Hybrid vehicle electromagnetic mechanical composite brake device and control method thereof

Abstract

The application relates to a hybrid vehicle electromagnetic mechanical composite brake device and a control method thereof, which comprises a vehicle frame, a vehicle axle installed on the vehicle frame, a vehicle-mounted power supply arranged on the vehicle frame and a whole vehicle controller arranged on the vehicle frame, a wheel and a brake disc are arranged on the vehicle axle, an excitation coil is arranged on the vehicle frame, the excitation coil is electrically connected with a current controller, a reciprocating moving mechanism, a speed sensor, a disc brake and a brake disc controller electrically connected with the disc brake are further arranged on the vehicle frame, the reciprocating moving mechanism is provided with an electrically-conductive piece electrically connected with the vehicle-mounted power supply, and a wheel-side driving motor is further arranged, the wheel-side driving motor is drivingly connected with the vehicle axle through a planetary gear power coupling mechanism, and the wheel-side driving motor is electrically connected with a motor controller, so that the kinetic energy of the vehicle during braking can be effectively recycled.

Description

Technical Field

[0001] This invention relates to the field of braking and energy recovery technology for hybrid electric vehicles, and in particular to an electromagnetic-mechanical composite braking device for hybrid electric vehicles and its control method. Background Technology

[0002] Hybrid electric vehicles and pure electric vehicles generally use mechanical braking or electric motor braking to recover energy. Traditional electromagnetic braking often uses an integrated braking and power generation coil structure, which is prone to problems such as coil overheating, aging, and failure under high load conditions. At the same time, single electromagnetic braking provides insufficient braking torque at low speeds, resulting in reduced braking efficiency and posing safety hazards. Existing braking systems cannot simultaneously meet the requirements of efficient energy recovery, stable braking at all vehicle speeds, system reliability, and service life, thus limiting the application of electromagnetic braking technology in hybrid electric vehicles.

[0003] Existing composite braking solutions have many inherent defects: Existing patent CN103640487B discloses an electromagnetic-hydraulic composite brake that relies on a permanent magnet built into the rotating shaft to generate electricity to excite its own electromagnetic coil. There is no external controllable conductive component to recover electrical energy to the vehicle's power supply, so it cannot supply braking energy to the wheel-side drive motor to assist the vehicle's drive. At the same time, the brake disc and excitation coil rotate synchronously with the wheel, resulting in severe heat generation during long-term operation, and the permanent magnet is at risk of demagnetization at high temperatures.

[0004] The existing patent CN106246765A adopts a dual-disc structure of split friction disc and electromagnetic retarder disc. It relies on electromagnetic coils to clamp the brake blocks to achieve friction braking. It has no conductive energy recovery mechanism, and the excitation coil is completely powered by the vehicle battery. It does not have a closed-loop reuse function for braking energy, nor does it have speed-based graded coordinated braking control logic. Summary of the Invention

[0005] In view of this, the purpose of the present invention is to provide a hybrid electric vehicle electromagnetic mechanical composite braking device and its control method, so as to solve the problems of coil heating and braking safety of existing automotive electromagnetic brakes, while also effectively recovering the kinetic energy of the vehicle during braking and using the kinetic energy to improve the vehicle's power performance, taking into account stability, safety and long range.

[0006] The technical solution adopted by this invention to solve the above-mentioned technical problems is as follows: a hybrid electric vehicle electromagnetic mechanical composite braking device, including a frame, an axle mounted on the frame, an on-board power supply mounted on the frame, and a vehicle controller mounted on the frame. The axle has wheels and a brake disc. An excitation coil is mounted on the frame opposite the brake disc end face, and the excitation coil is electrically connected to a current controller. The frame also includes a reciprocating mechanism, a speed sensor, a disc brake, and a brake disc controller electrically connected to the disc brake. The reciprocating mechanism has a conductive element electrically connected to the on-board power supply, and the conductive element is positioned facing the outer circumferential surface of the brake disc. The reciprocating mechanism is used to move the conductive element closer to or away from the brake disc to achieve contact or separation between the conductive element and the brake disc. The speed sensor is used to collect wheel rotation speed. The device also includes a wheel-side drive motor, which is connected to the axle via a planetary gear power coupling mechanism. The wheel-side drive motor is electrically connected to a motor controller. The motor controller, speed sensor, reciprocating mechanism, brake disc controller, and current controller are respectively connected to the vehicle controller. When the excitation coil is energized, it interacts with the rotating brake disc to generate electromagnetic braking force. The energized excitation coil generates a magnetic field, and the rotating brake disc cuts the magnetic field lines to induce a current on the brake disc. When the conductive component contacts the brake disc, the induced current generated on the brake disc is transmitted to the vehicle power supply through the conductive component.

[0007] As a preferred embodiment, the reciprocating movement mechanism includes an electric push rod and an electric push rod controller electrically connected to the electric push rod, the electric push rod controller being connected to the vehicle controller.

[0008] As a preferred embodiment, the conductive element is a brush, which is disposed at the end of the push rod of the electric push rod.

[0009] As a preferred embodiment, the motor controller, speed sensor, electric actuator controller, brake disc controller, and current controller are electrically connected to the vehicle power supply.

[0010] As a preferred option, the vehicle power source is a storage battery.

[0011] As a preferred embodiment, the motor controller, speed sensor, electric actuator controller, brake disc controller, and current controller are each connected to the communication bus, which is connected to the vehicle controller.

[0012] This application also provides a control method for a hybrid electric vehicle electromagnetic mechanical composite braking device as described above, characterized by comprising the following steps: S1. When the vehicle is in motion, the speed sensor acquires the real-time wheel speed signal and transmits it to the vehicle controller. When the vehicle controller does not receive a braking signal, the vehicle controller controls the reciprocating movement mechanism to separate the conductive parts from the brake disc and controls the excitation coil to be de-energized. S2. When the driver presses the brake pedal, a braking signal is generated and transmitted to the vehicle controller. When the real-time wheel speed is higher than the first threshold, the vehicle controller controls the excitation coil to be energized and controls the reciprocating movement mechanism to make the conductive parts contact the brake disc. After the excitation coil is energized, it interacts with the rotating brake disc and generates electromagnetic braking force to achieve electromagnetic braking. When the real-time wheel speed is lower than or equal to the first threshold, the vehicle controller controls the excitation coil to be energized, and controls the reciprocating mechanism to make the conductive part contact the brake disc. After the excitation coil is energized, it interacts with the rotating brake disc and generates electromagnetic braking force. The controller controls the brake disc controller so that the disc brake applies mechanical braking force to the brake disc, thereby realizing electromagnetic-mechanical composite braking.

[0013] Furthermore, when the vehicle controller receives an emergency braking signal, it controls the reciprocating mechanism to make the conductive parts contact the brake disc. After the excitation coil is energized, it interacts with the rotating brake disc and generates electromagnetic braking force. This controls the brake disc controller, causing the disc brake to apply mechanical braking force to the brake disc, thereby achieving electromagnetic-mechanical composite braking.

[0014] Furthermore, after the excitation coil is energized, it generates a magnetic field. The rotating brake disc cuts the magnetic field lines to induce a current on the brake disc. When the conductive component comes into contact with the brake disc, the induced current generated on the brake disc is transmitted to the vehicle power supply through the conductive component, thus completing the recovery of braking energy.

[0015] The beneficial effects of this application are as follows: 1. In this application, the brake disc is mounted on the axle, and the excitation coil is mounted on the frame. The excitation coil does not rotate with the brake disc, making the excitation coil and the brake disc a separate structure. The excitation coil only serves as a magnetic field excitation component and does not directly participate in the generation and flow of braking current. Furthermore, the brush only contacts the brake disc through a reciprocating movement mechanism when it is necessary to recover electrical energy. This avoids the problems of overheating, aging, or even failure caused by high current and long-term operation of traditional integrated braking and power generation coils under high-load braking conditions, significantly improving the reliability and service life of the braking system.

[0016] 2. This invention utilizes reciprocating brushes to selectively contact or separate from the outer circumferential surface of the brake disc. The brake disc cuts the magnetic lines of the excitation coil to generate an induced current, which is then directly transferred to the vehicle's power supply for storage via conductive components. The recovered electrical energy can be used to power the excitation coil itself or supplied to the wheel-side drive motors via the vehicle's power supply. This, in turn, assists in driving the axles through a planetary gear power coupling mechanism, achieving efficient closed-loop reuse of braking energy at the vehicle level and significantly improving the vehicle's energy utilization efficiency. Furthermore, the recovered electrical energy can drive the wheel-side drive motors to output auxiliary power under high-load conditions such as climbing, starting, and rapid acceleration, converting braking kinetic energy into driving assistance, achieving closed-loop energy utilization and effectively improving the vehicle's power and driving range.

[0017] 3. The control method of this application can switch between pure electromagnetic braking and electromagnetic-mechanical composite braking modes based on the braking signal and real-time wheel speed. When the vehicle controller does not receive a braking signal, the control brushes are separated from the brake discs and the excitation coil is de-energized, reducing energy loss and mechanical wear. In particular, when an emergency braking signal is received, the electromagnetic braking and mechanical braking composite action is immediately triggered, providing maximum braking torque, significantly shortening the braking distance, and effectively improving the vehicle's active safety protection level in emergency situations.

[0018] 4. This application acquires wheel speed in real time through speed sensors and performs graded coordinated control of braking force based on a set threshold. At high speeds above the first threshold, the electromagnetic braking force generated by the excitation coil alone is sufficient to meet braking requirements while simultaneously recovering energy. At low speeds below or equal to the first threshold, the vehicle controller actively controls the disc brakes to intervene, applying mechanical braking force in addition. This effectively compensates for the inherent deficiency of insufficient braking torque in low-speed regions with single electromagnetic braking, ensuring stable braking performance and driving safety across all operating conditions from high to low speeds. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of the present invention.

[0020] Figure 2 This is a schematic diagram of the control principle of the present invention.

[0021] The diagram shows the following components: 1. Axle; 2. Planetary gear power coupling mechanism; 3. Wheel-side drive motor; 4. Motor controller; 5. On-board power supply; 6. Communication bus; 7. Current controller; 8. Electric actuator controller; 9. Electric actuator; 10. Brush; 11. Excitation coil; 12. Brake disc; 13. Speed ​​sensor; 14. Disc brake; 15. Wheel; 16. Brake disc controller; 17. Vehicle controller. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that, in the description of this invention, unless otherwise stated, "a plurality of" means two or more; the terms "upper," "lower," "left," "right," "inner," "outer," "front end," "rear end," "head," "tail," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0023] Please see Figure 1-2 This invention provides an electromagnetic-mechanical composite braking device for a hybrid electric vehicle, including a frame, an axle 1 mounted on the frame, an on-board power supply 5 mounted on the frame, and a vehicle controller 17 mounted on the frame. The axle 1 has wheels 15 and a brake disc 12. An excitation coil 11 is mounted on the frame opposite the end face of the brake disc 12, and the excitation coil 11 is electrically connected to a current controller 7. The frame also includes a reciprocating mechanism, a speed sensor 13, a disc brake 14, and a brake disc controller 16 electrically connected to the disc brake 14. The reciprocating mechanism has a conductive element electrically connected to the on-board power supply 5, with the conductive element facing the outer circumferential surface of the brake disc 12. The reciprocating mechanism is used to move the conductive element closer to or away from the brake disc 12, thereby achieving the interaction between the conductive element and the brake disc. The rotating disc 12 is in contact or separated, and the speed sensor 13 is used to collect the rotational speed of the wheel 15. It also includes a wheel-side drive motor 3, which is connected to the axle 1 via a planetary gear power coupling mechanism 2. The wheel-side drive motor 3 is electrically connected to a motor controller 4. The motor controller 4, speed sensor 13, reciprocating movement mechanism, brake disc controller 16 and current controller 7 are respectively connected to the vehicle controller 17. After the excitation coil 11 is energized, it acts on the rotating brake disc 12 and generates electromagnetic braking force. After the excitation coil 11 is energized, it generates a magnetic field. The rotating brake disc 12 cuts the magnetic field lines to generate an induced current on the brake disc 12. When the conductive part is in contact with the brake disc 12, the induced current generated on the brake disc 12 is transmitted to the vehicle power supply 5 through the conductive part.

[0024] The excitation coil 11 does not rotate with the wheel 15. The reciprocating movement mechanism includes an electric push rod 9 and an electric push rod controller 8 electrically connected to the electric push rod 9. The electric push rod controller 8 is connected to the vehicle controller 17. The conductive component is a brush 10, which is disposed at the push rod end of the electric push rod 9.

[0025] Specifically, the motor controller 4, speed sensor 13, electric actuator controller 8, brake disc controller 16, and current controller 7 are electrically connected to the vehicle power supply 5. The vehicle power supply 5 is a storage battery. All electrical components are powered by the vehicle power supply 5. It should be noted that any parts not detailed in this application are prior art.

[0026] In addition, the motor controller 4, speed sensor 13, electric actuator controller 8, brake disc controller 16 and current controller 7 are respectively connected to the communication bus 6, and the communication bus 6 is connected to the vehicle controller 17.

[0027] This application also provides a control method for a hybrid electric vehicle using the above-described electromagnetic-mechanical composite braking device, comprising the following steps: S1. When the vehicle is in motion, the speed sensor 13 acquires the real-time wheel speed signal and transmits it to the vehicle controller 17. When the vehicle controller 17 does not receive a braking signal, it controls the reciprocating mechanism to separate the conductive component from the brake disc 12 and controls the excitation coil 11 to be de-energized. The vehicle controller 17 controls the electric push rod 9 to retract through the electric push rod controller 8, so that the brush 10 is separated from the brake disc 12, and controls the excitation coil 11 to be de-energized through the current controller 7, allowing the brake disc 12 to rotate freely.

[0028] S2. When the driver depresses the brake pedal, a braking signal is generated and transmitted to the vehicle controller 17. When the real-time wheel speed exceeds a first threshold, the vehicle enters electromagnetic braking mode. The vehicle controller 17 energizes the excitation coil 11 and controls the reciprocating mechanism to bring the conductive parts into contact with the brake disc 12. After being energized, the excitation coil 11 interacts with the rotating brake disc 12 to generate electromagnetic braking force, thus achieving electromagnetic braking. The vehicle controller 17 controls the current controller 7 to energize the excitation coil 11 and simultaneously controls the electric push rod controller 8 to drive the electric push rod 9 to extend, so that the brush 10 contacts the outer circumferential surface of the brake disc 12. After being energized, the excitation coil 11 generates a magnetic field. The rotating brake disc 12 cuts the magnetic field lines, generating an induced current on the brake disc 12. When this induced current flows within the brake disc 12, it generates an electromagnetic braking torque, thus achieving electromagnetic braking. At the same time, the induced current generated on the brake disc 12 is transmitted to the on-board power supply 5 via the brush 10 for storage, completing the recovery of braking energy. The recovered electrical energy can be supplied to the wheel-side drive motor 3 through the on-board power supply 5, and then the axle 1 can be driven by the planetary gear power coupling mechanism 2 to realize the whole-vehicle closed-loop reuse of braking energy.

[0029] When the real-time wheel speed is below or below the first threshold, the vehicle is in an electromagnetic-mechanical composite braking condition. The vehicle controller 17 controls the excitation coil 11 to be energized, and controls the reciprocating mechanism to make the conductive part contact the brake disc 12. After the excitation coil 11 is energized, it interacts with the rotating brake disc 12 and generates electromagnetic braking force. The vehicle controller 17 controls the brake disc controller 16 to make the disc brake 14 apply mechanical braking force to the brake disc 12, thereby realizing electromagnetic-mechanical composite braking. The vehicle controller 17 controls the current controller 7 to energize the excitation coil 11, and controls the electric push rod controller 8 to drive the electric push rod 9 to extend so that the brush 10 contacts the brake disc 12, realizing electromagnetic braking and energy recovery. At the same time, the vehicle controller 17 controls the brake disc controller 16 to make the disc brake 14 apply mechanical braking force to the brake disc 12, thereby realizing composite braking of electromagnetic braking and mechanical braking.

[0030] When the vehicle controller 17 receives an emergency braking signal, the vehicle enters an electromagnetic-mechanical composite braking state. The vehicle controller 17 controls the reciprocating mechanism to bring the conductive parts into contact with the brake disc 12. After the excitation coil 11 is energized, it interacts with the rotating brake disc 12 to generate electromagnetic braking force. This controls the brake disc controller 16, causing the disc brake 14 to apply mechanical braking force to the brake disc 12, thereby achieving electromagnetic-mechanical composite braking. When the vehicle controller 17 receives an emergency braking signal, regardless of the vehicle speed, it immediately controls the electric push rod 9 to extend, bringing the brush 10 into contact with the brake disc 12. The excitation coil 11 is energized to generate electromagnetic braking, and the disc brake 14 is simultaneously controlled to apply mechanical braking force, achieving electromagnetic-mechanical composite braking to provide maximum braking torque. A rectifier and voltage regulator circuit is also provided between the brush 10 and the vehicle power supply 5. This circuit rectifies and regulates the induced current generated by the brake disc 12 before sending it to the vehicle power supply 5. The rectifier and voltage regulator circuit adopts a commonly used existing rectifier and voltage regulator circuit, which is existing technology and will not be described in detail here. During braking, the vehicle controller 17 adjusts the current of the excitation coil 11 in real time according to the real-time wheel speed and braking intensity, thereby changing the electromagnetic braking torque and making the braking process smooth.

[0031] The first threshold speed in this application is 8-10 km / h, preferably 10 km / h. When the excitation coil 11 is energized, it generates a magnetic field. The rotating brake disc 12 cuts the magnetic field lines, inducing a current on the brake disc 12. When the conductive element contacts the brake disc 12, the induced current on the brake disc 12 is transmitted to the vehicle power supply 5 via the conductive element, completing the recovery of braking energy. The recovered electrical energy can power the wheel-side drive motor 3 when the vehicle starts, accelerates, or climbs a hill, achieving energy recycling, reducing overall vehicle energy consumption, and extending the driving range.

[0032] Furthermore, the emergency braking signal in this application is triggered by the vehicle's automatic emergency braking system (AEB). Alternatively, the emergency braking signal can be a braking signal generated by a brake pedal position sensor or a braking force sensor when the driver depresses the brake pedal at a rate or force exceeding a preset threshold. Emergency braking signal generation is prior art and will not be described in detail here.

[0033] This system employs a separate arrangement of the excitation coil 11 and the brake disc 12. The excitation coil 11 does not rotate with the wheel 15, effectively avoiding problems such as coil overheating and aging under high load conditions, thus improving the reliability and service life of the braking system. Through the coordinated control of electromagnetic braking and mechanical braking, stable braking is achieved across the entire vehicle speed range, while simultaneously completing efficient recovery of braking energy. The system features a compact structure, clear control logic, and is suitable for hybrid vehicle braking systems.

[0034] It should be noted that the above embodiments are only used to illustrate the present invention, but the present invention is not limited to the above embodiments. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention shall fall within the protection scope of the present invention.

Claims

1. A hybrid electric vehicle electromagnetic-mechanical composite braking device, comprising a frame, an axle (1) mounted on the frame, an on-board power supply (5) mounted on the frame, and a vehicle controller (17) mounted on the frame, wherein the axle (1) is provided with a wheel (15) and a brake disc (12), characterized in that, An excitation coil (11) is provided on the frame relative to the end face of the brake disc (12). The excitation coil (11) is electrically connected to the current controller (7). The frame is also provided with a reciprocating movement mechanism, a speed sensor (13), a disc brake (14), and a brake disc controller (16) electrically connected to the disc brake (14). The reciprocating movement mechanism is provided with a conductive component electrically connected to the vehicle power supply (5). The conductive component is set facing the outer circumferential surface of the brake disc (12). The reciprocating movement mechanism is used to drive the conductive component to approach or move away from the brake disc (12) so as to realize the contact or separation of the conductive component with the brake disc (12). The speed sensor (13) is used to collect the rotational speed of the wheel (15). It also includes a wheel-side drive motor (3), which is connected to the axle (1) via a planetary gear power coupling mechanism (2). The wheel-side drive motor (3) is electrically connected to a motor controller (4). The motor controller (4), speed sensor (13), reciprocating movement mechanism, brake disc controller (16) and current controller (7) are respectively connected to the vehicle controller (17). When the excitation coil (11) is energized, it interacts with the rotating brake disc (12) and generates electromagnetic braking force. When the excitation coil (11) is energized, it generates a magnetic field. The rotating brake disc (12) cuts the magnetic field lines to generate an induced current on the brake disc (12). When the conductive part contacts the brake disc (12), the induced current generated on the brake disc (12) is transmitted to the vehicle power supply (5) through the conductive part.

2. The electromagnetic-mechanical composite braking device for a hybrid electric vehicle according to claim 1, characterized in that, The reciprocating movement mechanism includes an electric push rod (9) and an electric push rod controller (8) electrically connected to the electric push rod (9). The electric push rod controller (8) is connected to the vehicle controller (17).

3. The electromagnetic-mechanical composite braking device for a hybrid electric vehicle according to claim 2, characterized in that, The conductive component is a brush (10), which is disposed at the end of the push rod of the electric push rod (9).

4. The electromagnetic-mechanical composite braking device for a hybrid electric vehicle according to claim 3, characterized in that, The motor controller (4), speed sensor (13), electric actuator controller (8), brake disc controller (16) and current controller (7) are electrically connected to the vehicle power supply (5).

5. The electromagnetic-mechanical composite braking device for a hybrid electric vehicle according to claim 4, characterized in that, The vehicle power supply (5) is a storage battery.

6. The electromagnetic-mechanical composite braking device for a hybrid electric vehicle according to claim 5, characterized in that, The motor controller (4), speed sensor (13), electric actuator controller (8), brake disc controller (16) and current controller (7) are respectively connected to the communication bus (6), and the communication bus (6) is connected to the vehicle controller (17).

7. A control method for a hybrid electric vehicle's electromechanical composite braking device as described in any one of claims 1-6, characterized in that, Includes the following steps: S1. When the vehicle is in motion, the speed sensor (13) acquires the real-time wheel speed signal and transmits it to the vehicle controller (17). When the vehicle controller (17) does not receive the braking signal, the vehicle controller (17) controls the reciprocating movement mechanism to separate the conductive parts from the brake disc (12) and controls the excitation coil (11) to be de-energized. S2. When the driver presses the brake pedal, a braking signal is generated and transmitted to the vehicle controller (17). When the real-time wheel speed is higher than the first threshold, the vehicle controller (17) controls the excitation coil (11) to be energized and controls the reciprocating movement mechanism to make the conductive part contact the brake disc (12). After the excitation coil (11) is energized, it acts on the rotating brake disc (12) and generates electromagnetic braking force to achieve electromagnetic braking. When the real-time wheel speed is lower than or equal to the first threshold, the vehicle controller (17) controls the excitation coil (11) to be energized, controls the reciprocating movement mechanism to make the conductive part contact the brake disc (12), and the excitation coil (11) interacts with the rotating brake disc (12) after being energized and generates electromagnetic braking force. The brake disc controller (16) is controlled so that the disc brake (14) applies mechanical braking force to the brake disc (12), thereby realizing electromagnetic mechanical composite braking.

8. The control method for a hybrid electric vehicle electromagnetic-mechanical composite braking device according to claim 7, characterized in that, When the vehicle controller (17) receives an emergency braking signal, the vehicle controller (17) controls the reciprocating movement mechanism to make the conductive part contact the brake disc (12). After the excitation coil (11) is energized, it acts on the rotating brake disc (12) and generates electromagnetic braking force. The controller (16) controls the brake disc controller to make the disc brake (14) apply mechanical braking force to the brake disc (12), thereby realizing electromagnetic mechanical composite braking.

9. The control method for a hybrid electric vehicle electromechanical composite braking device according to claim 8, characterized in that, When the excitation coil (11) is energized, it generates a magnetic field. The rotating brake disc (12) cuts the magnetic field lines to generate an induced current on the brake disc (12). When the conductive part contacts the brake disc (12), the induced current generated on the brake disc (12) is transmitted to the vehicle power supply (5) through the conductive part, thus completing the recovery of braking energy.

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