Session: 08-01-01: Environmental Impact of Energy Systems, Components Optimization, and AI for Energy Systems

Paper Number: 144856

144856 - Design and Preliminary Test of an Innovative Test Bench for Zero Emission Braking System 

In response to the imperative for emission reduction within the automotive sector, the pursuit of advanced braking technologies has intensified. As the automotive market strives to curtail secondary emissions, innovative braking solutions emerge as pivotal responses to this pressing need. Crucially, ensuring the functionality and reliability of these braking systems necessitates a comprehensive validation process.

This paper presents a zero emission innovative Magneto Rheological braking system specifically designed for automotive applications. The proposed system is subjected to thorough analysis, elucidating its unique design features meticulously optimized for significant automotive performance. A central aspect of this analysis involves the development of a bespoke test bench explicitly engineered for assessing and validating the Magneto Rheological braking technology. Detailed insights into the comprehensive strategy underpinning the design of the test bench are provided, emphasizing its innate capacity to faithfully replicate diverse driving scenarios and meticulously evaluate multiple braking performances.

After a preliminary virtual validation procedure, the first prototype solution, which is made by an electric in-wheel motor with the innovative braking system integrated (in this first step the prototype regards to a single wheel) must undergo rigorous testing on a dedicated test bench. The primary objective of this testing regimen is to verify the braking performances in terms of peak torque and reliability of the innovative braking system.

The test beach has been designed to be integrated in a dedicate infrastructure of Politecnico enables testing cycles required by international regulations as well as non-standard driving cycles, such as those obtained by road testing to validate control strategies of the energy management system by measuring consumption, efficiencies and emissions. In fact, the infrastructure is equipped with measurement systems of fuel and pollutants, mechanical power to the wheels and electric power. The infrastructure is also equipped with a driving simulator interface system and external simulation models to validate assisted and autonomous driving technologies as well as their impact on energy consumption and emissions.

Furthermore, the paper presents in details the defined testing protocols essential for ensuring the functionality of the Magneto Rheological braking system. Preliminary results gleaned from these assessments are presented, offering discerning glimpses into the system's performance attributes and potential effectiveness. Moreover, the paper outlines the structured testing plan followed to ascertain the functionality and reliability of the braking system.

In the context of developing a novel braking technology, the preservation of safety features and performance integrity remains paramount. Through the comprehensive analyses presented in this paper, stakeholders can effectively evaluate the innovative braking solution and gain critical insights into the requisite enhancements needed to transition it into a market-ready product. By adhering to stringent testing protocols and meticulous validation procedures, this study advances the discourse on automotive braking technologies, paving the way for the realization of sustainable and efficient solutions aligned with contemporary environmental imperatives.

Presenting Author: Massimiliana Carello Politecnico di Torino

Presenting Author Biography: Associate Professor at the Mechanical and Aerospace Engineering Department - Politecnico of Torino. She gives courses and lessons of: Impostazione progettuale dell’autoveicolo and The future E-mobility.
Responsible of Research Group of “Innovative Electric and Hybrid Vehicle”, with 10 phD students and research fellows.
The research activity has been developed in the Automotivefields, in cooperation with companies, with specific research project and in National, Regional Programs and European Project. In particular the Automotive applications are relative to: vehicle dynamics and regenerative braking, NVH analysis, innovative aerodynamic integration, electric and hybrid solutions for low consumption vehicle, fuel cell and battery control/applications, composite materials for automotive and/or structural applications.
The approach, usually, follows the main steps: model development, virtual testing, laboratory validation for sub-system and validation on track for full vehicle, to validate the performance in terms of vehicle dynamics, control strategies and consumption.
Co-founder of Beond a Spin off of the Politecnico of Torino, now innovative PMI company, that now has 40 employers (almost all engineers).
Co-inventor of 6 patents and author of more than 180 scientific papers presented in international conferences or published in international journals.
Faculty Advisor of Team H2politO (composed by 80 students) that design, build and test vehicles prototype to partecipe at the Shell Eco-marathon competition. She followed design and testing of eight vehicles.

Authors:

Massimiliana Carello Politecnico di Torino
Giovanni Imberti Politecnico di Torino
Henrique De Carvalho Pinheiro Politenico di Torino