The increasing electrification of automotive subsystems is driving the development of advanced mechatronic braking solutions capable of delivering high performance, robustness, and efficiency under a wide range of operating conditions. In particular, single-corner braking systems that integrate electric machines with mechanical braking components represent a promising architecture for future brake-by-wire and electro-mechanical brake applications. This thesis focuses on the electromechanical optimization of such systems, considering both dry and wet operating conditions.
The objective of the thesis is to develop a unified modeling and optimization framework in which the electric machine design and the mechanical braking system are optimized simultaneously. The electric subsystem will include the electromagnetic design of the electric machine, accounting for torque density, efficiency, thermal limits, and dynamic response. The mechanical subsystem will focus on the brake mechanism at the single-corner level, including transmission elements, friction interfaces, and actuation mechanisms, with particular attention to force generation, stiffness, response time, and wear behavior.
Both dry and wet braking systems will be explicitly considered. The coupled electromechanical model will be used within a multi-objective optimization framework aimed at minimizing energy consumption, system mass, and response time while maximizing braking torque capability, controllability, and robustness. Design variables will include geometric parameters, material properties, electromagnetic layout variables, and mechanical transmission characteristics. Trade-offs between electrical efficiency and mechanical performance will be systematically analyzed.
The expected outcome of this work is a set of optimized design solutions and performance maps highlighting the benefits of integrated electromechanical optimization compared to traditional sequential design approaches. The results will provide valuable insights for the development of next-generation automotive braking systems, supporting both industrial design processes and future research in mechatronic system integration.
Contacts: michele.vignati@polimi.it, francesco.braghin@polimi.it, nicola.toscani@polimi.it, mattia1.belloni@polimi.it