Rollover accidents involving buses adversely affect highway traffic and personal safety. The roll stability limit (RSL) of vehicles is analysed by investigating the roll dynamics and rollover mechanism of vehicles using a non-linear roll plane model. Taking the influence of suspension, the dynamic characteristic of the vehicle, and cross-fall, superelevation, or adverse camber on roads, on the RSL of vehicles, the threshold value of lateral acceleration for a rollover warning algorithm is acquired. The influence of the adhesion between tyres and the ground on the rollover warning threshold is analysed to distinguish it from false rollover alarms caused by sideslip. In addition, the research provides a method for calculating dangerous speeds. Then, the rollover warning algorithm based on those dangerous speeds is proposed, and verified in terms of accuracy and robustness by using a numerical simulation. The result shows that the proposed rollover warning algorithm can predict possible rollover accidents and is robust with respect to vehicle parameters and changes in working conditions. Brake control after a rollover warning indicates that rollover accidents can be effectively reduced by using the warning algorithm.
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