Motor Controller Regenerative Braking via Pedal Rotation Sensor
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Solution Overview
Problem
Existing regenerative braking systems in electric power-assisted vehicles, such as electric bicycles, face challenges in providing consistent braking force with rider intentions due to mechanical brake mismatch, hand fatigue from prolonged braking, and inefficient energy conversion, as they can only detect binary brake operation states and lack precise control over regenerative braking force.
Innovation Solution
A controller system that includes a driving control unit and a regenerative control unit, utilizing a pedal rotation sensor to initiate and control regenerative braking based on the rotation direction and amount of the pedal, with a control coefficient calculation unit to adjust the regenerative force dynamically according to vehicle speed and pedal position, allowing easy start and stop of regeneration and reducing burden on the rider.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional binary brake operation detection is used, then device complexity is reduced, but measurement precision of braking operation is insufficient
Solution Approach 1:
The patent replaces mechanical brake wire tension detection with magnetic field-based pedal rotation detection. The pedal rotation sensor uses a magnet and magnetic sensor to detect pedal position and rotation direction, eliminating the need for mechanical brake wire tension sensors and providing precise detection of both brake application and release states.
Solution Approach 2:
The pedal rotation sensor serves multiple functions: detecting brake application, detecting brake release, determining rotation direction, and measuring rotation amount. This single sensor replaces multiple separate detection systems, reducing overall device complexity while improving measurement precision.
2Ease of operation
If mechanical brakes are operated for prolonged periods, then speed control is achieved, but rider ease of operation deteriorates due to hand fatigue
Solution Approach 1:
The system enables automatic regenerative braking that operates without continuous rider input. Once the rider releases the brake lever, the control unit automatically activates regenerative braking to maintain speed control, eliminating the need for prolonged manual brake operation and reducing hand fatigue.
Solution Approach 2:
The control unit continuously monitors pedal rotation sensor signals and vehicle speed to automatically adjust regenerative braking force. This feedback mechanism ensures smooth and natural deceleration that matches rider intentions, making the braking experience more comfortable and easier to operate.
3Adaptability or versatility
If pre-determined regenerative braking configurations are used, then device complexity is reduced, but adaptability to rider intentions is insufficient
Solution Approach 1:
The control unit dynamically adjusts regenerative braking force based on real-time detection of pedal rotation amount and rotation direction. Instead of using fixed pre-determined configurations, the system continuously adapts the braking force to match the rider's instantaneous intentions, providing smooth and natural deceleration characteristics.
Solution Approach 2:
The control unit uses feedback from the pedal rotation sensor to continuously monitor rider input and automatically adjusts regenerative braking force accordingly. This real-time feedback mechanism enables the system to adapt to varying rider intentions without requiring complex pre-programmed configurations for different riding conditions.
4Reliability
If brake wire tension detection is used, then braking operation amount can be detected, but manufacturing precision deteriorates due to brake wire stretching over time
Solution Approach 1:
The patent replaces mechanical brake wire tension detection with a magnetic field-based pedal rotation detection system. The pedal rotation sensor uses a magnet attached to the pedal arm and a magnetic sensor to detect pedal position and rotation, eliminating the problems of brake wire stretching and calibration drift associated with mechanical tension sensors.
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
Enables regenerative braking force that aligns with the rider's intentions, reducing hand fatigue and improving energy efficiency by dynamically controlling the regenerative braking force based on real-time pedal input, ensuring consistent and comfortable deceleration.
Implementation Method 1
a motor that drives a vehicle
Implementation Method 2
regenerative operation of the motor, which stores the kinetic energy of the vehicle into the battery
Data Source
AI summary
In one aspect, a controller for driving a motor of the present invention includes a driving control unit that controls driving of a motor, and a regenerative control unit that instructs the driving control unit to start regeneration when a signal from a pedal rotation sensor that detects a rotation direction of the pedal indicates that the rotation direction of the pedal is backwards, the regenerative control unit controlling an amount of the regeneration in accordance with a backward rotation amount of the pedal while the rotation direction of the pedal is backwards, the backward rotation amount being obtained by the pedal rotation sensor.