Use of driving simulator to develop a brake by wire system designed for electric vehicles and car stability controls

Vehicles with electrical propulsion and energy recovery need specific brake sys-tems able to guarantee the correct integration of electrical energy recovery and high braking capability. The use of advanced controls with brake by wire systems al-lows to integrate such functionalities leaving the correct feedback to brake pedal and the possibility to enhance vehicle dynamics. We present a study done with simulation and simulators with human in the loop to show the potentiality of spe-cific controls to enhance vehicle dynamics and their integration with electric motor controls. In detail, we will show how a physical brake-by-wire unit can be installed on a simulator environment obtaining an enhancement in the driving realism and enabling the virtual development of advanced vehicle functions. The same testing architecture can be used also for fault-injection activities and precise pedal feeling calibration. The case-study test bench has been installed on a static driving simula-tor equipped with a concurrent real-time machine, a vi-grade car real time model, the complete vehicle network and the full steering system.