Virtual Verification of Complete Vehicle Requirements for Heavy Vehicles for Development of Brake Systems

Abstract

Heavy vehicles mainly have electronic controlled pneumatically actuated braking systems or the EBS systems. Developments are carried out in this sector to improve the braking performances of these vehicles as well as costs and their ability to be integrated with other vehicle functions. Subsystem manufactures which mainly works on the braking systems, came up with the idea of fast actuators or advanced actuation system, which substantially reduces the braking distances of heavy vehicles. The main aim of this thesis is to develop simulation tools and methods for the development of control system and actuation system of brake systems. Vehicles as a whole is a complex product. Different subsystem manufacturers and vehicle manufacturers have to collaborate to develop a vehicle. Traditionally, prototypes were built for development and testing of technical solutions. With the advancement of technology, CAE tools are used for development of technical solutions before the testing can start. This virtual testing has reduced the time for development and also cost. This thesis focuses on the development process for control system of the brake system which comprises of simulation tools that can be used both by the truck manufacturers and also by the subsystem manufacturers to improve the communication between them and hence reduces the development time. IPG TruckMaker is selected as the software to be used for this thesis. A Volvo FH semi-truck was set up which was used for all the simulations. Vehicle maneuvers considered are straight-line braking . Different road frictions are used along with split-mu conditions to get a wide range of results. Basic actuator system and advanced actuator system are types of brakes control system which have been implemented on this heavy vehicle and hence results were obtained.