Electric Braking Control for Regenerative Energy Recovery
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Solution Overview
Problem
Existing electric vehicles face inefficiencies in regenerative braking, where not all generated power is stored due to energy source capacity limitations, leading to the use of mechanical braking devices and potential safety issues, especially when the energy source is fully charged.
Innovation Solution
An electric braking control method that distributes regenerative braking power based on the energy source's charge status, allowing for maximum energy recovery by either charging the energy source or dissipating excess power through the electric drive system, thereby reducing the need for mechanical braking and improving vehicle handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If regenerative braking is used to charge the energy source, then energy recovery is improved, but when the energy source is fully charged, mechanical braking devices must be used which worsens vehicle handling
Solution Approach 1:
The patent replaces mechanical braking devices with an electric braking system that uses the motor as a generator. The motor converts kinetic energy into electrical energy during braking, which is then fed back to the energy source. This substitution eliminates the need for mechanical friction braking, improving energy recovery while maintaining smooth and controllable braking without the handling issues associated with mechanical brakes.
Solution Approach 2:
The patent introduces a controller as an intermediary between the braking command and the motor. The controller manages the braking process by converting mechanical braking commands into appropriate motor control signals, coordinating between regenerative braking and energy source charging status. This intermediary ensures optimal energy recovery while preventing overcharging and maintaining vehicle handling quality.
2Loss of energy
If regenerative braking is used when energy source is full, then energy recovery is attempted, but safety issues arise due to inability to dissipate excess power
Solution Approach 1:
The patent implements dynamic braking control where the controller continuously adjusts the motor's braking torque based on real-time monitoring of the energy source's charging status. When the energy source can accept more charge, regenerative braking is maximized. When the energy source is full or near-full, the controller dynamically transitions to using the motor as a dynamic brake with controlled energy dissipation, ensuring safety while maintaining energy recovery optimization.
Solution Approach 2:
The patent employs feedback control by continuously monitoring the energy source's state of charge and using this information to adjust the braking strategy. The controller receives feedback about the energy source status and modifies the motor's operating mode accordingly - switching between regenerative braking and controlled dynamic braking to prevent overcharging while ensuring braking safety and reliability.
3Loss of energy
If mechanical braking devices are used to dissipate power, then energy recovery is reduced, but the service life of mechanical braking devices is extended
Solution Approach 1:
The patent substitutes mechanical friction braking with an electric braking system using the motor as a generator. This replacement dramatically reduces the usage frequency and load on mechanical braking devices, extending their service life. Simultaneously, the electric braking system recovers energy that would otherwise be lost as heat in mechanical brakes, improving overall energy efficiency.
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 method enhances the vehicle's range by maximizing energy recovery, improves drive capability, and extends the service life of mechanical braking devices by minimizing their use, while also eliminating the need for current dump resistors, thus lowering costs.
Implementation Method 1
The motor is configured to receive the drive electrical power provided from the converter and provide mechanical power for driving at least one load in drive mode of operation, and configured to convert mechanical power from the load into the regenerative electrical power in regenerative mode of operation
Implementation Method 2
The converter is configured to convert the electrical power received from the energy source into drive electrical power, and configured to convert regenerative electrical power into charge electrical power for charging the energy source
Data Source
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AI summary
An example of an apparatus is disclosed comprising an energy source 102, a first motor 106, a second motor and a control system. The first motor 106 is configured to drive a first load 103 and the second motor is configured to drive a second load. The control system is coupled to the energy source 102, the first and the second motors. The control system dumps the braking power generated by the first load 103 at least partially on the first motor 106 according to a first braking command. The control system dumps the braking power generated by the second load at least partially on the second motor, according to a second braking command. Also disclosed are other varieties of apparatuses, vehicles, such as electric tractors, electric forklifts and relative methods, etc.