前桥制动装置效能及检测系统研究
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摘要
目前，制动系统电子化为大趋势。然而电子化装备需配备可靠的制动执行装置，研究表明，如果电子装备没有良好的执行机构，其导致的结果比不用电子化装备的要严重。另外，近年来的交通建设和物流增长加快汽车运输向大吨位、高速度和高性能方向发展。汽车的安全问题越来越突出，因此人们不得不加强对汽车制动原理及装置的研究和检测，要求不断地改进结构和性能，以适应汽车的各种工况。
本文针对北方奔驰车桥公司的前桥制动性能研究、检测与生产一体化的要求，结合汽车制动原理和当前台式检测的特点，开展了以下几个方面的研究工作：
(1)制动装置理论分析。从制动装置的结构、工作原理出发，分析了制动器和制动气室的有关理论。
(2)制动装置建模及分析。应用制动装置有关理论建立制动器和气室的模型以及装置的耦合模型。利用Matlab分析了气室以及制动装置的工作特性和重要影响因素。
(3)台架制动性能检测系统的开发。根据制动装置的特点、相关工作特性和惯性式台架检测的特点，提出了在生产线领域的台式检测方案。然后从系统总体要求出发，给出机械模拟实现方法，以及进行系统硬件和系统软件以及检测流程等设计。
(4)结合模型分析检测结果。比较理想模型和检测结果，分析出模型与实际结果的差别；给出弥补模型缺陷的方法，并解释检测结果的各种现象。并结合实际技术指标评判检测结果，提出借鉴意见。
在研究工作的进行中，同时也取得了一些重要的结果。例如，制动器和制动气室的工作特性及一些重要影响参数，制动装置良好的耦合性能；进而发现改变气压法来改变附着系数的办法，为制动装置的检测方法提供了新方法；结合变频技术，将惯性滚筒式方法进行改造并应用于在线检测；在结果与模型的比较中，得出了弥补响应延时缺陷的经验法。在技术指标和检测结果的分析中，提出计算的实用方法和装置改进措施，从而将检测研究紧密的结合起来。
Electronic of braking system has become a distinct trend at present. However, electronic facility should be equipped with reliable braking executive mechanism. It is indicated by research that the result of usage of electronic equipment would be even worse than without using it unless appropriate executive mechanism has been employed. On the other hand, large-tonnage & high-speed & high-powered has increasingly become the trend of vehicle transportation as a result of enhancement of transportation construction and logistics. People have to strengthen the research and test on principle and mechanism of automobile's braking system with the increasingly distinctness of vehicle's safety problem. Continuous improvement of structure and performance are required to adjust to the various working condition of vehicles.
Having aimed at braking performance of front axle and requirement of integration of test & produce in Northern Benz Axle Corporation, this thesis has carried some research with the discussion of vehicle's braking principle and platform's testing characteristic. The main content of this paper are as follows:
(1) Theoretical analysis of braking mechanism. Having based on the structure and principle of braking structure, this thesis has analyzed some relevant theories on arrester and gas chamber of arrester.
(2) Modeling and analysis of braking mechanism. Models of arrester and gas chamber have been established with the application of theories of braking mechanism. Working performance and important influencing factors of braking performance have been analyzed with the utility of Matlab.
(3) Development of braking performance testing system. Based on the characteristics of braking mechanism and inertial platform testing, this paper has brought forward the testing scheme in product line field. Realization methods of mechanical simulation, design of hardware & software and testing flow are put forward on the basis of the requirement of system's overall requirement.
(4) Analysis of testing result combined with model. Having compared ideal model with testing result, this paper has analyzed the distinction between ideal result and actual result. This thesis also has provided with the methods of remedy of model's defect and explanations of various phenomenon in testing result. Some suggestions are raised on the basis of practical & technical testing result.
Also, some important results are achieved in the process of research work. For instance, the performance characteristics and some important influencing factors of arrester and gas chamber of arrester, coupling performance of braking mechanism; discovery of new methods(change gas pressure) to change adhesive coefficient, new testing methods are provided with for braking mechanism; Inertial roller method has been rebuilt to be used in online testing; Experiential method has been achieved to remedy the responsive delay defect on the basis of the comparison between result and model. Having analyzed the technical parameters and testing result, this paper has brought forward the applied calculating methods and improving measures of mechanism. Therefore, testing and research have been tightly combined.
本文针对北方奔驰车桥公司的前桥制动性能研究、检测与生产一体化的要求，结合汽车制动原理和当前台式检测的特点，开展了以下几个方面的研究工作：
(1)制动装置理论分析。从制动装置的结构、工作原理出发，分析了制动器和制动气室的有关理论。
(2)制动装置建模及分析。应用制动装置有关理论建立制动器和气室的模型以及装置的耦合模型。利用Matlab分析了气室以及制动装置的工作特性和重要影响因素。
(3)台架制动性能检测系统的开发。根据制动装置的特点、相关工作特性和惯性式台架检测的特点，提出了在生产线领域的台式检测方案。然后从系统总体要求出发，给出机械模拟实现方法，以及进行系统硬件和系统软件以及检测流程等设计。
(4)结合模型分析检测结果。比较理想模型和检测结果，分析出模型与实际结果的差别；给出弥补模型缺陷的方法，并解释检测结果的各种现象。并结合实际技术指标评判检测结果，提出借鉴意见。
在研究工作的进行中，同时也取得了一些重要的结果。例如，制动器和制动气室的工作特性及一些重要影响参数，制动装置良好的耦合性能；进而发现改变气压法来改变附着系数的办法，为制动装置的检测方法提供了新方法；结合变频技术，将惯性滚筒式方法进行改造并应用于在线检测；在结果与模型的比较中，得出了弥补响应延时缺陷的经验法。在技术指标和检测结果的分析中，提出计算的实用方法和装置改进措施，从而将检测研究紧密的结合起来。
Electronic of braking system has become a distinct trend at present. However, electronic facility should be equipped with reliable braking executive mechanism. It is indicated by research that the result of usage of electronic equipment would be even worse than without using it unless appropriate executive mechanism has been employed. On the other hand, large-tonnage & high-speed & high-powered has increasingly become the trend of vehicle transportation as a result of enhancement of transportation construction and logistics. People have to strengthen the research and test on principle and mechanism of automobile's braking system with the increasingly distinctness of vehicle's safety problem. Continuous improvement of structure and performance are required to adjust to the various working condition of vehicles.
Having aimed at braking performance of front axle and requirement of integration of test & produce in Northern Benz Axle Corporation, this thesis has carried some research with the discussion of vehicle's braking principle and platform's testing characteristic. The main content of this paper are as follows:
(1) Theoretical analysis of braking mechanism. Having based on the structure and principle of braking structure, this thesis has analyzed some relevant theories on arrester and gas chamber of arrester.
(2) Modeling and analysis of braking mechanism. Models of arrester and gas chamber have been established with the application of theories of braking mechanism. Working performance and important influencing factors of braking performance have been analyzed with the utility of Matlab.
(3) Development of braking performance testing system. Based on the characteristics of braking mechanism and inertial platform testing, this paper has brought forward the testing scheme in product line field. Realization methods of mechanical simulation, design of hardware & software and testing flow are put forward on the basis of the requirement of system's overall requirement.
(4) Analysis of testing result combined with model. Having compared ideal model with testing result, this paper has analyzed the distinction between ideal result and actual result. This thesis also has provided with the methods of remedy of model's defect and explanations of various phenomenon in testing result. Some suggestions are raised on the basis of practical & technical testing result.
Also, some important results are achieved in the process of research work. For instance, the performance characteristics and some important influencing factors of arrester and gas chamber of arrester, coupling performance of braking mechanism; discovery of new methods(change gas pressure) to change adhesive coefficient, new testing methods are provided with for braking mechanism; Inertial roller method has been rebuilt to be used in online testing; Experiential method has been achieved to remedy the responsive delay defect on the basis of the comparison between result and model. Having analyzed the technical parameters and testing result, this paper has brought forward the applied calculating methods and improving measures of mechanism. Therefore, testing and research have been tightly combined.
引文
[1] 余志生．汽车理论(第三版)[M]．北京：机械工业出版社，2000．
[1] 程国华．汽车制动系统发展漫谈．汽车运用[J]，2003(06)．
[2] 程军。重型车制动技术的发展趋势[J]．汽车研究与开发，1995(02)
[3] 马文席，刘继锋。从ABS防抱死系统到ASR、ESP[J]．实用汽车技术，2006(04)
[4] 李君．车辆ABS控制系统快速开发研究[D]．上海交通大学机械与动力工程学院，2002．
[5] 孙仁云，郭辛，龙行现．基于门限值控制的汽车ABS控制器的研制[J]．西南交通大学学报，2003(04)
[6] 赵治国．车辆动力学及其非线性控制理论技术的研究[D]．西北工业大学机械工程学院，2002．
[7] ZHU Weixing, CHEN Yinchang. Application and simulation of automotive ABS using fuzzy PID control[J]. Journal of Jiangsu University: Natural Science Edition, 2004 (04)
[8] 孙骏．基于模糊控制的汽车防抱制动系统仿真[J]．计算机仿真，2004(10)
[9] Lee Yonggon, Zak Stanislaw H. Designing a genetic neural lhzzy antilock Brake system controller[J]. IEEE Transactions on Evolutionary Compution[J], 2002 (02)
[10] Kokes, Guy, Singh, etal. Adaptive fuzzy logic control of an anti-lock braking system [C]. IEEE Conference on Control Applications Proceedings. Kohala Coast, USA: [S. n.]1999.
[11] 侯光钰，张为公．防抱死制动系统的滑模变结构控制[J]．测控技术，2004(10)
[12] 宋健，李永．汽车防抱死制动系统控制方法的研究进展[J]．公路交通科技，2002(12)
[13] 宋健，陈在峰．制动器耗散功率最大化目标的ABS控制方法[J]．清华大学学报(自然科学版)，1997(12)
[14] 中华人民共和国国家质量监督检验检疫总局，GB7258—2004《机动车运行安全技术条件》，中华人民共和国国家标准，北京：人民交通出版社，2005．
[15] 刘建农，基于车轮制动力测量系统评价汽车制动性能[D]。吉林大学博士学位论文，2005
[16] 刘君华．现代检测技术与测试系统设计[M]．西安：西安交通大学出版社，1999
[17] 林荣会，刘明美．制动器试验台中模拟负载的新方法[J]．机械科学与技术，1997(06)
[18] 徐光泉．汽车制动试验台数据采集处理系统研制[D]．硕士学位论文，吉林大学，2005
[19] 秦文虎．汽车制动系统试验装置的开发及应用[J]．试验测试，2003(02)
[20] national highway tracffic satety administration. federal motor vehicle safety standards, hydrsulic brake system.passenger car brake systems.detroit, federal register, 1985
[21] 周德光，陶素连等。滚筒制动实验台和平板制动实验台德受力模型建立及其分析[J]。机械设计与制造，2005
[22] 冯晋祥等一种检验汽车制动性能新方法[J]．山东交通学院学报，2002
[23] 周德光，陶素连，李卫民．滚筒制动试验台和平板制动试验台的受力模型建立及分析[J]．机械设计与制造，2005(01)
[24] 刘跃明．滚筒试验台检测能力分析[J]．农机化研究，2005(01)
[25] 徐礼超．汽车制动试验台存在的问题及其改进[J]．公路与汽车，2003(04)
[26] 余志生．汽车理论(第三版)[M]．北京：机械工业出版社，2000．
[27] (英)T．P纽康姆等．汽车制动文集[M]．北京：人民交通出版社，1984．
[28] (美)鲁道夫．汽车制动系统的分析与设计[M]．北京：机械工业出版社．1985．
[29] H. Strien, Computation and Testing of Automotive Brakes, Dissertation, Technical University, Braunschweig, Germany, 1949
[30] 王涛，朱文坚．摩擦制动器—原理、结构与设计[M]．广州：华南理工大学出版社，1992．
[31] (苏)马什克，罗扎诺夫．汽车的制动系[M]．北京：人民交通出版社，1980．
[32] 潘锦珊．气体动力学基础(第二版)[M]．北京：国防工业出版社，1995．
[33] 马恩，李素敏．制动气室有效承压面积的研究[J]．中国农机化，2005(06)．
[34] 刘振华．3t汽车用储能弹簧制动气室的设计与试验分析[J]．湖北汽车，2000(04)．
[35] 马恩，武华，李素敏，郭松战．拖拉机挂车制动气室推力的试验研究[J]．农业机械学报，1999(01)．
[36] 程军，袁金光．载重车气制动气室建模的研究[J]．陕西汽车，1995(02)．
[37] 黄声显．重型汽车制动系[M]．北京：人民交通出版社，1987．
[38] 刘秋生，阮宏雁．气制动系统特性试验台设计和研究[J]．中国机械工程，1995(06)．
[39] 李鸿吉．Visual Basic 6.0编程方法详解[M]．北京：科学出版社，2001．
[40] F.sido, "analysis of the response characteristics of Pneumatic Brake Systems Through-Model Test", Automobiltechnische Zeitschrift, Vol. 71, No. 3, 1969.
[41] M. Mueller, G. P. Ostermeyer. Cellular automata method for macroscopic surface and friction dynamics in brake systems. Tribology International, Volume 40, Issue 3, 2007
[42] Masaharu Harada, Katsushi Matsuda, etc. A study on the brake characteristics for full air brake system of heavy duty vehicles. JSAE Review, Volume 18, Issue 2, April 1997
[43] V. A. SAMSONOV. THE DYNAMICS OF BRAKE SHOE AND "IMPACT GENERATED BY FRICTION". Volume 69, Issue 6, Nov 2005
[1] 程国华．汽车制动系统发展漫谈．汽车运用[J]，2003(06)．
[2] 程军。重型车制动技术的发展趋势[J]．汽车研究与开发，1995(02)
[3] 马文席，刘继锋。从ABS防抱死系统到ASR、ESP[J]．实用汽车技术，2006(04)
[4] 李君．车辆ABS控制系统快速开发研究[D]．上海交通大学机械与动力工程学院，2002．
[5] 孙仁云，郭辛，龙行现．基于门限值控制的汽车ABS控制器的研制[J]．西南交通大学学报，2003(04)
[6] 赵治国．车辆动力学及其非线性控制理论技术的研究[D]．西北工业大学机械工程学院，2002．
[7] ZHU Weixing, CHEN Yinchang. Application and simulation of automotive ABS using fuzzy PID control[J]. Journal of Jiangsu University: Natural Science Edition, 2004 (04)
[8] 孙骏．基于模糊控制的汽车防抱制动系统仿真[J]．计算机仿真，2004(10)
[9] Lee Yonggon, Zak Stanislaw H. Designing a genetic neural lhzzy antilock Brake system controller[J]. IEEE Transactions on Evolutionary Compution[J], 2002 (02)
[10] Kokes, Guy, Singh, etal. Adaptive fuzzy logic control of an anti-lock braking system [C]. IEEE Conference on Control Applications Proceedings. Kohala Coast, USA: [S. n.]1999.
[11] 侯光钰，张为公．防抱死制动系统的滑模变结构控制[J]．测控技术，2004(10)
[12] 宋健，李永．汽车防抱死制动系统控制方法的研究进展[J]．公路交通科技，2002(12)
[13] 宋健，陈在峰．制动器耗散功率最大化目标的ABS控制方法[J]．清华大学学报(自然科学版)，1997(12)
[14] 中华人民共和国国家质量监督检验检疫总局，GB7258—2004《机动车运行安全技术条件》，中华人民共和国国家标准，北京：人民交通出版社，2005．
[15] 刘建农，基于车轮制动力测量系统评价汽车制动性能[D]。吉林大学博士学位论文，2005
[16] 刘君华．现代检测技术与测试系统设计[M]．西安：西安交通大学出版社，1999
[17] 林荣会，刘明美．制动器试验台中模拟负载的新方法[J]．机械科学与技术，1997(06)
[18] 徐光泉．汽车制动试验台数据采集处理系统研制[D]．硕士学位论文，吉林大学，2005
[19] 秦文虎．汽车制动系统试验装置的开发及应用[J]．试验测试，2003(02)
[20] national highway tracffic satety administration. federal motor vehicle safety standards, hydrsulic brake system.passenger car brake systems.detroit, federal register, 1985
[21] 周德光，陶素连等。滚筒制动实验台和平板制动实验台德受力模型建立及其分析[J]。机械设计与制造，2005
[22] 冯晋祥等一种检验汽车制动性能新方法[J]．山东交通学院学报，2002
[23] 周德光，陶素连，李卫民．滚筒制动试验台和平板制动试验台的受力模型建立及分析[J]．机械设计与制造，2005(01)
[24] 刘跃明．滚筒试验台检测能力分析[J]．农机化研究，2005(01)
[25] 徐礼超．汽车制动试验台存在的问题及其改进[J]．公路与汽车，2003(04)
[26] 余志生．汽车理论(第三版)[M]．北京：机械工业出版社，2000．
[27] (英)T．P纽康姆等．汽车制动文集[M]．北京：人民交通出版社，1984．
[28] (美)鲁道夫．汽车制动系统的分析与设计[M]．北京：机械工业出版社．1985．
[29] H. Strien, Computation and Testing of Automotive Brakes, Dissertation, Technical University, Braunschweig, Germany, 1949
[30] 王涛，朱文坚．摩擦制动器—原理、结构与设计[M]．广州：华南理工大学出版社，1992．
[31] (苏)马什克，罗扎诺夫．汽车的制动系[M]．北京：人民交通出版社，1980．
[32] 潘锦珊．气体动力学基础(第二版)[M]．北京：国防工业出版社，1995．
[33] 马恩，李素敏．制动气室有效承压面积的研究[J]．中国农机化，2005(06)．
[34] 刘振华．3t汽车用储能弹簧制动气室的设计与试验分析[J]．湖北汽车，2000(04)．
[35] 马恩，武华，李素敏，郭松战．拖拉机挂车制动气室推力的试验研究[J]．农业机械学报，1999(01)．
[36] 程军，袁金光．载重车气制动气室建模的研究[J]．陕西汽车，1995(02)．
[37] 黄声显．重型汽车制动系[M]．北京：人民交通出版社，1987．
[38] 刘秋生，阮宏雁．气制动系统特性试验台设计和研究[J]．中国机械工程，1995(06)．
[39] 李鸿吉．Visual Basic 6.0编程方法详解[M]．北京：科学出版社，2001．
[40] F.sido, "analysis of the response characteristics of Pneumatic Brake Systems Through-Model Test", Automobiltechnische Zeitschrift, Vol. 71, No. 3, 1969.
[41] M. Mueller, G. P. Ostermeyer. Cellular automata method for macroscopic surface and friction dynamics in brake systems. Tribology International, Volume 40, Issue 3, 2007
[42] Masaharu Harada, Katsushi Matsuda, etc. A study on the brake characteristics for full air brake system of heavy duty vehicles. JSAE Review, Volume 18, Issue 2, April 1997
[43] V. A. SAMSONOV. THE DYNAMICS OF BRAKE SHOE AND "IMPACT GENERATED BY FRICTION". Volume 69, Issue 6, Nov 2005