Real-Time Axle-Load Sensing and AI-Enhanced Braking-Distance Prediction for Multi-Axle Heavy-Duty Trucks

Accurate braking-distance prediction for heavy-duty multi-axle trucks remains challenging due to the large gross vehicle weight, tandem-axle interactions, and strong transient load transfer during emergency braking. Recent studies on tire–road friction estimation, commercial-vehicle braking control (EBS/AEBS), and weigh-in-motion (WIM) sensing have highlighted that unmeasured vertical-load dynamics and time-varying friction are key sources of prediction uncertainty. To address these limitations, this study proposes an integrated sensing–simulation–AI framework that combines real-time axle-load estimation, full-scale robotic braking tests, fused road-friction sensing, and physics-consistent machine-learning modeling. A micro-electro-mechanical systems (MEMS)-based load-angle sensor was installed on the leaf-spring panel linking tandem axles, enabling the continuous estimation of dynamic vertical loads via a polynomial calibration model. Full-scale on-road braking tests were conducted at 40–60 km/h under systematically varied payloads (0–15.5 t) using an actuator-based braking robot to eliminate driver variability. A forward-looking optical friction module was synchronized with dynamic axle-load estimates and deceleration signals, and additional scenarios generated in a commercial ASM environment expanded the operational domain across a broader range of friction, grade, and loading conditions. A gradient-boosting regression model trained on the hybrid dataset reproduced measured stopping distances with a mean absolute error (MAE) of 1.58 m and a mean absolute percentage error (MAPE) of 2.46%, with most predictions falling within ±5 m across all test conditions. The results indicate that incorporating real-time dynamic axle-load sensing together with fused friction estimation improves braking-distance prediction compared with static-load assumptions and purely kinematic formulations. The proposed load-aware framework provides a scalable basis for advanced driver-assistance functions, autonomous emergency braking for heavy trucks, and infrastructure-integrated freight safety management. All full-scale braking tests were carried out at approximately 60% of the nominal service-brake pressure, representing non-panic but moderately severe braking conditions, and the proposed model is designed to accurately predict the resulting stopping distance under this prescribed braking regime rather than to minimize the absolute stopping distance itself.