盘鼓混合式磁流变踏板力调控装置结构设计与优化

doi:10.3969/j.issn.1674-8484.2023.06.006

摘要/Abstract

摘要：

为了解决踏板感觉对电动汽车再生制动应用的不良影响问题，设计了可嵌入安装于制动踏板根部的磁流变踏板力调控装置。基于嵌入安装需求，设计了盘鼓混合式的磁流变装置，运用有限元方法优化设计装置磁路结构，并进行样机性能测试分析。结果显示：所设计的磁流变踏板力调控装置结构紧凑，能有效实现嵌入式安装；磁流变踏板力调控装置的输出力矩可调范围广，可达0.2~32.0 Nm，能满足踏板力调控需求；同时，磁流变踏板力调控装置输出力矩受转速影响较小，可通过控制电流调节输出力矩，易于实现踏板力的精准调控。

关键词: 再生制动, 踏板力, 磁流变装置, 结构设计, 磁路优化

Abstract:

In order to solve the adverse effects of pedal feeling on regenerative braking of electric vehicles, a magnetorheological device (MRD) for pedal force control was designed with characteristics of root-embedding of the brake pedal. Based on the embedded installation requirements, a disk-drum hybrid structure was designed for the MRD. The magnetic circuit of the MRD was optimized by the finite element method. Finally, the performances of the MRD prototype were tested and analyzed. Results show that the designed MRD has a compact structure, which can implement embedded installation effectively. The output torque of the MRD is over 0.2-32 Nm, indicating its wide adjustable torque range. This wide range meets the needs of pedal force regulation. At the same time, the output torque is less affected by the speed. Thus, it can be accurately adjusted by the current control, which makes the MRD easy to control the pedal force adjustment.

Key words: regenerative brake, pedal force, magnetorheological device, structural design, magnetic circuit optimization

中图分类号:

U463.5

屈贤, 张金龙, 渠立红. 盘鼓混合式磁流变踏板力调控装置结构设计与优化[J]. 汽车安全与节能学报, 2023, 14(6): 698-706.

QU Xian, ZHANG Jinlong, QU Lihong. Structure design and optimization of a disc-drum hybrid magnetorheological device for pedal force control[J]. Journal of Automotive Safety and Energy, 2023, 14(6): 698-706.

图/表 15

图1 磁流变踏板力调控装置的安装示意图与基本工作原理

图2 磁流变踏板力调控装置结构图

图3 磁流变踏板力调控装置关键尺寸

图4 磁流变液工作间隙示意图

图5 磁流变踏板力调节装置磁路优化过程

基础油比例	磁粉比例	密度 (g·cm³)	粘度 Pa·s	工作温度 ℃	稳定性
≥16%	≥81%	2.96~3.10	0.115 ±0.025	-40~140	具较高的抗沉降性，容易重新分散

表1 MRF-181型磁流变液基础性能

图6 MRF-181型磁流变液特性曲线

图7 电工纯铁DT4C B-H曲线

图8 磁流变踏板力调节装置优化迭代过程

	r₂ / mm	r₃ / mm	r₄ / mm	r₅ / mm
原结构	20	47	59.1	64.3
优化结构	21.7	39.6	50.5	54.9
	l_c / mm	l_d / mm	l / mm	T / Nm
原结构	12.6	22.6	36.6	22.3
优化结构	10.4	20.4	37.5	25.4

表2 磁流变踏板力调节装置尺寸优化结果

图9 磁流变踏板力调节装置优化结构的磁路分布特性图

图10 磁流变踏板力调节装置设计图与样机

图11 磁流变踏板力调节装置力矩输出测试台架

图12 磁流变踏板力调节装置输出力矩对电流的变化曲线

图13 磁流变踏板力调节装置输出力矩对转速的变化曲线

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