Design and Preliminary Experimental Tests of an Innovative Test Bench for Zero Emission Braking System
摘要
In response to the imperative for emission reduction within the automotive sector, the pursuit of advanced braking technologies has intensified. As the automotive market strives to curtail secondary emissions, innovative braking solutions emerge as pivotal responses to this pressing need. Crucially, ensuring the functionality and reliability of these new braking systems necessitates a comprehensive validation process. This paper presents a zero-emission innovative Magneto Rheological braking system specifically designed for automotive applications. The proposed system is subjected to thorough analysis, elucidating its unique design features optimized for high automotive performance. A central aspect of this analysis involves the development of a test bench explicitly engineered for assessing and validating the Magneto Rheological braking technology. In particular, detailed insights into the comprehensive strategy underpinning the design of the test bench are provided, emphasizing its capacity to faithfully replicate diverse driving scenarios and evaluate multiple braking performances. After a preliminary virtual validation procedure, the first brake prototype solution, which is made by an electric in-wheel motor with the innovative braking system integrated (in this first step the prototype regards to a single wheel) have to undergo testing on a dedicated test bench. The primary objective of the experimental tests is to verify the braking performance in terms of peak torque and reliability of the braking system. The test bench has been designed to be integrated in a dedicate infrastructure of Politecnico enables testing cycles required by international regulations as well as non-standard driving cycles, such as those obtained by road testing to validate control strategies of the energy management system by measuring consumption, efficiencies, and emissions. The infrastructure is also equipped with a driving simulator interface system and external simulation models to validate, for example, autonomous driving technologies as well as their impact on energy consumption and emissions. Furthermore, the paper presents in detail the defined testing protocols essential for ensuring the functionality of the Magneto Rheological braking system. Preliminary results gleaned from these assessments are presented, offering discerning glimpses into the system’s performance attributes and potential effectiveness. Moreover, the structured testing plan followed to ascertain the functionality and reliability of the braking system is presented. In the context of developing a novel braking technology, the preservation of safety features and performance integrity remains paramount. Through the comprehensive analyses presented in this paper, stakeholders can effectively evaluate the innovative braking solution and gain critical insights into the requisite enhancements needed to transition it into a market-ready product. By adhering to stringent testing homologation and validation procedures, this study advances the theme on automotive braking technologies, paving the way for the realization of sustainable and efficient solutions aligned with contemporary environmental imperatives.