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KeyTechnologiesandApplicationsofDynamicDesignandEvaluationforFull-FrequencyBandAutomotiveBrakeSystems

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Registration number:G20250457

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Subject classification:

Key words: brake pedal feel Brake squeal car brakes

Green classification:

Publisher:管理人员

Release time:2025-08-09 08:53:31.0

  • Essential information
Name of achievement: KeyTechnologiesandApplicationsofDynamicDesignandEvaluationforFull-FrequencyBandAutomotiveBrakeSystems
Result registration number: G20250457 Subject classification:
Green classification: Item keywords: brake pedal feel  Brake squeal   car brakes    
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Tongji University

The stage of achievement:
Mode of cooperation: JointVentureandCooperation Outcome Information:
Countries/regions: China Intellectual property rights: Invention patent, others
Introduction: Click to view
The project belongs to the key component development technology field of automotive engineering in the transportation industry. The braking system is one of the core assemblies of a car and is crucial for driving safety and comfort. With the increasing demands for car quality and user experience, ultra-low frequency brake pedal feel (0-5Hz), low frequency brake chatter (0-200Hz), medium frequency brake vibration (50-1kHz), and high frequency brake squeal (1k-16kHz) have always been at the forefront of car user quality complaints, posing a challenging technical issue for the entire industry globally. This project focuses on the technical difficulties of 'evaluation diagnosis' and 'design control' in the above issues, independently overcoming object-oriented full-band automotive braking system dynamic design and evaluation key technologies. The overall technology is internationally advanced, with some being world firsts, effectively supporting the new pattern of positive development in China's automotive braking system from following to leading. The innovation points are as follows: (1) Facing the two major difficulties of poor correlation between subjective and objective evaluations of brake pedal feel and weak correlation between structural parameters and objective indicators, an independent hierarchical analysis-based interconnection evaluation technology for static/dynamic subjective and objective indicators of brake pedal feel was established. A world-first gas-liquid-solid multiphase nonlinear parameterization brake pedal feel prediction model and design matching technology were developed, successfully achieving effective substitution of objective evaluation tests for subjective evaluation tests. The development cycle was shortened by more than 60%, the model prediction accuracy exceeded The vehicle multi-level test specifications and evaluation methods, the international first integrated brake finite element thermal-mechanical coupling model and chassis torsional stiffness-flexural coupling model's heat jitter joint simulation technology, as well as the driving torque active compensation braking jitter control method, have formed a complete path of brake heat jitter test specifications. The model prediction accuracy has reached over 90%, and the number of faults per hundred vehicles has been reduced by 52%. (3) In response to the challenges of unclear understanding of the mechanisms behind brake chatter excitation, low prediction technology accuracy, and high cost of control measures, we have independently developed a brake chatter test bench and road test specifications as well as a nonlinear non-steady state feature extraction and evaluation method. We have also pioneered the dual-action coupling mechanism of small-scale stick-slip vibration in brakes and large-scale bow-shaped deformation in suspension systems, as well as object-oriented multi-dimensional multi-scale simulation technology. We were among the first to propose passive control methods without additional mass and active control methods that do not require replacement of friction materials. The prediction accuracy has reached over 90%, which is equivalent to the control effect of adding an additional 13.3kg abroad. (4) In response to the challenges of evaluating and predicting the time-varying nature and uncertainty of brake squeal, we have innovatively proposed the concept of system dynamic friction coefficient under high-frequency frictional vibration conditions and its identification method. We have also established a time-varying evaluation index system for brake squeal with a high-efficiency transient simulation model, an uncertainty evaluation index system for brake squeal with a finite element prediction model, and robust design methods. The computational efficiency has increased by more than 20,000 times, and the incidence rate has been reduced by more than 40.7%. This project has obtained 16 invention patents, 6 industry standards, 68 utility model patents, 11 software copyright registrations, and published 56 SCI/EI papers. The project's achievements have been widely applied in 6 component/vehicle enterprises including Shanghai Automotive Brake System Co., Ltd. and Shanghai Huizong Automobile Manufacturing Co., Ltd. In the past three years, direct added value has reached 1.3225 billion yuan, profit of 119 million yuan, export earnings of 1.768 million US dollars; indirect added value is 395 million yuan and export earnings are 14.256 million US dollars, with significant economic benefits. It has promoted the independent development capability of China's automotive braking system core technology and formed a good international influence and reputation.
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