汽车制动抖动试验和控制研究
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摘要
制动抖动是指制动时发生的低频振动,主要表现为方向盘剧烈抖动,伴随制动踏板、车身底板和座椅的振动,是制动系统常见的故障之一。制动抖动严重影响了车辆的操纵稳定性和舒适性,也加速了相关部件的老化和疲劳破坏,制动抖动甚至增加了驾驶员疲劳和误操作的可能性。
制动抖动的影响因素众多,针对某前盘式制动器车型市场的投诉情况,进行了相应的解析调查,了解客户诉求的内容、发生工况和具体振动表现;通过整车道路试验了解制动抖动的特征,以及研究行驶工况对制动抖动的影响。本论文通过试验和理论相结合的研究方法,从振动激励与响应的角度研究了制动抖动发生的根源和传递途径以及相应的对策,得出以下几个结论:(1)对故障车进行制动抖动道路试验,方向盘的振动频率与车轮转速呈阶次关系,以一阶振动成分为主,对应的振动频率范围为10 18Hz。(2)制动抖动是具有共振环节的强迫振动,振源在于制动盘,劣化抖动占绝大部分,是发生制动抖动振源方面的主要因素。(3)控制振源和通过减小传递路径的振动放大作用是消除和减小制动抖动的两个有效途径。在传递路径方面,悬下系统10 20Hz的共振频率无法避免,只可以通过改变悬挂系统和转向系统连接点的位置和改变相应的结构,以及在允许范围内对刚度、阻尼进行调整,削弱传递路径对制动抖动的主要影响;其中最直接的方式是车型悬挂结构的变更,如将双横臂独立悬挂更改为麦弗逊独立悬挂。对于本车型悬架和转向结构来说,没有有效的解决措施,所以只能通过控制振源来控制制动抖动问题。(4)在控制振源方面,从设计、加工制造、装配、防护以及维修处理等八个方面,总结有效减少制动抖动的措施。
Brake judder refers to the lowfrequency vibration when the brake happens. The main characteristic of the brake judder is the violent shaking of the steering wheel, accompanied with vibrations in brake pedal, floor, and seats, which is one of the common braking faults. Brake judder seriously impacts the vehicle steering stability and comfort, speeds the aging and fatigue damage of related components, and even increases the possibility of the pilot fatigue and mistake.
Brake judder is affected by many factors. According to the market complaint of a type of front disk brake vehicle, investigations are carried out to realize the demands of customers, work conditions and the specific vibration performances. The influence of driving condition and the characteristics of brake judder are studied through a series of road reappearance tests. The sources and the transfer paths of disc brake are studied by both experimental and theoretical methods, and there are three conclusions: (1) The steering wheel vibration frequency has an order relationship with wheel speeds, the first order is the most important, and the corresponding frequency range is 10 18Hz. (2) The brake judder is refers to the forced vibration of a resonance link, and the vibration source is the brake disc. DTV is the main factor. (3) Controlling vibration sources and reducing the amplifying influence of transfer path are the two effective manners to eliminate or reduce brake judder. As to transfer path, suspension system resonance frequency (10 20Hz) is unavoidable, the only way is to weaken the influence of transfer path by changing the location of connection point between suspension system and steering system and the corresponding structure, and adjusting the stiffness and damping in an allowing range; One of the most direct way is to change the vehicle suspension structure, for example, changing double wishbone independent suspension into McPherson suspension. For the suspension and steering construction of the car, there are no choices unless the controlling vibration sources; (4) For the controlling vibration sources, effective measures can be done from eight ways, such as design, manufacture, assembly protection, maintenance and so on.
制动抖动的影响因素众多,针对某前盘式制动器车型市场的投诉情况,进行了相应的解析调查,了解客户诉求的内容、发生工况和具体振动表现;通过整车道路试验了解制动抖动的特征,以及研究行驶工况对制动抖动的影响。本论文通过试验和理论相结合的研究方法,从振动激励与响应的角度研究了制动抖动发生的根源和传递途径以及相应的对策,得出以下几个结论:(1)对故障车进行制动抖动道路试验,方向盘的振动频率与车轮转速呈阶次关系,以一阶振动成分为主,对应的振动频率范围为10 18Hz。(2)制动抖动是具有共振环节的强迫振动,振源在于制动盘,劣化抖动占绝大部分,是发生制动抖动振源方面的主要因素。(3)控制振源和通过减小传递路径的振动放大作用是消除和减小制动抖动的两个有效途径。在传递路径方面,悬下系统10 20Hz的共振频率无法避免,只可以通过改变悬挂系统和转向系统连接点的位置和改变相应的结构,以及在允许范围内对刚度、阻尼进行调整,削弱传递路径对制动抖动的主要影响;其中最直接的方式是车型悬挂结构的变更,如将双横臂独立悬挂更改为麦弗逊独立悬挂。对于本车型悬架和转向结构来说,没有有效的解决措施,所以只能通过控制振源来控制制动抖动问题。(4)在控制振源方面,从设计、加工制造、装配、防护以及维修处理等八个方面,总结有效减少制动抖动的措施。
Brake judder refers to the lowfrequency vibration when the brake happens. The main characteristic of the brake judder is the violent shaking of the steering wheel, accompanied with vibrations in brake pedal, floor, and seats, which is one of the common braking faults. Brake judder seriously impacts the vehicle steering stability and comfort, speeds the aging and fatigue damage of related components, and even increases the possibility of the pilot fatigue and mistake.
Brake judder is affected by many factors. According to the market complaint of a type of front disk brake vehicle, investigations are carried out to realize the demands of customers, work conditions and the specific vibration performances. The influence of driving condition and the characteristics of brake judder are studied through a series of road reappearance tests. The sources and the transfer paths of disc brake are studied by both experimental and theoretical methods, and there are three conclusions: (1) The steering wheel vibration frequency has an order relationship with wheel speeds, the first order is the most important, and the corresponding frequency range is 10 18Hz. (2) The brake judder is refers to the forced vibration of a resonance link, and the vibration source is the brake disc. DTV is the main factor. (3) Controlling vibration sources and reducing the amplifying influence of transfer path are the two effective manners to eliminate or reduce brake judder. As to transfer path, suspension system resonance frequency (10 20Hz) is unavoidable, the only way is to weaken the influence of transfer path by changing the location of connection point between suspension system and steering system and the corresponding structure, and adjusting the stiffness and damping in an allowing range; One of the most direct way is to change the vehicle suspension structure, for example, changing double wishbone independent suspension into McPherson suspension. For the suspension and steering construction of the car, there are no choices unless the controlling vibration sources; (4) For the controlling vibration sources, effective measures can be done from eight ways, such as design, manufacture, assembly protection, maintenance and so on.
引文
[1] Jacobsson H. Aspects of Disc Brake Judder[J]. Proceedings of the Institution of Mechanical Engineers. Journal of Automobile Engineering,2003,217(Part D):419 430
[2] David C. Brake System Vibration Analysis:Virtual Prototyping Brake Systems Using ADAMS[A]. ADAMS 1998 User Conference[C].1998
[3] K.Brent Dunlap, Michael A, Riehle and Richard E, Longhouse. An Investigative Overview of Automotive Disc Brake Noise[J].SAE Technical Paper Serials 1999 01 0142
[4] Abdelhamid,M.K. Brake judder analysis: case studies[J]. SAE Technical Paper Serials 972027
[5]尹东晓.汽车制动抖动发生机理研究[D].上海:同济大学博士学位论文,2006
[6]孙善勇.制动抖动仿真平台开发与研究[D].南京:南京航空航天大学硕士学位论文, 2007
[7]李运超,盛云,吴光强.盘式制动器制动抖动研究综述[J].噪声与振动控制,2008,28(5): 6 12
[8] Jacobsson H.Analysis of Brake Judder by Use of Amplitude Functions[J].SAE Technical Paper Serials 1999 01 1779
[9] A.C.Leslie. Mathematical Model of Brake Caliper to Determine Brake Torque Variation Associated with Disc Thickness Variation (DTV)Input [J]. SAE Technical Paper Serials 2004 01 2777
[10] Thomas Valvano , Kwangjin Lee. An Analytical Method to Predict Therma1.Distortion of a Brake Rotor[J].SAE Technical Paper Serials 2000 01 0445
[11] Suryatama,D.Stewart,D.J.Meyland,S.C.Hou,L.J.Contact Mechanics Simulation for Hot Spots Investigation[J]. SAE Technical Paper Serials.2001 01 0035
[12]高晓杰,余卓平,张立军.基于ADAMS的制动抖动现象仿真分析[J].系统仿真学报,2006,18(6) :1668 1670
[13]张立军,宁国宝,尹东晓,余卓平.制动力矩波动引起方向盘抖动的传递途径试验研究[J].振动与冲击,2006 ,25 (2 ):77 82
[14]高晓杰,余卓平,张立军.制动抖动引起的转向盘振动传递途径分析[J].汽车工程,2006. 28(3):267 271
[15]管仁梅.车辆大客车鼓式制动器的多柔体ADAMS建模[D].吉林:吉林大学硕士学位论文,2004
[16]翁建生,Wei yi LOH,胡海岩.消除刹车不平顺性车辆底盘转向系统的半主动控制[A].第八届全国振动理论及应用学术会议论文集[C].上海,2003: 1 10
[17] Alex Wang, Lixin Zhang, Naim Jaber and Joe Rieker .On Brake Moan Mechanism from the Modeling Perspective[J]. SAE Technical Paper Serials.2003 01 0681
[18]韩建荣.汽车制动抖动分析的研究[D].南京:南京航空航天大学硕士学位论文,2008
[19]韩建荣,翁建生.盘式制动器的热分析[J].机械设计与制造,2008,(10):180 183
[20]高晓杰,袁李莉,袁蒋励.浮钳盘式制动器及其零部件的模态分析[J].设计研究, 2006, (1):31 33
[21] Stefn Gassmann ,Hans Georg Engel. Excitation and transfer mechanism of brake judder [J]. SAE Technical Paper Serials 931880
[22]尹东晓,张立军,宁国宝,余卓平.制动力矩波动台架试验研究[J].振动、测试与诊断, 2005, 25(2):117 121
[23] Masahiro Kubota,Tomihiro Suenaga, Kazuhiro Doi.A study of the mechanism causing high speed brake judder [J]. SAE Technical Paper Serial.980594
[24]张立军,缪唯佳,余卓平.汽车盘式制动器摩擦振动耦合特性试验研究[J].摩擦学学报, 2008,28(5):480 484
[25]李莉,尹东晓,张立军.盘式制动器制动抖动现象机理研究[J].汽车工程,2006,28(4): 361 365
[26]孟德建,张立军,余卓平.基于制动器多点接触模型的初始SRO和DTV对制动抖动的影响分析[J].振动与冲击,2010,29(7):43 48
[27]孟德建,张立军,余卓平.多点接触模型的盘式制动器制动抖动分析[J].振动、测试与诊断,2010,30(3):304 309
[28]张立军,宁国宝,余卓平.制动抖动引起的方向盘振动现象试验与理论分析[A]. APC联合学术年会论文[C].天津,2007:118 126
[29]宁国宝,张立军,尹东晓,余卓平.制动引起的方向盘抖动现象试验研究[J].中国工程机械学报,2004,2(3):355 359
[30]黄文兵,刘守银.制动引起的方向盘抖动试验研究[J].现代振动与噪声技术,2008(6):452 458
[31]高晓杰,余卓平,张立军.制动抖动引起的转向盘振动传递途径分析[J].汽车工程,2006, 28(3):267 270
[32]高晓杰,余卓平,张立军,尹东晓,宁国宝.基于ADAMS的制动抖动现象仿真分析[J].系统仿真学报, 2006, 18(6):1668 1670
[33] Myung Gyu Kim, Ho ll Jeong, Wan Suk Yoo. Sensitivity analysis of chassis system to improve shimmy and brake judder vibration on steering wheel [J]. SAE Technical Paper Serials. 960734
[34] Takashige Takegawa, Tsukasa Ohhara,Yoshihiro Wakabayashi. Brake judder and shimmy simulation technology development [J].Mazda Technical Review,2004,(22):33 37
[2] David C. Brake System Vibration Analysis:Virtual Prototyping Brake Systems Using ADAMS[A]. ADAMS 1998 User Conference[C].1998
[3] K.Brent Dunlap, Michael A, Riehle and Richard E, Longhouse. An Investigative Overview of Automotive Disc Brake Noise[J].SAE Technical Paper Serials 1999 01 0142
[4] Abdelhamid,M.K. Brake judder analysis: case studies[J]. SAE Technical Paper Serials 972027
[5]尹东晓.汽车制动抖动发生机理研究[D].上海:同济大学博士学位论文,2006
[6]孙善勇.制动抖动仿真平台开发与研究[D].南京:南京航空航天大学硕士学位论文, 2007
[7]李运超,盛云,吴光强.盘式制动器制动抖动研究综述[J].噪声与振动控制,2008,28(5): 6 12
[8] Jacobsson H.Analysis of Brake Judder by Use of Amplitude Functions[J].SAE Technical Paper Serials 1999 01 1779
[9] A.C.Leslie. Mathematical Model of Brake Caliper to Determine Brake Torque Variation Associated with Disc Thickness Variation (DTV)Input [J]. SAE Technical Paper Serials 2004 01 2777
[10] Thomas Valvano , Kwangjin Lee. An Analytical Method to Predict Therma1.Distortion of a Brake Rotor[J].SAE Technical Paper Serials 2000 01 0445
[11] Suryatama,D.Stewart,D.J.Meyland,S.C.Hou,L.J.Contact Mechanics Simulation for Hot Spots Investigation[J]. SAE Technical Paper Serials.2001 01 0035
[12]高晓杰,余卓平,张立军.基于ADAMS的制动抖动现象仿真分析[J].系统仿真学报,2006,18(6) :1668 1670
[13]张立军,宁国宝,尹东晓,余卓平.制动力矩波动引起方向盘抖动的传递途径试验研究[J].振动与冲击,2006 ,25 (2 ):77 82
[14]高晓杰,余卓平,张立军.制动抖动引起的转向盘振动传递途径分析[J].汽车工程,2006. 28(3):267 271
[15]管仁梅.车辆大客车鼓式制动器的多柔体ADAMS建模[D].吉林:吉林大学硕士学位论文,2004
[16]翁建生,Wei yi LOH,胡海岩.消除刹车不平顺性车辆底盘转向系统的半主动控制[A].第八届全国振动理论及应用学术会议论文集[C].上海,2003: 1 10
[17] Alex Wang, Lixin Zhang, Naim Jaber and Joe Rieker .On Brake Moan Mechanism from the Modeling Perspective[J]. SAE Technical Paper Serials.2003 01 0681
[18]韩建荣.汽车制动抖动分析的研究[D].南京:南京航空航天大学硕士学位论文,2008
[19]韩建荣,翁建生.盘式制动器的热分析[J].机械设计与制造,2008,(10):180 183
[20]高晓杰,袁李莉,袁蒋励.浮钳盘式制动器及其零部件的模态分析[J].设计研究, 2006, (1):31 33
[21] Stefn Gassmann ,Hans Georg Engel. Excitation and transfer mechanism of brake judder [J]. SAE Technical Paper Serials 931880
[22]尹东晓,张立军,宁国宝,余卓平.制动力矩波动台架试验研究[J].振动、测试与诊断, 2005, 25(2):117 121
[23] Masahiro Kubota,Tomihiro Suenaga, Kazuhiro Doi.A study of the mechanism causing high speed brake judder [J]. SAE Technical Paper Serial.980594
[24]张立军,缪唯佳,余卓平.汽车盘式制动器摩擦振动耦合特性试验研究[J].摩擦学学报, 2008,28(5):480 484
[25]李莉,尹东晓,张立军.盘式制动器制动抖动现象机理研究[J].汽车工程,2006,28(4): 361 365
[26]孟德建,张立军,余卓平.基于制动器多点接触模型的初始SRO和DTV对制动抖动的影响分析[J].振动与冲击,2010,29(7):43 48
[27]孟德建,张立军,余卓平.多点接触模型的盘式制动器制动抖动分析[J].振动、测试与诊断,2010,30(3):304 309
[28]张立军,宁国宝,余卓平.制动抖动引起的方向盘振动现象试验与理论分析[A]. APC联合学术年会论文[C].天津,2007:118 126
[29]宁国宝,张立军,尹东晓,余卓平.制动引起的方向盘抖动现象试验研究[J].中国工程机械学报,2004,2(3):355 359
[30]黄文兵,刘守银.制动引起的方向盘抖动试验研究[J].现代振动与噪声技术,2008(6):452 458
[31]高晓杰,余卓平,张立军.制动抖动引起的转向盘振动传递途径分析[J].汽车工程,2006, 28(3):267 270
[32]高晓杰,余卓平,张立军,尹东晓,宁国宝.基于ADAMS的制动抖动现象仿真分析[J].系统仿真学报, 2006, 18(6):1668 1670
[33] Myung Gyu Kim, Ho ll Jeong, Wan Suk Yoo. Sensitivity analysis of chassis system to improve shimmy and brake judder vibration on steering wheel [J]. SAE Technical Paper Serials. 960734
[34] Takashige Takegawa, Tsukasa Ohhara,Yoshihiro Wakabayashi. Brake judder and shimmy simulation technology development [J].Mazda Technical Review,2004,(22):33 37