智能化、电动化为汽车工业带来颠覆性变革，智能新能源汽车成为全球行业竞相角逐的战略高地。底盘线控制动执行系统是其核心部件，而我国长期面临国外核心技术封锁与垄断的困境，成为制约汽车产业自主可控与可持续发展的瓶颈性问题。本文针对智能新能源汽车主动制动、线控制动以及深度制动能量回收三个层次技术需求，开展半解耦式线控制动系统研究，包含线控制动系统建模、结构参数协同优化设计、产品级控制器可靠性设计、系统级精确控制技术实现等。具体内容如下：（1）提出了一种新型半解耦式线控制动系统构型方案，采用非解耦式电动制动助力器与电子稳定控制系统协同的“双核”架构，满足主动制动快速建压以及电制动与机械制动解耦控制需求的同时，实现制动系统安全冗余。并从系统设计角度提出了关键参数协同优化方法，实现了系统功能、性能的综合最优。（2）针对电子控制器严苛的车规级应用需求，设计了产品级线控制动系统嵌入式控制器：研究了降额设计、热设计以及容差分析等可靠性设计技术，解决了永磁同步电机控制器低压大电流工况下的可靠性设计难题。（3）针对线控制动系统主动建压过程的非线性摩擦、液压迟滞等瞬态动力学难题，建立了系统Karnopp摩擦模型以及分段预测控制方法。利用台架实测数据进行了动摩擦与静摩擦参数辨识；考虑制动系统非线性特点，提出了分段线性化技术实现对主缸压力预测控制，动态控制精度优于常规控制方法，为后续制动能量回收过程制动力矩协调提供了基础技术支持。（4）针对深度制动能量回收中轮缸压力与制动踏板耦合的问题，提出了制动力矩分层协调控制方法，实现了电制动与液压制动交互过程的平滑切换控制，保证了制动过程的平顺性；并通过实时改变线控制动系统的助力特性解决了轮缸压力解耦控制中系统液压特性改变导致的脚感不一致难题。研究成果支撑了电控助力制动系统的产业化，产品应用到东风、江淮等多款自主品牌，为实现底盘核心电控产品的自主可控做出了积极贡献。
Intelligence and electrification bring a fundamental change to automobile industry, and the intelligent new energy vehicle have become a strategic highland which global industry competes fiercely. Chassis brake-by-wire system is the core component of the intelligent new energy vehicle, but the monopolization of foreign technology has become the bottleneck of the independent controllable and sustainable development of Chinese automobile industry. Aiming at the three-level technical requirements of active braking, brake-by-wire and deep braking energy recovery of intelligent new energy vehicles, this paper researches on the semi-decoupled brake-by-wire control system technology, including the system modeling, structural parameter synchronous optimization, reliability design of electric controller and system-level precise control technology implementation, etc and specific content is shown as follows.(1) This paper proposes a new type of semi-decoupled brake-by-wire system configuration, which contains a non-decoupled electric brake booster and an electronic stability control system. It can meet the requirements of rapid pressure build-up and the decoupling control of electric and mechanical braking, moreover it has the characteristic of safety redundancy. From the perspective of system design, a collaborative system parameters optimization method is proposed to achieve the comprehensive optimization of system functions and performance.(2) In terms of the stringent automotive-level application requirements of electronic controllers, a product-level brake-by-wire system embedded controller is designed based on the reliability design technologies such as derating design, thermal design and tolerance analysis. It solves the reliability design problems of permanent magnet synchronous motor controllers under low-voltage and high-current conditions and provides a reliable research platform for subsequent algorithm research.(3) Considering the transient dynamics problems such as nonlinear friction and hydraulic hysteresis in the active pressure building process of the brake-by-wire system, the system Karnopp friction model and the segmented predictive control method are established. The dynamic friction and static friction parameters are identified by using the measured data of the hardware in the loop platform; considering the nonlinear characteristics of the brake system, a piecewise linearization technology is proposed to realize the predictive control of the master cylinder pressure. The proposed method performs better than the conventional method, especially in dynamic control accuracy, and it provides a basic technical support for the following research of braking energy recovery.(4) In terms of problem of coupling between wheel cylinder pressure and brake pedal in deep braking energy recovery, a layered coordinated control method of braking torque is proposed, which realizes the smooth switching control during the interactive process of electric braking and hydraulic braking, and ensures the smoothness of the braking process. In addition, it solves the problem of inconsistent foot feeling caused by the change of the system hydraulic characteristics in the wheel cylinder pressure decoupling control by changing the boost characteristics of the brake-by-wire system in real time.The research findings have supported the industrialization of electronically braking booster system. The products have been applied to some domestic OEM such as Dongfeng Motor Co., Ltd and Jianghuai Automobile Co. Ltd etc, and make positive contributions to the realization of independent of the core electronic control products of the vehicle chassis.
