Symmetry Breaking Under Single-Wheel Failure: Coordinated Fault-Tolerant Control of EMB for Emergency Braking and Lateral Stability

Single-wheel brake failure in electromechanical brake (EMB) systems breaks the left-right symmetry of wheel forces and yaw moments, creating a critical conflict between emergency braking effectiveness and lateral stability. To address this symmetry-breaking condition, this paper proposes a bimodal, adaptive, coordinated fault-tolerant control strategy that integrates dynamic brake torque redistribution with active front steering (AFS). A novel dynamic interaction model linking deceleration demand with tire adhesion utilization enables real-time assessment and optimization of the balance between longitudinal braking performance and yaw stability. Braking forces are allocated based on adhesion utilization through a layered two-mode strategy—balanced distribution prioritizing lateral stability and compensatory distribution engaging the healthy front wheel when rear axle capacity is exceeded. An integral sliding-mode controller computes the additional yaw moment needed to suppress yaw-rate deviation, with rigorous Lyapunov stability analysis confirming closed-loop stability. AFS is triggered only when yaw-rate deviation exceeds 0.05 rad/s or adhesion utilization reaches 90%, incorporating hysteresis to ensure smooth transitions and minimize unnecessary steering intervention. Comprehensive co-simulations using Carsim and MATLAB/Simulink under diverse failure locations (left-front and right-rear wheels), road adhesion levels (μ = 0.85 and 0.5), and braking intensities (0.2 g–0.6 g) demonstrate that the proposed strategy reduces lateral displacement by up to 85.3% compared to full-time AFS control while maintaining over 99% deceleration satisfaction. The results establish an effective dual-objective fault-tolerant framework that enhances both robustness and functional safety of EMB systems under symmetry-breaking faults, offering a physically interpretable, computationally efficient solution well-suited for real-time automotive applications.