Lightweight friction brakes for a road vehicle with regenerative braking. Design analysis and experimental investigation of the potential for mass reduction of friction brakes on a passenger car with regenerative braking.

摘要

One of the benefits of electric vehicles (EVs) and hybrid vehicles (HVs) isudtheir potential to recuperate braking energy. Regenerative braking (RB) willudminimize duty levels on the brakes, giving advantages including extendedudbrake rotor and friction material life and, more significantly, reduced brakeudmass and minimised brake pad wear. In this thesis, a mathematical analysisud(MATLAB) has been used to analyse the accessibility of regenerative brakingudenergy during a single-stop braking event. The results have indicated that audfriction brake could be downsized while maintaining the same functionaludrequirements of the vehicle braking in the standard brakes, includingudthermomechanical performance (heat transfer coefficient estimation,udtemperature distribution, cooling and stress deformation). This would allowudlighter brakes to be designed and fitted with confidence in a normaludpassenger car alongside a hybrid electric drive. An approach has beenudestablished and a lightweight brake disc design analysed FEA andudexperimentally verified is presented in this research. Thermal performanceudwas a key factor which was studied using the 3D model in FEA simulations.udUltimately, a design approach for lightweight brake discs suitable for use inudany car-sized hybrid vehicle has been developed and tested. The resultsudfrom experiments on a prototype lightweight brake disc were shown toudillustrate the effects of RBS/friction combination in terms of weight reduction.udThe design requirement, including reducing the thickness, would affect theudtemperature distribution and increase stress at the critical area. Based on theudrelationship obtained between rotor weight, thickness and each performanceudrequirement, criteria have been established for designing lightweight brakeuddiscs in a vehicle with regenerative braking.