Trailer Brake Gain Control Based on Regenerative Brake Capacity
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Solution Overview
Problem
Conventional electrified vehicles with regenerative braking systems and manual trailer brake gain settings often lead to unnecessary wear on vehicle and trailer brakes due to improper settings during towing operations.
Innovation Solution
A dynamic braking system that automatically adjusts trailer brake gain based on the regenerative braking capacity of the vehicle's electric propulsion system, maximizing energy recovery and minimizing brake wear by prioritizing regenerative braking when capacity is high and using friction brakes when capacity is low.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual trailer brake gain settings are used in conventional electrified vehicles, then the braking system can be operated with simple control, but unnecessary wear on vehicle and trailer brakes occurs due to improper settings
Solution Approach 1:
The brake controller automatically adjusts trailer brake gain based on regenerative braking capacity without requiring manual user input. The system monitors regenerative braking capacity and autonomously optimizes brake distribution, allowing the system to serve itself rather than requiring continuous user adjustment.
Solution Approach 2:
The system continuously monitors regenerative braking capacity and uses this feedback to dynamically adjust trailer brake gain settings. The brake controller receives information about available regenerative braking capacity and automatically modifies brake distribution to optimize performance and minimize wear.
2Loss of energy
If regenerative braking capacity is high, then energy recovery is maximized, but trailer brake gain must be precisely controlled to avoid excessive wear
Solution Approach 1:
The trailer brake gain setting is made dynamic rather than fixed. The system continuously adjusts trailer brake gain based on real-time regenerative braking capacity, transitioning from static manual settings to dynamic automated control that adapts to changing operating conditions.
Solution Approach 2:
The system changes the brake gain parameter automatically based on regenerative braking capacity. When regenerative capacity is high, the system adjusts trailer brake gain to optimize energy recovery while preventing excessive brake wear through automated parameter modification.
3Reliability
If regenerative braking capacity is low, then friction brakes must be used more, but this increases brake wear and reduces energy recovery efficiency
Solution Approach 1:
The system prepares for reduced regenerative braking capacity by automatically adjusting trailer brake gain in advance. When regenerative capacity decreases, the system proactively modifies brake distribution to maintain reliable braking function while minimizing friction brake wear through preemptive adjustment.
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
The system optimizes brake wear and energy recovery by dynamically adjusting trailer brake gain, ensuring efficient vehicle and trailer braking while towing, thereby reducing wear on brakes and maximizing energy regeneration.
Implementation Method 1
a regenerative braking system configured to generate electrical energy to recharge the HV battery system
Implementation Method 2
a vehicle brake actuator configured to selectively actuate one or more vehicle friction brakes
Data Source
AI summary
A dynamic braking system for an electrified vehicle having a high voltage (HV) battery system and an electric propulsion system includes a regenerative braking system configured to recharge the HV battery system, a vehicle controller configured to monitor and control the regenerative braking system to selectively perform a regenerative braking operation, and a vehicle brake actuator configured to selectively actuate one or more vehicle friction brakes. A brake controller is in signal communication with the vehicle brake actuator and configured for signal communication with a trailer brake actuator to selectively actuate trailer friction brakes. The brake controller is programmed to receive a driver braking request, receive a signal indicating a regenerative braking capacity of the electric propulsion system, and based on the driver braking request and the regenerative braking capacity, automatically adjust a trailer brake gain to (i) maximize energy recovery via regenerative braking and (ii) reduce brake wear.