UNIVERSITI PUTRA MALAYSIA

AMEER M. F. SIDER

FK 2014 27

FUZZY-PID CONTROLLER DESIGN FOR BRAKE-BY-WIRE SYSTEM OF ELECTRICAL VEHICLE

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FUZZY-PID CONTROLLER DESIGN FOR BRAKE-BY-WIRE SYSTEM OF

ELECTRIC VEHICLE

By

AMEER M. F. SIDER

Thesis Submitted to the School of Graduate Studies,

Universiti Putra Malaysia, in fulfillment of the

requirements for the Degree of Master Science

June 2014

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COPYRIGHT

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DEDICATED

عالى:قال ت

ه وهىا على وهه وفصاله في عاميه أن اشكر لي وسان بوالديه حملته أم يىا ال ولوالديك إلي المصير(( ))ووص

44لقمان

This thesis is dedicated to:

my beloved parents who encourage, side and patronize me

my darling brothers Islam and Ameen who support, stimulate and stand with me

during my study,

my sweetheart sisters Tasneem, Ala’ and Ayah

my all friends particularly Abbas, Arafat, Alala, Sameer, Fadil, Masri, Ferasa,

Hassan and Bilal

and to my beloved holy land Palestine.

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Abstract of thesis presented to the Senate of Universiti Putra Malaysia in fulfilment

of the requirement for the degree of Master of Science

FUZZY-PID CONTROLLER DESIGN FOR BRAKE-BY-WIRE SYSTEM OF

ELECTRICAL VEHICLE

By

AMEER M. F. SIDER

June 2014

Chair: Mohd Khair Bin Hassan, PhD

Faculty: Engineering

This study presents Fuzzy-PID controller design for brake-by-wire of electric vehicle.

BBW is a new brake technology in which mechanical and hydraulic components of

traditional brake systems are replaced by electric circuits and devices to carry out the

function of braking in a vehicle by wire-transmitted information. The advantages of

electronic devices such as reducing vehicle weight and increasing brake performance are

considered the main purposes trend of automotive industry towards this new brake

technology.

The motivation of this study is to enhance the safety aspects for the vehicle while

attaining any desired speed. To achieve that, an optimal brake force at different road

types and conditions and for different brake commands must be obtained within a

reasonable time and without vehicle sliding.

The aforementioned matters are accomplished essentially by obtaining mathematical

modeling of the vehicle-wheel dynamics based on braking characteristics behavior. The

derived model after that is utilized to construct two different BBW systems named as

hard brake and normal brake system to handle and meet various brake situations and

conditions which they are built according to the selected state dynamics of each system.

In view of that, the mechanism behavior and operating process of both brake systems are

dominated by implementing distinct control algorithms based on PID and Fuzzy-PID

controllers. Indeed, the fundamental objective of the applied control methods is to attain

desired vehicle speed from one side and to maintain vehicle stability and controllability

from other side. Above and beyond, BBW operating process is improved by developing

new integrated control strategy that involves both designed brakes (hard and normal) in

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one sole framework. Constructing such a system is primarily based on conventional IF-

ELSE conditional control. Nonetheless, the braking operation of the proposed BBW

systems is carried out by utilizing permanent magnetic DC motor according to the

predetermined control signal.

The simulation analysis of the proposed BBW schemes and their controllers are

conducted on MATLAB software using Simulink tool, where five road types and

conditions (asphalt (dry, wet), cobblestone (dry, wet) and concrete) are engaged in the

analysis and investigation of the output behavior of the plant and its operating process.

Moreover, the study presents supplementary explanation about performance of the

proposed actuator (PMDC) as well as about the process of braking mechanism.

The simulation results and outcomes demonstrate efficient operating brake systems that

lead to obtain desired vehicle speed successfully within reasonable brake time. This is a

clear evidence of obtaining safety aspects of the vehicle as well as passengers since

control strategy could maintain optimal brake force that leads to shorter stopping

distance, hence increasing safety aspects. Furthermore, the ability of proposed control

strategies to operate during various situations (hard or normal brake request) at different

road conditions is also achieved effectively. Consequently, the aim of the study which is

designing electronically brake system for BBW of electric vehicle that can operate in

different brake situations and at different road conditions is successfully accomplished

and achieved.

Finally, after the analysis and discussion of BBW and controller design, suggestions for

key future development and enhancement of the current study are presented such as

implementing adopted BBW design practically.

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Abstrak tesis yang dikemukakan kepada Senat Universiti Putra Malaysia

Sebagai memenuhi keperluan untuk ijazah Master Sains

FUZZY-PID REKABENTUK BAGI SISTEM BREK-DENGAN-WAYAR UNTUK

KENDERAAN ELEKTRIK

Oleh

AMEER M. F. SIDER

Jun 2014

Pengerusi: Mohd Khair Bin Hassan, PhD

Fakulti: Kejuruteraan

Kajian ini mengenai reka bentuk kawalan Fuzzy-PID untuk sistem brek-dengan-wayar

(BBW) elektrik kenderaan. BBW adalah teknologi baru bagi brek di mana komponen-

komponen mekanikal dan hidraulik sistem brek tradisional digantikan dengan sistem

pintar, litar elektrik dan alat-alat untuk menjalankan fungsi brek di dalam kenderaan

oleh penghantaran maklumat melalui wayar. Kelebihan elektronik dan sistem bantuan

pintar ini dapat mengurangkan berat kenderaan, meningkatkan prestasi brek dan

keupayaan untuk mereka bentuk sistem kawalan bersepadu dianggap trend utama

industri automotif ke arah teknologi brek baru.

Motivasi kajian ini adalah untuk memperbaiki aspek keselamatan untuk kenderaan serta

mencapai kelajuan kenderaan. Oleh itu, satu daya brek yang optimum pada jalan yang

berlainan jenis dan keadaan dan bagi arahan brek yang berbeza mesti diperolehi dalam

masa yang munasabah serta tanpa gelongsoran kenderaan.

Perkara tersebut dapat dicapai pada dasarnya dengan mencipta model matematik

dinamik kenderaan roda berdasarkan ciri-ciri tingkah laku brek. Model yang diperolehi

akan digunakan untuk membina dua sistem BBW berbeza dinamakan sebagai brek keras

dan sistem brek biasa untuk mengendali dan memenuhi pelbagai situasi brek

(kecemasan atau keadaan biasa) yang mereka dibina mengikut keadaan dinamik bagi

setiap sistem.

Sehubungan itu, tingkah laku mekanisme dan proses operasi kedua-dua sistem brek

dilakukan dengan menggunakan algoritma kawalan yang berbeza berdasarkan pengawal

PID dan Fuzzy-PID. Oleh itu, matlamat asas kaedah kawalan yang digunakan adalah

untuk mencapai kelajuan kenderaan yang diingini dan juga dalam masa yang sama

untuk mengekalkan kestabilan kenderaan dan pengawalan. Seterusnya, proses operasi

BBW bertambah baik dengan membangunkan strategi kawalan bersepadu yang

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melibatkan kedua-dua brek direka (keras dan normal) dalam satu rangka kerja tunggal.

Membina sistem seperti ini adalah berdasarkan kawalan bersyarat konvensional IF-

ELSE. Walaubagaimanapun, operasi sistem brek BBW yang dicadangkan dijalankan

adalah dengan menggunakan magnet kekal DC motor mengikut isyarat kawalan yang

telah ditetapkan.

Analisis simulasi dan kajian skim BBW yang dicadangkan dan pengawalan

dikendalikan pada perisian MATLAB menggunakan alat Simulink, di mana lima jenis

jalan raya dan syarat (asfalt (kering, basah), batu bulat (kering, basah) dan konkrit)

terlibat dalam analisis dan penyiasatan terhadap tindakan yang diberi oleh output sistem

dan proses operasi. Selain itu, kajian ini memberi penerangan yang tambahan serta

ilustrasi mengenai prestasi penggerak yang dicadangkan (PMDC) dan juga tentang

proses mekanisme brek.

Keputusan simulasi dan hasil menunjukkan sistem brek operasi yang cekap membawa

kepada kelajuan kenderaan diingini berjaya diperoleh dalam masa tindakbalas brek yang

munasabah. Ini adalah bukti yang jelas bagi mendapatkan aspek keselamatan kenderaan

dan juga penumpang memandangkan strategi kawalan boleh mengekalkan kuasa brek

yang optimum yang membawa kepada jarak berhenti lebih singkat, seterusnya

meningkatkan aspek keselamatan. Tambahan pula, keupayaan strategi kawalan yang

dicadangkan untuk beroperasi dalam pelbagai situasi (permintaan brek keras atau biasa)

pada keadaan jalan yang berbeza juga dicapai dengan berkesan. Oleh itu, tujuan kajian

yang merekabentuk secara elektronik sistem brek untuk BBW elektrik kenderaan yang

boleh beroperasi dalam keadaan brek yang berbeza dan pada keadaan jalan yang berbeza

adalah berjaya dilaksana dan dicapai.

Akhir sekali, selepas analisis dan perbincangan mengenai BBW dan reka bentuk

pengawal, cadangan untuk pembangunan utama pada masa hadapan dan peningkatan

kajian semasa dapat dibentangkan seperti mengguna pakai reka bentuk BBW secara

praktikal.

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ACKNOWLEDGEMENTS

First of all, thanks is due to Allah, the Most Gracious, Most Merciful (S.W.T.) whom we

attain our ability and strength. I would like to express my gratitude and appreciation to

Dr. Mohd Khair Hassan for his wise supervision, advice, guidance, suggestion, and

support during the research time. Thanks also to my co-supervisors (Dr. Siti Fauziah

Tohara and Dr. Mohd Amran Bin Mohd Radzi) for their opinion and wonderful

suggestion during the research time. My sincere gratitude is due to them.

I would like also to thank laboratory management of Control System Engineering

Department for the support and assistance.

Thanks are also to my parents who deserve my deepest appreciation for their un-

bordered help and patronize. I am grateful for the countless sacrifices they made to

ensure that I can pursue and finish my study successfully particularly Dr. Arafat. May

ALLAH bless and protect all of them and may they live long and healthy.

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I certify that a Thesis Examination Committee has met on 30th

of June 2014 (Monday)

to conduct the final examination of Ameer M. F. Sider on his thesis entitled “Design

Fuzzy-PID controller for Brake-By-Wire of Electric Vehicle” in accordance with the

Universities and University Colleges Act 1971 and the Constitution of the Universiti

Putra Malaysia [P.U(A) 106] 15 March 1998. The Committee recommends that the

student be awarded the degree of Master of Science.

Members of the Thesis Examination Committee were as follows:

Dr. Siti Anom Bt. Ahmad

Faculty of Engineering

Universiti Putra Malaysia

(Chairman)

Prof. Madya Dr. Mohd Hamiruce Marhaban

Faculty of Engineering

Universiti Putra Malaysia

(Internal Examiner 1)

Dr. Noor Izrii Abdul Wahab

Faculty of Engineering

Universiti Putra Malaysia

(Internal Examiner 2)

Assoc. Prof. Dr. Mohd Zarhamdy Md Zain

Faculty of Engineering

Universiti Teknologi Malaysia

(External Examiner)

SEOW HENG FONG, PhD

Professor and Deputy Dean

School of Graduate Studies

Universiti Putra Malaysia

Date:

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This thesis was submitted to the Senate of Universiti Putra Malaysia and has been

accepted as fulfilment of the requirement for the degree of Master Of Science. The

members of the Supervisory Committee were as follows:

Mohd Khair Hassan, PhD

Senior Lecturer

Faculty of Engineering

Universiti Putra Malaysia

(Chairman)

Mohd Amran Bin Mohd Radzi, PhD

Associate Professor

Faculty of Engineering

Universiti Putra Malaysia

(Member)

Siti Fauziah Tohara, PhD

Assistant Professor

Faculty of Engineering

International Islamic University Malaysia

(Member)

BUJANG KIM HUAT, PhD

Professor and Dean

School of Graduate Studies

Universiti Putra Malaysia

Date:

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Declaration of Graduate Student

I hereby confirm that:

this thesis is my original work;

quotations, illustrations and citations have been duly referenced;

this thesis has not been submitted previously or concurrently for any other degree at

any other institutions;

intellectual property from the thesis and copyright of thesis are fully-owned by

Universiti Putra Malaysia, as according to the Universiti Putra Malaysia (Research)

Rules 2012;

written permission must be obtained from supervisor and the office of Deputy Vice-

Chancellor (Research and Innovation) before thesis is published (in the form of

written, printed or in electronic form) including books, journals, modules,

proceedings, popular writings, seminar papers, manuscripts, posters, reports, lecture

notes, learning modules or any other materials as stated in the Universiti Putra

Malaysia (Research) Rules 2012;

there is no plagiarism or data falsification/fabrication in the thesis, and scholarly

integrity is upheld as according to the Universiti Putra Malaysia (Graduate Studies)

Rules 2003 (Revision 2012-2013) and the Universiti Putra Malaysia (Research)

Rules 2012. The thesis has undergone plagiarism detection software.

Signature: _______________________ Date: __________________

Name and Matric No.: ______________________________________

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Declaration By Members Of Supervisory Committee

This is to confirm that:

the research conducted and the writing of this thesis was under our supervision;

supervision responsibilities as stated in the Universiti Putra Malaysia (Graduate

Studies) Rules 2003 (Revision 2012-2013) are adhered to.

Signature: ________________________ Signature: _______________________

Name of

Chairman of

Supervisory

Committee: _______________________

Name of

Member of

Supervisory

Committee: ______________________

Signature: ______________________ Signature: ________________________

Name of

Member of

Supervisory

Committee: _______________________

Name of

Member of

Supervisory

Committee: ________________________

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Page TABLE OF CONTENTS

ABSTRACT i

ABSTRAK iii

ACKNOWLEDGEMENT v

APPROVAL vi

DECLARATION viii

LIST OF TABLES xii

LIST OF FIGURES xiii

LIST OF ABBREVIATIONS xvi

LIST OF SYMBOLS xvii

CHAPTER

1 INTRODUCTION 1 1.1 Background 1

1.2 Problem statement 2

1.3 Objectives 3

1.4 Thesis Scope 3

1.5 Contribution 4

1.6 Thesis Organization 4

2 LITERATURE REVIEW 5 2.1. Introduction 5

2.2. Traditional Brake System 5

2.2.1. Concept and Definition 5

2.2.2. Hydraulic Brake System 6

2.2.3. Mechanical Brake System 6

2.3. Brake-by-Wire System (BBW) 8

2.3.1. Brake-by-wire Concept and Definition 8

2.3.2. BBW System Structure and Design 9

2.3.3. BBW Segments and Parts 10

2.4. Anti-Lock Brake System (ABS) 14

2.5. Longitudinal Brake Control in Traditional Brake System 15

2.6. Power Supply in BBW System 16

2.7. Characteristics and Types of Electrical Actuator 17

2.8. Fuzzy-PID Controller 19

2.9. Summary of the Chapter 21

3 METHODOLOGY 22 3.1 Introduction 22

3.2 Flowchart of the Study 23

3.3 Mathematical Modeling 24

3.3.1 Vehicle and Wheel Dynamics 25

3.3.2 Friction Force 26

3.3.3 Wheel Slip (s) 27

3.3.4 Dynamic State 28

3.4 BBW principle work and design 29

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3.4.1 BBW principle work 29

3.4.2 Normal brake system design and structure 31

3.4.3 Hard brake system design and structure 32

3.5 Electrical motor selection and design 33

3.5.1 PMDC mathematical model derivation 34

3.6 Computational design of electrical motor and BBW parameters 36

3.7 Control system design 39

3.7.1 Control System Design for Normal brake system 39

3.7.2 Control system design for hard brake request 45

3.7.3 Integrated control system 46

3.8 Summary 48

4 RESULTS AND DISCUSSIONS 49 4.1 Introduction 49

4.2 Simulation Set-up and Parameters 49

4.3 Results and discussions of brake control system design 50

4.3.1 Normal Brake Control System 50

4.3.2 Hard Brake Control System 59

4.3.3 Results and discussions of Integrated control system 67

4.4 Validation of proposed system and simulation result 70

4.5 Stability analysis and performance of the vehicle speed 71

4.6 Performance and analysis of electrical motor and braking mechanism

72

4.6.1 Obtained armature current 72

4.6.2 Motor torque performance 73

4.7 Summary 75

5 CONCLUSION AND FUTURE WORK 77 5.1 Conclusion 77

5.2 Suggestion and Future work 78

REFERENCES 80

APPENDICES A 85

APPENDICES B 86

BIO DATA OF STUDENT 88