Pneumatic booster regulators (PBR) are in great demand in modern pneumatic systems for their energy-saving abilities. A new booster regulator with energy recovery (VBA-R) was proposed, and its energy efficiency was investigated by introducing the concept of air power. On the basis of quality-alterable gas thermodynamics, an energy efficiency assessment and pressure response model for VBA-R was proposed. First, a model was solved using MATLAB/Simulink software, and an alternative experiment was designed to verify the mathematical model and performance improvement. The results showed that the simulation was consistent with the experiment. We also can conclude that, first of all, the energy efficiency decreases with the increasing of supply pressure and flow-rate consumption; a VBA-R has the highest efficiency when its diameter ratio is closest to 1.3. Finally, a recovery chamber helped to improve the performance of the VBA-R, which included a boost ratio improvement of 15–25% and an efficiency improvement of 5–10% compared with a conventional VBA booster regulator. This research lays the foundation for optimism regarding the proposed booster regulator.

This study aims to propose an analysis method for resolving the pressure response of a pneumatic brake circuit considering the effect of a transmission pipe. Pneumatic brake systems (PBS) are widely used in commercial vehicles. The pressure response characteristic of the PBS is the key factor affecting braking performance. By using the thermodynamics of a variable-quality system, the pressure response model of the brake chamber is established, which includes the dynamic model of the pipe considering the unsteady friction and heat transfer. The partial-differential control equations of pipe are solved by introducing the constrained interpolation profile (CIP) method, and a virtual chamber model is proposed to set the boundary condition so as to solve the pressure response in the brake chamber simultaneously. Thus, the regularity of the brake pressure response is obtained by considering the influence of the pipe. Lastly, the model is verified experimentally. The present study indicates that the main factors that affect the pressure response delay are the pipe length and the combination forms of the sonic conductances of the orifices inlet and outlet. Furthermore, it helps to verify that the CIP method is an effective way of solving the pressure response of a brake circuit because of its high accuracy. The present study serves as a foundation for the design and analysis of a PBS.

For intelligence brakes in the electronic pneumatic brake system of commercial vehicles, the pressure change rate is used as the key control parameter and evaluation index. This can improve the brake safety, stability, and ride comfort of the vehicle. The real-time detection of the brake pressure change rate for commercial vehicles is the premise for realizing the accurate control of brake pressure change rate. Based on Poiseuille’s law, an efficient measurement method of brake pressure change rate is proposed for commercial vehicles, and a new measuring device with an isothermal container and laminar flow resistance tube as the core components is designed. Through thermal insulation performance tests, flow resistance tests and measurement accuracy tests, combined with simulations, the effects of structural parameters and copper wire filling density on the performance of the isothermal container are analyzed, and these key parameters are optimized to improve the thermal insulation performance. A tubular laminar flow resistance tube composed of 304 stainless steel capillaries in parallel is designed. The influence mechanism of core parameters such as the number, radius, and length of laminar flow channels on its performance is studied, and the optimal parameter array is selected to optimize its performance. The experimental platform for measuring brake pressure change rate is constructed. By comparing the measurement curve of brake pressure change rate under simulation and experiment, the correctness and effectiveness of the pressure change rate measurement principle and the key components for electronically controlled pneumatic brakes of commercial vehicles are verified to meet engineering requirements.

Air brake system is one of the common braking methods for buses and trucks; its excellent performance guarantees the safety of the vehicle and the stability of the braking. As an important part of the pneumatic brake system, the brake pipe is an important factor influencing the pressure response time of the pneumatic brake system. Based on the exploratory experiment of pneumatic brake pipe, the influence of pipe length, pipe diameter, inlet sonic conductance, initial pressure, and supply pressure on pipe pressure response time was analyzed by fuzzy gray correlation analysis method. The results show that tube length is the most important factor affecting the pressure response time. Combined with the analysis results of gray correlation degree, the experimental scheme of the response time of the pneumatic brake pipe was designed by the response surface experimental design method. Based on the multiparameter analysis method, the influence of the experimental parameters on the pipe pressure response time was analyzed. Based on the experimental data, the form of calculation formula is derived by dimension analysis method, which provides a theoretical basis for the selection of pneumatic brake pipes and the design of air brake system.

The pressure change rate (PCR) of the brake chamber is the key control parameter and evaluation index in the pneumatic braking system for intelligent braking. The PCR threshold value of commercial vehicle brake chambers for braking comfort is analyzed. The PCR measurement method based on a laminar flow resistance tube is proposed, and the PCR test system is designed. The simulation model of a PCR test system for commercial vehicle brake chambers is presented. By analyzing the simulation and experimental results, it is validated that the PCR test system of commercial vehicle brake chambers has the function of measuring PCR in real time. Finally, according to the MSA (Measurement System Analysis) evaluation method, the performance of the PCR test system for commercial vehicle brake chambers is analyzed, and the correctness and applicability of the test system are verified.