智能汽车集成式线控制动系统传动机构优化设计

随着汽车智能驾驶技术的快速发展，线控技术正加速制动助力系统和主动制动系统向电气化和集成化方向发展。在介绍国际知名厂商研发的制动助力和主动制动二合一集成系统(One Box)产品及其传动机构特点后，提出了基于单电机+双作用制动缸构型的集成式线控制动系统，相较传统助力器(booster)+汽车电子稳定控制系统(Electronic stability controller，ESC)的组合系统，能够更好地满足汽车对制动系统功能、空间等设计需求。传动机构能够降速增扭、运动副转换，是集成式线控制动系统主动建压的基础。对比几种传动机构组合的优缺点，基于制动系统的设计指标以及电机性能曲线，建立传动机构的数学模型。基于约束优化设计方法以及Matlab/Simulink与AMESim联合仿真模型和控制器，对传动机构的减速比进行了设计匹配和仿真验证，得到了两组最佳的齿轮副传动比。对两组设计的齿轮副进行了有限元强度校核和疲劳寿命计算，按照有限元仿真结果，推荐传动比为2.4，主动轮齿数15，从动轮齿数36的方案为最优选择。基于理论分析与仿真分析结果，研制了一台样机，并设计开发了专用试验台架，通过台架试验证明了设计方法的可行性，为类似制动系统的优化设计提供了新的思路和参考。

Optimal Designing of Transmission Mechanism in Integrated Brake-by-wire System of Intelligent Vehicles

With the rapid development of intelligent driving technology, wire control technology is pushing brake booster system and active braking system towards electrification and integration. The characteristics of some One Box products integrated by brake booster system and electronic stability control system which produced by international well-known manufacturers are illustrated with examples as well as the transmission mechanism. An integrated brake-by-wire system based on single motor and bi-directional acting brake cylinder is proposed, compared with the traditional system combined by booster and ESC, this integrated Brake-by-Wire system can meet the function and space requirements more properly. The transmission mechanism can reduce the speed and increase the torsion and convert the motion type, which is the basis of the active pressure control of the integrated brake-by-wire system. By comparing the advantages and disadvantages of some transmission mechanism, the transmission mechanism mathematic model is established based on the braking objectives and motor performance. After calculation and simulation, two optimized transmission ratios are obtained with the help of constraint optimization method as well as the co-simulation model and controller created by Matlab/Simulink and AMESim. According to the finite element analysis results, the recommended parameters: the transmission ratio is 2.4, the number of driving gear teeth is 15, and the number of driven gear teeth is 36, which provides a favorable reference for production and application. Based on the results of theoretical analysis and simulation analysis, a prototype was developed, and a special test bench was designed and developed. The feasibility of the design method was proved by bench test, which provides a new idea and reference for the optimization design of similar braking system.