Modeling the Magnetic Performance of a Fast Pneumatic Brake Actuator

A novel pneumatic valve was constructed to improve the response of air-actuated brakes for heavy vehicles to demand pressures generated during electronically controlled braking by an order of magnitude. Investigations were made into the interactions between the magnetic, mechanical, and electrical subsystems of the valve with a view toward informing design optimization. The valve was modeled using a magnetic circuit approach. The quasi-static model included the influences of the permanent magnet, field-line fringing, saturation, and the coil. Mechanical forces outputted by the model matched physical measurements with an error smaller than 10%, and magnetic fluxes throughout the circuit were generally within 20% of those found from experiments based on Faraday's law of induction, Gaussmeter measurements, and FEA simulations. A magneto-mechanical simulation of the valve switching states was created using mechanical and electrical equations, and curve-fits to the outputs of the magnetic circuit model. The simulation produced time histories of the valve's armature position that matched experimental measurements and adequately predicted working pressures. The final model required an approximation to the influence of the coil based on experimental results. Consequently, further research is recommended into the influence of solenoid coils on fringing in magnetic circuits.