Brake Power Allocation for Regenerative Braking Priority
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Solution Overview
Problem
Existing brake systems in electric machines, such as vehicles, often rely heavily on friction-based systems, leading to increased wear and tear, reduced energy efficiency, and thermal capacity issues, as they are used in a high percentage of braking situations, rather than utilizing regenerative and auxiliary systems for energy storage and reuse.
Innovation Solution
A computer-implemented method and brake controller that identifies braking operations, determines the amount of energy associated with brake power, and allocates it to systems based on priority, favoring regenerative and auxiliary systems over mechanical brake systems to maximize energy storage and reuse, thereby reducing the reliance on friction-based systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If friction-based brake systems are used in a high percentage of braking situations, then reliable braking performance is achieved, but wear and tear on brake components increases and energy efficiency decreases
Solution Approach 1:
The brake control system dynamically adjusts the selection between regenerative and friction-based braking based on real-time conditions including battery state of charge, temperature, and braking requirements. This dynamic adaptation allows the system to maximize regenerative braking usage while maintaining reliable braking performance, thereby reducing friction-based brake wear.
Solution Approach 2:
The system replaces mechanical friction-based braking with regenerative electromagnetic braking whenever conditions permit. By substituting the mechanical friction system with an electromagnetic regenerative system, the patent reduces wear on mechanical brake components while maintaining braking effectiveness.
2Ease of operation
If friction-based brake systems are used in a high percentage of braking situations, then braking control is maintained, but energy efficiency is reduced due to loss of brake power
Solution Approach 1:
The system substitutes mechanical friction braking with regenerative electromagnetic braking to capture and reuse brake power energy. This substitution maintains braking control while converting previously lost energy into usable electrical energy for the battery, significantly improving overall energy efficiency.
Solution Approach 2:
The system converts the previously harmful energy loss during braking into a beneficial resource by capturing brake power through regenerative braking and storing it in the battery. This transforms energy that would have been wasted as heat and sound into reusable electrical energy, improving energy efficiency while maintaining braking control.
3Force
If friction-based brake systems are used extensively, then braking capability is ensured, but thermal capacity of the brake system is exceeded
Solution Approach 1:
The system replaces friction-based mechanical braking with regenerative electromagnetic braking, which does not generate excessive heat through friction. This substitution maintains the required braking force while avoiding the thermal capacity problems associated with extensive friction-based braking usage.
4Loss of energy
If regenerative and auxiliary systems are prioritized for energy storage, then energy efficiency is enhanced, but system complexity increases
Solution Approach 1:
The brake control system integrates multiple functions into a single unified controller that manages both regenerative braking and friction-based braking operations. This multi-functional approach enhances energy efficiency through optimized regenerative braking usage while avoiding the complexity that would arise from separate independent control systems.
Solution Approach 2:
The patent merges the regenerative braking system and friction-based braking system into a unified brake control architecture that coordinates both systems. This integration optimizes energy efficiency by prioritizing regenerative braking while maintaining the simplicity of a single coordinated control system rather than multiple independent systems.
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 extends the life of brake components, enhances energy efficiency, and optimizes energy utilization by prioritizing energy storage and reuse in regenerative and auxiliary systems during braking operations, minimizing the use of mechanical brake systems and associated wear.
Implementation Method 1
a regenerative brake system configured to charge the battery system based on energy captured during a braking operation
Implementation Method 2
a battery system configured to store energy
Data Source
AI summary
A brake controller of a machine can be configured to determine brake power associated with braking operations, such as operations to slow the machine or maintain a speed of the machine. The brake controller can allocate the brake power among systems such as a battery system, a resistive grid, auxiliary systems, a mechanical brake system, and/or other systems, based on a defined priority order of the systems. For example, the brake controller can prioritize using a regenerative brake system to charge a battery system during a braking operation up to a currently-available capacity of the battery system, and allocating any remaining brake power to a lower-priority system. The mechanical brake system can be the lowest-priority system, such that use of the mechanical brake system can be avoided unless an amount of brake power exceeds capacities of higher-priority systems to consume the brake power.