Brake Control Device for Regenerative Energy Recovery
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Solution Overview
Problem
Conventional braking systems with electric drives face limitations in recuperative efficiency, especially when using a single brake circuit configuration, which restricts the ability to effectively blend generator braking torque with hydraulic braking, leading to suboptimal energy recovery and increased energy consumption.
Innovation Solution
A control device and method for a braking system that allows for an X brake circuit split, enabling wheels on different axles to share a common brake circuit, with advanced valve control strategies to suppress brake pressure build-up in specific wheel brake calipers, allowing for efficient generator charging without compromising driver feedback or vehicle deceleration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single brake circuit configuration is used, then the system structure is simple, but the recuperative efficiency is severely limited
Solution Approach 1:
The brake system is divided into multiple independent brake circuits (first brake circuit with first wheel brake caliper, second brake circuit with second wheel brake caliper) that can be controlled separately. This segmentation allows selective application of regenerative braking to specific circuits while maintaining hydraulic braking in others, thereby improving overall recuperative efficiency without requiring complete system redesign.
Solution Approach 2:
The control device dynamically switches between different operating modes (first operating mode with suppressed brake pressure build-up for regenerative braking, second operating mode with normal brake pressure build-up for hydraulic braking) based on real-time conditions such as deceleration demand and generator availability. This dynamic adaptation optimizes energy recovery while maintaining braking performance.
2Productivity
If brake pressure build-up is suppressed in all wheel brake calipers, then generator charging is maximized, but driver feedback and vehicle deceleration are compromised
Solution Approach 1:
Different brake pressure control strategies are applied to different brake circuits based on local requirements. The first brake circuit operates in regenerative mode with suppressed pressure build-up for maximum charging, while the second brake circuit maintains normal pressure build-up to provide adequate driver feedback and deceleration control. This localized differentiation resolves the contradiction between charging rate and feedback quality.
Solution Approach 2:
Instead of completely suppressing brake pressure build-up in all circuits, the system applies partial suppression only in the first brake circuit while allowing normal pressure development in the second brake circuit. This partial action maintains sufficient driver feedback and vehicle control while still enabling significant generator charging.
3Loss of energy
If an X brake circuit split is implemented, then recuperative efficiency is enhanced, but the device complexity increases
Solution Approach 1:
The control device is designed to manage multiple brake circuits and operating modes through a single integrated control unit that can selectively apply different control strategies to different circuits. This multi-functionality allows the system to achieve enhanced recuperative efficiency through X-brake circuit configuration without proportionally increasing overall system complexity, as the control logic handles multiple functions within a unified architecture.
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 solution enhances recuperative efficiency, reduces energy consumption, and minimizes emissions by enabling faster battery charging while maintaining standard brake actuation feelings, even during sharp braking, and allows for regenerative braking in both sharp and slight braking scenarios.
Implementation Method 1
a generator (102) arranged on the vehicle, by means of which a vehicle battery (103) can be charged
Implementation Method 2
the pressure medium displaced from the master brake cylinder to the wheel brakes by the actuation of the brake pedal
Data Source
Figure 1
Figure 2A
Figure 2B~2D
AI summary
The invention relates to a control device (100) for a brake system of a vehicle, by means of which control device (100) the brake system can be controlled in a first operating mode in which, in the case of activation of a brake activation element (64) applied by a driver, a buildup of brake pressure is prevented at least in a first wheel brake calliper (53a) of a first brake circuit (50) of the brake system, while during the first operating mode a first wheel inlet valve (74a) of the first wheel brake calliper (53a) can be placed at least temporarily in an at least partially open state, and a first wheel outlet valve (78a) of the first wheel brake calliper (53a) can be kept in an at least partially open state, wherein a second wheel inlet valve (75a) of a second wheel brake calliper (54a) of the first brake circuit (50) can be placed in an at least partially open state, and a second wheel outlet valve (79a) of the second wheel brake calliper (54a) can be placed in a closed state, in such a way that a brake pressure can be built up in the second wheel brake calliper (54a). Furthermore, the invention relates to a method for operating a brake system of a vehicle.