Regenerative Brake Device with Linear Lever Control
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Solution Overview
Problem
Current regenerative brake devices for electric assist bicycles do not provide a linear adjustment of regenerative braking force proportional to the operation amount of the brake lever, leading to inefficient energy recapture and user discomfort due to abrupt braking.
Innovation Solution
A regenerative brake device that includes a manual brake, a motor, a brake sensor to detect the operation amount of the brake lever, and a power control unit using Pulse Width Modulation to adjust the regenerative braking force based on the detected lever operation, ensuring the regenerative braking force is applied in accordance with the user's input before the manual brake is engaged.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a regenerative brake switch with reed switch and magnet piece is used to trigger regenerative braking, then regenerative braking can be activated during deceleration, but the regenerative braking force cannot be adjusted linearly in proportion to the brake lever operation amount
Solution Approach 1:
The patent replaces the conventional mechanical reed switch-based brake control system with a sensor-based detection system. The brake sensor detects the operation amount of the brake lever and converts it into electrical signals that can be processed by the power control unit, enabling linear adjustment of regenerative braking force proportional to lever operation while maintaining system simplicity.
Solution Approach 2:
The patent changes the control parameter from binary (switch on/off) to continuous (operation amount detection). By detecting the brake lever operation amount as a continuous variable and using it to modulate the regenerative braking force, the system achieves linear adjustment capability without requiring complex mechanical linkages or multiple switches.
2Loss of energy
If regenerative braking force is not adjusted in proportion to brake lever operation amount, then the regenerative brake switch design is simple, but energy recapture efficiency is reduced and user comfort deteriorates due to abrupt braking
Solution Approach 1:
The patent implements a feedback control mechanism where the brake sensor continuously monitors the brake lever operation amount and feeds this information to the power control unit. The power control unit then adjusts the regenerative braking force in real-time based on the detected operation amount, creating a closed-loop control system that optimizes energy recapture while maintaining user comfort.
Solution Approach 2:
The patent transitions from a static binary switch system to a dynamic control system that continuously adapts the regenerative braking force according to the brake lever operation amount. This dynamic adjustment allows the system to optimize energy recapture efficiency across different braking scenarios while providing smooth and comfortable deceleration.
3Reliability
If manual brake is used for all braking situations, then braking force is sufficient and reliable, but energy is wasted as heat loss due to friction and travel distance on single charge is reduced
Solution Approach 1:
The patent merges the regenerative braking system and the manual friction brake system into a unified brake control system. The brake sensor detects the operation amount and the power control unit intelligently coordinates both braking mechanisms, using regenerative braking as the primary method to recover energy while maintaining the manual brake as a supplement to ensure sufficient and reliable braking force across all conditions.
Solution Approach 2:
The patent converts the kinetic energy that would normally be wasted as heat during friction braking into useful electrical energy through regenerative braking. By using the motor as a generator during deceleration, the system transforms the harmful energy loss into a beneficial energy recapture mechanism, extending travel distance while maintaining braking reliability.
4Loss of energy
If regenerative braking force is excessive and actuated abruptly when switch turns on, then energy recapture is maximized, but user comfort deteriorates and operation becomes difficult
Solution Approach 1:
The patent applies partial regenerative braking force initially, proportional to the brake lever operation amount, rather than applying maximum regenerative braking force abruptly. This partial action approach allows the system to begin energy recapture smoothly while avoiding excessive braking force that would compromise user comfort, with the understanding that additional braking force can be applied as needed.
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 allows for a smooth and desired braking force, reducing energy loss through heat and extending the travel distance of the vehicle on a single battery charge while maintaining the functionality of the manual brake for safety.
Implementation Method 1
a motor configured to be coupled to a wheel of the vehicle, the motor being driven by a power from a battery, and acting as a regenerative brake that charges the battery with an electromotive force of the motor
Implementation Method 2
a brake sensor that senses an operation amount of the brake lever
Data Source
AI summary
A regenerative brake device for a vehicle includes a manual brake configured to apply a brake to a wheel of the vehicle by a manual operation of a brake lever; a motor configured to be coupled to a wheel of the vehicle, the motor being driven by a power from a battery, and also alternatively acting as a regenerative brake that charges the battery with an electromotive force of the motor; a brake sensor that detects a manual brake application point at which the manual brake is actuated from an operation amount of the brake lever; and a power control unit that performs regenerative power control for charging the battery with the electromotive force of the motor based on an output signal from the brake sensor so that the regenerative brake is generated in accordance with the operation amount of the brake lever.