This research investigates the prototyping and testing of innovative active safety systems using Nonlinear Model Predictive Control (NMPC) technology to enhance vehicle safety and handling. The PhD dissertation, structured in a publication format, includes several articles that detail the development and validation of advanced controllers for systems such as Antilock Braking System (ABS), Traction Control (TC), Path Tracking (PT), Axle Torque Vectoring (ATV) and Autonomous Emergency Braking (AEB). These systems benefit significantly from NMPC’s ability to manage complex and nonlinear behaviours in real-time, optimizing vehicle performance and safety.

The methodology, structured around the V-model, ensures a systematic progression from simulation design to experimental validation. This approach highlights the iterative nature of engineering design, facilitating continual refinement and validation to achieve robust and efficient safety solutions. The thesis effectively bridges the gap between theoretical constructs and practical applications, confirming that the developed systems are not only theoretically sound but also practically viable.

Experimental validations were carried out using the IFEVS Demonstrator Vehicle, which was specially equipped with advanced sensors, actuators, and a rapid control prototyping unit to ensure real-time implementation of the controllers. Additionally, the vehicle’s suspension system was thoroughly revised and enhanced during this PhD research to optimize safety in subsequent experimental assessments.

The publications included in the dissertation demonstrate the real-time capability and effectiveness of the developed controllers. These publications detail extensive prototyping and testing conducted on this real vehicle, providing valuable insights into the practical challenges and solutions in active safety system development.

Looking forward, the thesis sets the stage for further exploration of NMPC applications within vehicle dynamics, integrating these systems with emerging technologies such as connected vehicles and autonomous driving. This research contributes significantly to the field of automotive safety and sets a comprehensive framework for future advancements in vehicle control systems.