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.

One of the benefits of electric vehicles (EVs) and hybrid vehicles (HVs) is their potential to recuperate braking energy. Regenerative braking (RB) will minimize duty levels on the brakes, giving advantages including extended brake rotor and friction material life and, more significantly, reduced...

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Bibliographic Details
Main Author: Sarip, S. Bin
Other Authors: Day, Andrew J.
Language:en
Published: University of Bradford 2012
Subjects:
Online Access:http://hdl.handle.net/10454/5486
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spelling ndltd-BRADFORD-oai-bradscholars.brad.ac.uk-10454-54862019-08-31T03:02:55Z 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. Sarip, S. Bin Day, Andrew J. Olley, Peter Qi, Hong Sheng Brakes Friction Regenerative braking Automotive Modelling Thermal Finite element analysis Lightweight Hybrid electric drive One of the benefits of electric vehicles (EVs) and hybrid vehicles (HVs) is their potential to recuperate braking energy. Regenerative braking (RB) will minimize duty levels on the brakes, giving advantages including extended brake rotor and friction material life and, more significantly, reduced brake mass and minimised brake pad wear. In this thesis, a mathematical analysis (MATLAB) has been used to analyse the accessibility of regenerative braking energy during a single-stop braking event. The results have indicated that a friction brake could be downsized while maintaining the same functional requirements of the vehicle braking in the standard brakes, including thermomechanical performance (heat transfer coefficient estimation, temperature distribution, cooling and stress deformation). This would allow lighter brakes to be designed and fitted with confidence in a normal passenger car alongside a hybrid electric drive. An approach has been established and a lightweight brake disc design analysed FEA and experimentally verified is presented in this research. Thermal performance was a key factor which was studied using the 3D model in FEA simulations. Ultimately, a design approach for lightweight brake discs suitable for use in any car-sized hybrid vehicle has been developed and tested. The results from experiments on a prototype lightweight brake disc were shown to illustrate the effects of RBS/friction combination in terms of weight reduction. The design requirement, including reducing the thickness, would affect the temperature distribution and increase stress at the critical area. Based on the relationship obtained between rotor weight, thickness and each performance requirement, criteria have been established for designing lightweight brake discs in a vehicle with regenerative braking. Ministry of Higher Education of Malaysia 2012-11-02T17:53:39Z 2012-11-02T17:53:39Z 2012-11-02 2011 Thesis doctoral PhD http://hdl.handle.net/10454/5486 en <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/"><img alt="Creative Commons License" style="border-width:0" src="http://i.creativecommons.org/l/by-nc-nd/3.0/88x31.png" /></a><br />The University of Bradford theses are licenced under a <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/">Creative Commons Licence</a>. University of Bradford School of Engineering, Design and Technology
collection NDLTD
language en
sources NDLTD
topic Brakes
Friction
Regenerative braking
Automotive
Modelling
Thermal
Finite element analysis
Lightweight
Hybrid electric drive
spellingShingle Brakes
Friction
Regenerative braking
Automotive
Modelling
Thermal
Finite element analysis
Lightweight
Hybrid electric drive
Sarip, S. Bin
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.
description One of the benefits of electric vehicles (EVs) and hybrid vehicles (HVs) is their potential to recuperate braking energy. Regenerative braking (RB) will minimize duty levels on the brakes, giving advantages including extended brake rotor and friction material life and, more significantly, reduced brake mass and minimised brake pad wear. In this thesis, a mathematical analysis (MATLAB) has been used to analyse the accessibility of regenerative braking energy during a single-stop braking event. The results have indicated that a friction brake could be downsized while maintaining the same functional requirements of the vehicle braking in the standard brakes, including thermomechanical performance (heat transfer coefficient estimation, temperature distribution, cooling and stress deformation). This would allow lighter brakes to be designed and fitted with confidence in a normal passenger car alongside a hybrid electric drive. An approach has been established and a lightweight brake disc design analysed FEA and experimentally verified is presented in this research. Thermal performance was a key factor which was studied using the 3D model in FEA simulations. Ultimately, a design approach for lightweight brake discs suitable for use in any car-sized hybrid vehicle has been developed and tested. The results from experiments on a prototype lightweight brake disc were shown to illustrate the effects of RBS/friction combination in terms of weight reduction. The design requirement, including reducing the thickness, would affect the temperature distribution and increase stress at the critical area. Based on the relationship obtained between rotor weight, thickness and each performance requirement, criteria have been established for designing lightweight brake discs in a vehicle with regenerative braking. === Ministry of Higher Education of Malaysia
author2 Day, Andrew J.
author_facet Day, Andrew J.
Sarip, S. Bin
author Sarip, S. Bin
author_sort Sarip, S. Bin
title 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.
title_short 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.
title_full 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.
title_fullStr 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.
title_full_unstemmed 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.
title_sort 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.
publisher University of Bradford
publishDate 2012
url http://hdl.handle.net/10454/5486
work_keys_str_mv AT saripsbin lightweightfrictionbrakesforaroadvehiclewithregenerativebrakingdesignanalysisandexperimentalinvestigationofthepotentialformassreductionoffrictionbrakesonapassengercarwithregenerativebraking
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