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Research on brake thermal fade compensation control strategy for multi-axle electric vehicles

Author

Listed:
  • Xu, Shiwei
  • Wang, Wuzhi
  • Li, Xuebo
  • Zhao, Xuan

Abstract

Thermal fade in braking systems significantly compromises vehicle safety and stability. To address the rapid decline in braking efficiency in multi-axle electric vehicles due to thermal degradation in either motor or friction brake systems, this study investigates a five-axle vehicle equipped with a composite braking system. A thermally coupled mechanical-electric braking model is developed, incorporating both the temperature field of the brake disc and the heat dissipation of the motor brake. Furthermore, a compensation control strategy is proposed, which prioritizes regenerative braking and implements closed-loop pressure regulation of the friction brake, guided by dynamic axle load distribution and the mapped relationship among temperature, friction coefficient, and braking torque. By reconstructing the braking torque in real time, the strategy mitigates braking force attenuation under thermal fade conditions. The effectiveness of the proposed control strategy is evaluated through hardware-in-the-loop (HIL) simulations under various driving scenarios. Results demonstrate that, compared to a non-compensated strategy, braking times in the proposed method are reduced by 0.071 s, 0.220 s, and 0.490 s under normal, motor-limited, and emergency braking conditions, respectively. Meanwhile, braking distances in the proposed method are shortened by 0.964 m, 1.512 m, and 3.069 m, respectively. These findings confirm that the proposed thermal fade compensation strategy for multi-axle electric vehicles can significantly enhance braking performance stability while ensuring maximum energy recovery.

Suggested Citation

  • Xu, Shiwei & Wang, Wuzhi & Li, Xuebo & Zhao, Xuan, 2025. "Research on brake thermal fade compensation control strategy for multi-axle electric vehicles," Energy, Elsevier, vol. 341(C).
    • Handle: RePEc:eee:energy:v:341:y:2025:i:c:s0360544225050844
    DOI: 10.1016/j.energy.2025.139442
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    References listed on IDEAS

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    1. Xiong, Siqin & Wang, Yunshi & Bai, Bo & Ma, Xiaoming, 2021. "A hybrid life cycle assessment of the large-scale application of electric vehicles," Energy, Elsevier, vol. 216(C).
    2. Tang, Qingsong & Yang, Yang & Luo, Chang & Yang, Zhong & Fu, Chunyun, 2022. "A novel electro-hydraulic compound braking system coordinated control strategy for a four-wheel-drive pure electric vehicle driven by dual motors," Energy, Elsevier, vol. 241(C).
    3. He, Qiang & Yang, Yang & Luo, Chang & Zhai, Jun & Luo, Ronghua & Fu, Chunyun, 2022. "Energy recovery strategy optimization of dual-motor drive electric vehicle based on braking safety and efficient recovery," Energy, Elsevier, vol. 248(C).
    4. Bravo, Rafael Rivelino da Silva & Gama, Artur Tozzi de Cantuaria & Oliveira, Amir Antonio Martins & De Negri, Victor Juliano, 2023. "Component sizing and sensitivity analysis of design parameters of a hydraulic-pneumatic regenerative braking system for heavy duty vehicles," Energy, Elsevier, vol. 264(C).
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