Braking Systems

Testing electronic braking systems using realistic braking forces

For testing complete electronic braking systems and their individual power electronic components under realistic operating conditions, we offer a wide range of test systems, including test benches with real braking system components.

Challenges

Braking systems require highly dynamic mechatronic test benches for extensive testing.

A wide range of technologies and concepts is available for vehicle braking systems. When it comes to electric (EV) and hybrid electric vehicles (HEV), the concept of regenerative braking is one of them. While braking, the vehicle’s electric traction motor turns into a generator, which converts the kinetic energy from the wheels into electric energy to be stored for later use. Another concept is brake-by-wire: Here, the brakes are operated by electronically controlled electric drives with no mechanical connection between the braking actuators on each wheel and the brake pedal.

In addition, today's braking systems include a brake booster, which reduces the required braking effort to assist the driver while braking. With the increasing acceptance of HEVs and EVs on the market, electric brake boosters are progressively replacing the conventional mechanical vacuum brake boosters thanks to their ability to recuperate a significant percentage of the traction motor’s braking energy. These systems must be designed in such a way that the brake discs can immediately support the braking process if the electrical energy is not sufficient. For this purpose, the electronic brake booster crossfades the braking energy between the electric traction motor and the brake discs. This crossfade must be implemented very smoothly so that the brake system behaves similarly during energy recovery and conventional braking.

When it comes to testing these complex systems, comprehensive validation is key to ensure their proper operation. Purely simulation-based approaches like software-in-the-loop (SIL), hardware-in-the-loop (HIL), and power HIL testing need to be complemented by highly dynamic mechatronic test benches to ensure that all components under test behave realistically. Test benches for braking systems must therefore be equipped with real parts, such as brake boosters, electronic parking brakes, brake calipers, or brake discs. Linear motors can be added to the test setup to simulate the driver’s leg while braking. 

dSPACE Solution

We provide the appropriate test bench for your braking system, for example, by integrating a driving simulator into the test setup for an electric brake booster.

dSPACE offers a wide range of solutions for signal and power level testing for the electric motors of braking systems. When it comes to testing electronic braking systems under realistic operating conditions, dSPACE even provides you with test benches that include real brake components, such as electromechanical brake boosters or the complete hydraulic braking system. These braking test benches let you create the perfect test environment for virtual test drives to evaluate and analyze the real braking system with different control and function algorithms at an early stage. For this purpose, the vehicle dynamics are simulated and the effective braking forces are applied to the brake by a brake robot. This brake robot is usually designed as a direct linear motor. We also provide the required equipment for man-in-the-loop testing, which lets you feel the real system behavior, for example, by receiving real feedback from the brake pedal. 

Selected Use Cases

Production Software for Safety-Related E-Mobility Applications

Transfer function models to production code efficiently and in compliance with safety standards.

Video Erfolgsstorys Anwendungsfälle

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