Real-Time Dynamic Brake Assessment Proof of Concept Final Report PDF Download

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Book Description
This proof-of-concept research was performed to explore the feasibility of using real-world braking data from commercial motor vehicles to make a diagnosis of brake condition similar to that of the performance-based brake tester (PBBT). This was done by determining the relationship between pressure and brake force (P-BF), compensating for the gross vehicle weight (GVW). The nature of this P-BF relationship (e.g., low braking force for a given brake application pressure) may indicate brake system problems. In order to determine the relationship between brake force and brake application pressure, a few key parameters of duty cycle information were collected. Because braking events are often brief, spanning only a few seconds, a sample rate of 10 Hz was needed. The algorithm under development required brake application pressure and speed (from which deceleration was calculated). Accurate weight estimation was also needed to properly derive the braking force from the deceleration. In order to ensure that braking force was the predominant factor in deceleration for the segments of data used in analysis, the data was screened for grade as well. Also, the analysis needed to be based on pressures above the crack pressure. The crack pressure is the pressure below which the individual brakes are not applied due the nature of the mechanical system. This value, which may vary somewhat from one wheel end to another, is approximately 10 psi. Therefore, only pressures 15 psi and above were used in the analysis. The Department of Energy s Medium Truck Duty Cycle research has indicated that under the real-world circumstances of the test vehicle brake pressures of up to approximately 30 psi can be expected. Several different types of data were collected during the testing task of this project. Constant-pressure stopping tests were conducted at several combinations of brake application pressure (15, 20, 25, and 30 psi), load conditions (moderately and fully laden), and speeds (20 and 30 mph). Data was collected at 10 Hz. Standard and stepped-pressure performance-based brake tests with brake pressure transducers were performed for each loading condition. The stepped-pressure test included the constant-pressure intervals of brake application at 15, 20, 25, and 30 psi. The PBBT data files included 10 Hz streaming data collected during the testing of each axle. Two weeks of real-world duty cycle (driving and braking) data was also collected at 10 Hz. Initial analysis of the data revealed that the data collected in the field (i.e., day-to-day operations) provided the same information as that obtained from the controlled tests. Analysis of the data collected revealed a strong linear relationship between brake application pressure and deceleration for given GVWs. As anticipated, initial speed was not found to be a significant factor in the deceleration-pressure relationship, unlike GVW. The positive results obtained from this proof of concept test point to the need for further research to expand this concept. A second phase should include testing over a wider range of speeds and include medium brake application pressures in addition to the low pressures tested in this research. Testing on multiple vehicles would also be of value. This future phase should involve testing to determine how degradation of braking performance affects the pressure-deceleration relationship.