.125
mf Coefficient of dynamic friction (the Delugrip surface: 0.5 Constant-brake-pressure tests
Fancher adhesion–slip model) Bridport Pebble surface: 0.20
Basalt surface: 0.112

Figure 9. Flow diagram of the local slip controller.


CAN: controller area network.

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10 Proc IMechE Part D: J Automobile Engineering

Figure 10. Rolling road dynamometer results and brake gain


calculations (all trailer wheels).

brake gain (which can be expected on a real vehicle)


can substantially reduce the performance of the sliding- Figure 11. Adhesion force–slip curves11 fitted against the test
results for an unladen semitrailer at an initial test speed of
mode slip controller.
30 km/h (8.33 m/s).
In order to obtain the brake gain estimates for the
test vehicle, calibration tests were carried out on a roll-
ing road dynamometer. The dynamometer (a Biesbarth
increasing brake pressure until complete wheel lock-up
MB 8000-S, located at MIRA) allowed one axle to be
was detected. Fx,total was divided by the average slip
driven at a time while measuring the brake force Fx at
levels of the braked wheels to obtain the adhesion–slip
each wheel. Tests were carried out on each of the three
model for a single (average) wheel station at 30 km/h
trailer axles at increasing brake pressure. The steady-
(8.33 m/s). The resulting adhesion–slip curves for all
state brake force at each wheel was recorded for each
three test surfaces are shown in Figure 11.
brake pressure, and a first-order curve was fitted to the
Load transfer was taken into account by adjusting
resulting data set. The ensemble-averaged results for all
the individual normal tyre loads Fz (presented in
six wheels are shown in Figure 10. The first-order fit
Table 1) to give adjusted ‘dynamic’ values F^z , accord-
shown provides an estimate of the average brake gain
ing to
KBG and Pcrack (the lowest pressure at which a braking
force is recorded), for all the trailer wheels. Fx ðmtractor h1 + mtrailer h2 Þ
Closer analysis of the data indicated that there was F^z = Fz  ð8Þ
l2 ðmtractor + mtrailer Þ
some difference (up to 15%) between the brake gains
for different wheel stations. The test data were there- Equation (8) was derived from the simplified free-body
fore separated for each wheel, and the curve fits were diagram of a tractor–semitrailer shown in Figure 12.
re-applied. These were uploaded to the individual slip Here, Fz is the static wheel load of an individual
controllers for the braking tests. trailer wheel (obtained from vehicle weigh-station
data), mtractor is the mass of the tractor, mtrailer is the
mass of the trailer, h1, h2 and l2 are the vehicle dimen-
Adhesion–slip curve estimation
sions stated in Table 1 and Fx is the average adhesion
Constant-pressure braking tests from 40 km/h (11.11 m/ force generated at each trailer wheel (noting that the
s) were used to fit appropriate Fancher adhesion–slip tractor unit brakes were not activated during any of
models.11 The total estimated force Fx,total for each test these tests). Equation (8) applies only to steady-state
was calculated using the equation braking and does not include the transient pitching of
vx, i  vx, f the vehicle, the tyre’s rolling resistance or the aerody-
Fx, total = mtotal  Faero  Frolling ð7Þ namic drag.
tf  ti
The load transfer was estimated to reduce the nor-
where Faero is the aerodynamic drag force and Frolling is mal loads on the trailer wheels by 8% on the Delugrip
the rolling resistance force; these were estimated at the test surface, by 4% on the Bridport Pebble test surface
required test speed using a separate coast-down test.36 and by 2% on the basalt-tile test surface (see Table 1).
The subscripts i and f correspond to the initial data The peak tyre–road adhesion coefficients mpeak were
point and the final data point respectively. Data over a calculated for each surface using the corresponding
period of 2 s were used for each braking force calcula- dynamic wheel loads F^z and are also provided in
tion, with vx,i set to 30 km/h (8.33 m/s), 10 km/h less Table 1. These values include a nominal 65% toler-
than the initial brake application speed, to allow the ance to account for differences in the adhesion along
vehicle to reach a steady state. Tests were repeated at the test track, as seen in the report by Bowman.37

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Henderson and Cebon 11

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.

1. The brake temperature is checked (tests were only


carried out if the brake disc temperature was
Straight-line braking test results
between 80 °C and 120 °C; repeated conventional The results for each of the three test surfaces are sum-
ABS stops were used to warm up the brake hard- marized in Table 2 for both a conventional ABS and
ware and tyres). the slip control system. The results presented for the slip
2. The braking system is selected (conventional ABS control system represent the switching gains ks within
or bi-stable ABS modulator valves) and data log- the optimal range (minimizing both the stopping dis-
ging is commenced. tance and the air use). Tests corresponding to controller
3. The air isolation valve is closed (for air consump- gain values near the apparent optimal value were com-
tion measurement). bined to ensure that at least three test runs were used to
4. The vehicle is driven on to the test surface at calculate each set of braking statistics. The average per-
approximately 42 km/h (11.67 m/s). formance improvements achieved by the slip controlled
5. The clutch is disengaged. bi-stable valve system are also summarised in Table 2.
6. The vehicle is allowed to coast to 40 km/h Significant improvements were seen in all three perfor-
(11.11 m/s). mance metrics (the stopping distance, the air use and

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12 Proc IMechE Part D: J Automobile Engineering

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).

Metric Conventional ABS CVDC slip control

Wet Delugrip surface Optimal sliding-mode gain ks (Pa) N/A 50,000–70,000


(mpeak = 0.58 6 0.03) Number of tests 4 3
Stopping distance (m) Mean: 28.9 Mean: 25.5 (–12%)
Maximum: 29.4 Maximum: 25.7 (–13%)
Minimum: 28.5 Minimum: 25.4 (–11%)
Air consumption (kg) Mean: 0.049 Mean: 0.038 (–22%)
Maximum: 0.051 Maximum: 0.051 (–0%)
Minimum: 0.048 Minimum: 0.029 (–40%)
MSE (unitless, calculated per test) Mean: 0.13 Mean: 0.053 (–59%)
Maximum: 0.15 Maximum: 0.060 (–60%)
Minimum: 0.12 Minimum: 0.047 (–61%)
Wet Bridport Pebble surface Optimal sliding-mode gain ks (Pa) N/A 50,000 - 70,000
(mpeak = 0.28 6 0.01) Number of tests 8 7
Stopping distance (m) Mean: 54.8 Mean: 45.8 (–16%)
Maximum: 56.1 Maximum: 46.7 (–17%)
Minimum: 49.7 Minimum: 44.2 (–11%)
Air consumption (kg) Mean: 0.073 Mean: 0.062 (–15%)
Maximum: 0.083 Maximum: 0.076 (–8%)
Minimum: 0.064 Minimum: 0.045 (–30%)
MSE (unitless, calculated per test) Mean: 0.20 Mean: 0.068 (–66%)
Maximum: 0.21 Maximum: 0.086 (–59%)
Minimum: 0.19 Minimum: 0.048 (–75%)
Wet basalt-tile surface Optimal sliding-mode gain ks (Pa) N/A 50,000-70,000
(mpeak = 0.122 6 0.006) Number of tests 10 6
Stopping distance (m) Mean: 129 Mean: 107 (–17%)
Maximum: 132 Maximum: 111 (–16%)
Minimum: 125 Minimum: 104 (–17%)
Air consumption (kg) Mean: 0.133 Mean: 0.093 (–30%)
Maximum: 0.140 Maximum: 0.115 (–18%)
Minimum: 0.127 Minimum: 0.070 (–45%)
MSE (unitless, calculated per test) Mean: 0.21 Mean: 0.087 (–59%)
Maximum: 0.22 Maximum: 0.090 (–59%)
Minimum: 0.20 Minimum: 0.084 (–58%)
Average change relative to ABS Stopping distance Baseline –1562%
(all surfaces) Air consumption Baseline –2269%
MSE (unitless) Baseline –6263%

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

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Henderson and Cebon 13

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

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14 Proc IMechE Part D: J Automobile Engineering

surface were still considerable; further tuning of the


pressure control loop may provide scope to reduce the
stopping distance further in future tests.
Figure 16 once again shows the distribution of the
wheel slip throughout the stop, this time for a wet
basalt-tile surface test. This figure further highlights the
difficulty that a conventional ABS has on this surface.
The distribution of the wheel slip for the ABS is very
wide and includes a peak close to l = 0, where the
adhesion force is low. The wheel slip distribution for
the slip control system on this surface is also wider than
that seen for the same system in Figure 14 (the wet
Delugrip surface); however, it is considerably narrower
than that for the conventional ABS, with much more
time spent near the peak of the slip curve and consider-
Figure 14. Probability distribution functions of the wheel slip ably less time near l = 0.
measured during a straight-line braking event on a wet Delugrip A conflict plot of the air use versus the stopping dis-
surface (mpeak = 0.58) from 40 km/h (11.11 m/s). tance for the wet basalt-tile test results is shown in
ABS: anti-lock braking system; CVDC: Cambridge Vehicle Dynamics
Consortium.
Figure 17. The reduction in the stopping distance
achieved by the slip control system is obvious in this

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.

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Henderson and Cebon 15

The overall percentage improvements achieved by


the slip control system (15% reduction in the stopping
distance, 22% reduction in the air use and 62% reduc-
tion in the MSE) are encouraging. The improvements
in the stopping distance were, however, slightly less
those predicted in previous HiL studies on a similar
system. Miller et al.21 predicted the improvement in the
stopping distance to be 23% for an icy surface, 6% bet-
ter than that achieved in the wet basalt-tile vehicle tests
summarised in Table 2. As has already been mentioned,
this difference may be attributed to the tuning of the
pressure controller, which was overly aggressive. It
may also be attributed to one or more of the following
factors:

(a) a slower controller operating frequency in vehicle


tests compared with tests with an HiL controller
(200 Hz in vehicle tests; 500 Hz in HiL tests);
Figure 16. Probability distribution functions of the wheel slip
measured during a straight-line braking event on a wet basalt-tile
(b) differences in the initial vehicle speeds;
surface (mpeak = 0.12) from 40 km/h (11.11 m/s). (c) differences in the tyre–road adhesion properties
ABS: anti-lock braking system; CVDC: Cambridge Vehicle Dynamics (lower adhesion coefficient in the vehicle tests);
Consortium. (d) a lower normal tyre load in the vehicle tests;
(e) inaccuracies in the adhesion force look-up table;
(f) imperfect knowledge of the adhesion–slip curve
peak value.

Some of these factors will be addressed in our next


project.
To investigate how the slip control system performs
at higher speeds, a small number of tests were per-
formed from 60 km/h (16.67 m/s) to 42 km/h (11.67 m/
s) on the basalt-tile surface. The sample results from
these tests are shown in Figure 18. At these higher vehi-
cle speeds, the slip controller demonstrates significantly
tighter slip point tracking than for the 40 km/h case
summarised in Table 2; this is highlighted by the slip
distribution in Figure 19. The MSE for this test was
0.05, almost 50% lower than that seen for the same sys-
tem at a lower speed. The adhesion utilisation plots
Figure 17. Conflict plot for the straight-line braking test shown in Figure 18 suggest that the slip control system
results obtained on a wet basalt-tile surface (mpeak = 0.12) with can consistently maintain the peak adhesion force
an initial speed of 40 km/h (11.11 m/s). The marker size is
throughout the speed range from 60 km/h (16.67 m/s)
proportional to the controller gain ks.
ABS: anti-lock braking system; CVDC: Cambridge Vehicle Dynamics to 42 km/h (11.67 m/s). It is hoped that, by introducing
Consortium. the bi-stable valve system to the tractor unit in future
work, straight-line braking tests will be possible from
80 km/h to a standstill on the same MIRA wet basalt-
figure. The size of the markers used to represent the slip tile surface. These future tests will provide a further
control system results in this figure is proportional to indication of what performance improvements can be
the magnitude of the sliding-mode switching gain ks. achieved by the slip control system.
The simulation results for the same test case (taking It should once again be noted that, in these tests, the
into account the mass of the unbraked tractor, as given GPS was used to provide a measurement of the vehicle
in Table 1) are overlaid; as can be seen, the stopping speed to the slip control system. The GPS is not sug-
distances predicted by the simulation model are very gested by the present authors as a feasible means of
close to the experimental results. The air consumption vehicle speed measurement for a commercial slip con-
is also similar for the lower gain settings, with some dis- trol system; it was used here simply to demonstrate the
crepancy at higher gains. A similar tuning pattern to improvements that can be achieved through better con-
that previously presented in Figure 6 and in other pub- trol of the wheel slip. Recent advancements in vehicle
lications12,21 can be seen in this figure (as indicated by state estimation38 suggest that an accurate estimate of
the superimposed arrow). the vehicle speed can be obtained using relatively low-

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16 Proc IMechE Part D: J Automobile Engineering

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

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Henderson and Cebon 17

University of Cambridge, for their assistance during


the vehicle installation and testing phase of the project.

Declaration of conflict of interest


The author(s) declared no potential conflicts of interest
with respect to the research, authorship, and/or publi-
cation of this article.

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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