BEV Charge Buffer Control for Regenerative Braking Capacity

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Solution Overview

Problem

Battery electric vehicles (BEVs) face challenges in maintaining a suitable battery state of charge to ensure regenerative braking is effective without overloading the energy storage device, particularly during Type II-A tests, due to uncertainties in energy balance and computing power limitations.

Innovation Solution

A method for an electrically drivable vehicle that involves determining and transmitting vehicle and position information to a vehicle-external server to calculate and set a target state of charge, allowing the energy storage device to be charged externally and optimizing regenerative braking capabilities without artificially emptying the battery.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If the battery is charged to maximum capacity at external charging stations, then the energy storage capacity is maximized, but the risk of battery overload during regenerative braking increases

Engineering Contradiction:
Improvebattery energy storage capacityVSAvoidbattery overload protection
Core Design Contradiction:
Quantity of substanceVSReliability

Solution Approach 1:

The system performs preliminary calculation of the buffer state of charge before charging at external charging stations. The server determines the current state of charge, calculates the buffer (difference between maximum capacity and target state of charge), and communicates this to the charging station. The charging process is then controlled to stop when the buffer is reached, preventing battery overload while maximizing energy storage capacity.

Inventive Principle:
Principle #10Preliminary action

2Reliability

If a buffer is maintained between maximum capacity and target state of charge, then battery overload is prevented, but the vehicle range is significantly reduced

Engineering Contradiction:
Improvebattery overload protectionVSAvoidvehicle range
Core Design Contradiction:
ReliabilityVSLength of moving object

Solution Approach 1:

The buffer state of charge is made dynamic rather than static. The system continuously monitors the current state of charge during operation and recalculates the buffer based on real-time conditions. When the current state of charge approaches the target, the buffer decreases, allowing more battery capacity to be utilized. This dynamic adjustment optimizes vehicle range while maintaining battery protection.

Inventive Principle:
Principle #15Dynamics

3Reliability

If additional wear-free continuous brakes (retarders or brake resistors) are added, then the Type II-A test can be fulfilled, but the device complexity and cost increase

Engineering Contradiction:
ImproveType II-A test complianceVSAvoidbraking system complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The system uses the battery's existing energy storage capability to fulfill the Type II-A test requirements through intelligent energy management. By calculating and controlling the buffer state of charge, the system enables regenerative braking to absorb excess energy during downhill sections without requiring additional braking devices. The battery serves itself as the energy absorption mechanism, eliminating the need for complex additional braking systems.

Inventive Principle:
Principle #25Self-service

4Length of moving object

If the target state of charge is set to maximum, then the vehicle range is maximized, but the ability to perform regenerative braking is restricted

Engineering Contradiction:
Improvevehicle rangeVSAvoidregenerative braking capability
Core Design Contradiction:
Length of moving objectVSUse of energy by moving object

Solution Approach 1:

The system performs preliminary calculation of the buffer state of charge before charging, allowing the target state of charge to be set to maximum while preventing actual overload. The server calculates the buffer based on route information, vehicle mass, and energy consumption data, then communicates this to the charging station. During operation, when the buffer is reached, regenerative braking automatically activates to maintain the target state of charge, preserving full regenerative braking capability while maximizing range.

Inventive Principle:
Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach ensures reliable and efficient operation of BEVs by accurately determining the target state of charge, preventing battery overload and reducing the need for additional retarders or complex brake performance estimators, thus enhancing range and cost-effectiveness.

Implementation Method 1

an electric drive capable of regenerative braking, wherein the energy storage device can be charged during regenerative braking

Methodology Applied
Scientific EffectRegenerative braking:

Data Source

PatentUS20250018829A1Method for electrically drivable vehicle, in particular a utility vehicle, method for a vehicle-external server, computer program, computer-readable medium, controller, electrically drivable vehicle, vehicle-external server
Publication Date: 2025.01.16 ZF CV SYST GLOBAL GMBH
  • US20250018829A1 patent drawing
  • US20250018829A1 patent drawing
  • US20250018829A1 patent drawing

AI summary

Method for an electrically drivable vehicle, in particular a utility vehicle, with an energy storage device and an electric drive capable of regenerative braking, wherein the energy storage device can be charged during regenerative braking and the energy storage device can be charged at a vehicle-external charging station, the method including the steps: determining a state of charge, wherein the state of charge includes information about whether the energy storage device is being charged by the vehicle-external charging station; detecting, depending on the state of charge, vehicle information concerning the vehicle, in particular the utility vehicle, and position information concerning the position of the vehicle, in particular the utility vehicle; transmitting the vehicle information and the position information to an external server; and receiving a target state of charge from the vehicle-external server.