Research and Implement of PMSM Regenerative Braking Control for Electric Vehicle

As the society pays more and more attention to the environment pollution and energy crisis, the electric vehicle (EV) development also entered in a new era. With the development of motor speed control technology and the improvement of motor performance, although the dynamic performance and economical cost of EVs are both better than the internal-combustion engine vehicle (ICEV), the driving range limit and charging station distribution are two major problems which limit the popularization of EVs. In order to extend driving range for EVs, regenerative braking (RB) emerges which is able to recover energy during the braking process to improve the energy efficiency. This thesis aims to investigate the RB based pure electric braking system and its implementation. There are many forms of RB system such as fully electrified braking system and blended braking system (BBS) which is equipped both electric RB system and hydraulic braking (HB) system. In this thesis the main research objective is the RB based fully electrified braking system, however, RB system cannot satisfy all braking situation only by itself. Because the regenerating electromagnetic torque may be too small to meet the braking intention of the driver when the vehicle speed is very low and the regenerating electromagnetic torque may be not enough to stop the vehicle as soon as possible in the case of emergency braking. So, in order to ensure braking safety and braking performance, braking torque should be provided with different forms regarding different braking situation and different braking intention. In this thesis, braking torque is classified into three types. First one is normal reverse current braking when the vehicle speed is too low to have enough RB torque. Second one is RB torque which could recover kinetic energy by regenerating electricity and collecting electric energy into battery packs. The last braking situation is emergency where the braking torque is provided by motor plugging braking based on the optimal slip ratio braking control strategy. Considering two indicators of the RB system which are regenerative efficiency and braking safety, a trade-off point should be found and the corresponding control strategy should be designed. In this thesis, the maximum regenerative efficiency is obtained by a braking torque distribution strategy between front wheel and rear wheel based on a maximum available RB torque estimation method and ECE-R13 regulation. And the emergency braking performance is ensured by a novel fractional-order integral sliding mode control (FOISMC) and numerical simulations show that the control performance is better than the conventional sliding mode controller

Integration of anti-lock braking system and regenerative braking for hybrid/electric vehicles

Vehicle electrification aims at improving energy efficiency and reducing pollutant emissions which creates an opportunity to use the electric machines (EM) as Regenerative Braking System (RBS) to support the friction brake system. Anti-lock Braking System (ABS) is part of the active safety systems that help drivers to stop safely during panic braking while ensuring the vehicle’s stability and steerability. Nevertheless, the RBS is deactivated at a safe (low) deceleration threshold in favour of ABS. This safety margin results in significantly less energy recuperation than what would be possible if both RBS and ABS were able to operate simultaneously. Vehicle energy efficiency can be improved by integrating RBS and friction brakes to enable more frequent energy recuperation activations, especially during high deceleration demands. The main aim of this doctoral research is to design and implement new wheel slip control with torque blending strategies for various vehicle topologies using four, two and one EM. The integration between the two braking actuators will improve the braking performance and energy efficiency of the vehicle. It also enables ABS by pure EM in certain situations where the regenerative brake torque is sufficient. A novelmethod for integrating the wheel slip control and torque blending is developed using Nonlinear Model Predictive Control (NMPC). The method is well known for the optimal performance and enforcement of critical control and state constraints. A linear MPC strategy is also developed for comparison purpose. A pragmatic brake torque blending algorithm using Daisy-Chain with sliding mode slip control is also developed based on a pre-defined energy recuperation priority. Simulation using high fidelity model using co-simulation in Matlab/Simulink and CarMaker is used to validate the developed strategies. Different test patterns are used to evaluate the controllers’ performance which includes longitudinal and lateral motions of the vehicle. Comparison analysis is done for the proposed strategies for each case. The capability for real-time implementation of the MPC controllers is assessed in simulation testing using dSPACE hardware

The Safety and Dynamic Performance of Blended Brake System on a Two-Speed DCT Based Battery Electric Vehicle

Copyright © 2016 SAE International. Regenerative braking has been widely accepted as a feasible option to extend the mileage of electric vehicles (EVs) by recapturing the vehicle’s kinetic energy instead of dissipating it as heat during braking. The regenerative braking force provided by a generator is applied to the wheels in an entirely different manner compared to the traditional hydraulic-friction brake system. Drag torque and efficiency loss may be generated by transmitting the braking force from the motor, axles, differential and, specifically in this paper, a two-speed dual clutch transmission (DCT) to wheels. Additionally, motors in most battery EVs (BEVs) and hybrid electric vehicle (HEVs) are only connected to front or rear axle. Consequently, conventional hydraulic brake system is still necessary, but dynamic and supplement to motor brake, to meet particular brake requirement and keep vehicle stable and steerable during braking. Therefore, a complicated effect on the safety and performance of braking, mainly relating to tyre slips and locks, vehicle body bounces and braking distance will be applied by the blended brake system. In this paper, the brake energy recovery potentials of typical driving cycles are presented. Relevant critical limitations are introduced to define the available brake force distribution range for front and rear axles. Then the distribution strategies are compared and analyzed to achieve a satisfied balance between braking performance, driving comfort and energy recovery rate. Next, the required motor brake force is tuned, according to the response time and efficiency loss in transfer process which obtained in testing bench. At last, solutions for some special cases are proposed, for instance, motor brake torque interruption when downshifting occurs on long downhill. A credible conclusion is gained, through experimental validation of optimized brake force distribution strategy on a two-speed DCT based BEV testing rig, that the selected force distribution strategy help the blended brake system achieve a comfortable and safety braking during all driving conditions

Motion Dynamics Control of Electric Vehicles

In this chapter, I will explain the dynamics of electric vehicle and the support systems of drivers in detail, considering both structure and the function of the vehicle. Furthermore, the reliability is discussed. In car development and design that I have, car dynamic control system, turn ability, comfort, and safety must all be considered simultaneously. The safety and the comfort for the driver which are connected with various road surfaces and as well as the speed depend on the physical performance of the vehicle. In this chapter, we will explain the dynamics of the vehicle and the support system of the driver in detail, considering both the structure and function of the vehicle. In the design and development of car dynamic control system, turn ability, comfort, and safety must all be considered simultaneously. The safeness and comfort during a drive on various road surfaces and speed depend on the performance of these basic abilities of the vehicle

Estudo de modelagem de veículos elétricos e estratégia de controle de torque para sistemas de frenagens regenerativa e antitravamento

Orientador: José Antenor PomilioTese (doutorado) - Universidade Estadual de Campinas, Faculdade de Engenharia Elétrica e de ComputaçãoResumo: Os veículos elétricos têm despertado crescente interesse devido à sua capacidade para reduzir a poluição no meio ambiente, usando elementos de energia elétrica acumulado em baterias e supercapacitores para o acionamento da máquina elétrica no lugar de um motor de combustão interna. Por outro lado, a baixa autonomia do veículo elétrico continua sendo uma barreira para seu sucesso comercial. Instituções automobilísticas junto com a Academia enfrentam esse desafio com diversas soluções para aumentar a energia disponível. Entre as possibilidades está a frenagem regenerativa. A frenagem regenerativa é um processo no qual recupera-se energia de um veículo durante as desacelerações. Esta pesquisa se concentra nas frenagens para diversas condições com mudanças da superficie da estrada, considerando o sistema de frenagem regenerativo e o sistema de antibloqueio. Analisamos e revisamos os aspectos básicos da modelagem de um veículo com/sem ABS, assim como o comportamento dinâmico das rodas e mostramos uma contribuição para o estudo do controle de torque na máquina e estratégias de controle para o torque distribuído na combinação e cooperação entre o torque elétrico e o mecânico, mesmo com mudanças do solo e de métodos de operação, como descidas, obtendo estabilidade do veículo e recuperação de energiaAbstract: The interest in electric vehicles has grown worldwide due to their efficiency for reducing environmental pollution, by using energy elements such as batteries and supercapacitors to drive the electric machine, instead of an internal combustion engine. Contrarily, the low vehicle autonomy remains a barrier to their commercial success. Therefore, automotive institutions together with academics face the challenge through various solutions to increase the available energy. The regenerative braking is one of the implementations that helps a better use of the stored energy. Regenerative braking is a process in which energy is recovered from a vehicle during decelerations. This research focuses on braking for various road surface conditions. Furthermore, it considers the regenerative braking and the anti-lock braking systems regarding energy recovery performance for friction coefficient changes. In this work, we will review and analyze the basic aspects of the modeling of a vehicle with or without ABS, as well as the dynamic behavior of wheels. We will also present a contribution to the study of torque control and control strategies for the torque distribution regarding combination and co-operation between electric and mechanical torque. This process is done despite changes in ground surfaces and operating methods such as downhill, leading to better performance in the flexibility of vehicle stability and in the recovery of powerDoutoradoEnergia EletricaDoutora em Engenharia Elétrica149810/2013-0CAPESCNP

Integrated braking control for electric vehicles with in-wheel propulsion and fully decoupled brake-by-wire system

This paper introduces a case study on the potential of new mechatronic chassis systems for battery electric vehicles, in this case a brake-by-wire (BBW) system and in-wheel propulsion on the rear axle combined with an integrated chassis control providing common safety features like anti-lock braking system (ABS), and enhanced functionalities, like torque blending. The presented controller was intended to also show the potential of continuous control strategies with regard to active safety, vehicle stability and driving comfort. Therefore, an integral sliding mode (ISM) and proportional integral (PI) control were used for wheel slip control (WSC) and benchmarked against each other and against classical used rule-based approach. The controller was realized in MatLab/Simulink and tested under real-time conditions in IPG CarMaker simulation environment for experimentally validated models of the target vehicle and its systems. The controller also contains robust observers for estimation of non-measurable vehicle states and parameters e.g., vehicle mass or road grade, which can have a significant influence on control performance and vehicle safety

Investigation of Novel Displacement-Controlled Hydraulic Architectures for Railway Construction and Maintenance Machines

This dissertation aims at showing how to transform hydraulic systems of railway multi-actuator machinery characterized by inefficient state-of-the-art systems into the 21st Century. Designing machines that are highly efficient, productive, reliable, and cost affordable represents the target of this research. In this regard, migrating from valve-controlled architectures to displacement-controlled layouts is the proper answer. Displacement-controlled systems remove the losses generated by flow throttling typical of conventional circuits, allow an easy implementation of energy recovery (e.g. during regenerative braking), and create the possibility for the use of hybrid systems capable of maximizing the downsizing of the combustion engine. One portion of the dissertation focuses on efficient propulsion systems suitable for railway construction and maintenance machines. Two non-hybrid architectures are first proposed, i.e. a novel layout grounded on two independent hydrostatic transmissions (HSTs) and two secondary controlled hydraulic motors (SCHMs) connected in parallel. Three suitable control strategies are developed according to the specific requirements for railway machines and dedicated controllers are implemented. Detailed analyses are conducted via high-fidelity virtual simulations involving accurate modeling of the rail/wheel interface. The performance of the propulsion systems is proven by acceptable velocity tracking, accurate stopping position, achieving regenerative braking, and the expected behavior of the slip coefficients on both axles. Energy efficiency is the main emphasis during representative working cycles, which shows that the independent HSTs are more efficient. They consume 6.6% less energy than the SCHMs working with variable-pressure and 12.8% less energy than the SCHMs controlled with constant-pressure. Additionally, two alternative hybrid propulsion systems are proposed and investigated. These architectures enable a 35% reduction of the baseline machine’s rated engine power without modifying the working hydraulics. Concerning the working hydraulics, the focus is to extend displacement-controlled technology to specific functions on railway construction and maintenance machines. Two specific examples of complete hydraulic circuits for the next generation tamper-liners are proposed. In particular, an innovative approach used to drive displacement-controlled dual function squeeze actuators is presented, implemented, and experimentally validated. This approach combines two functions into a unique actuator, namely squeezing the ballast and vibrating the tamping tools of the work-heads. This results in many advantages, such as variable amplitude and variable frequency of the tamping tools’ vibration, improved reliability of the tamping process, and energy efficient actuation. A motion of the squeeze actuator characterized by a vibration up to 45 Hz, i.e. the frequency used in state-of-the-art systems, is experimentally confirmed. In conclusion, this dissertation demonstrates that displacement-controlled actuation represents the correct solution for next-generation railway construction and maintenance machines

MPC BASED TORQUE ALLOCATION STRATEGY TO ENHANCE THE PERFORMANCE OF A REGENERATIVE BRAKING SYSTEM CONSIDERING HALF SHAFT VIBRATION

A regenerative brake system is widely used in the automotive industry mainly due to its ability for energy recovery. Since an electric motor used in the regenerative brake has a faster torque response compared to that of the hydraulic system, it can be applicable for various applications in the area of active safety systems, especially brake control applications. However, due to its actuation limitations, it cannot be independently used for all braking scenarios, and require to be used in combination with the conventional hydraulic brakes. In this work, a multi-objective brake torque allocation method using model predictive control is proposed. The proposed strategy has two objectives: bandwidth based torque allocation, and reduction in drive shaft vibrations. In order to show the effectiveness of the proposed control strategy, a simulation model with a single wheel and a five phase anti-lock brake system has been developed. This simulation study is then extended with a full vehicle model in Carsim software. The simulation results show that vehicle stopping distance and drive shaft vibrations are reduced by using the proposed control strategy.Master of Science in EngineeringAutomotive Systems Engineering, College of Engineering and Computer ScienceUniversity of Michigan-Dearbornhttp://deepblue.lib.umich.edu/bitstream/2027.42/136062/1/DEVELOPMENT OF A MODEL PREDICTIVE CONTROL BASED TORQUE ALLOCATION STRATEGY FOR A REGENERATIVE BRAKING SYSTEM, DURING ANTI-LOCK BRAKE SYSTEM OPERATION.pdfDescription of DEVELOPMENT OF A MODEL PREDICTIVE CONTROL BASED TORQUE ALLOCATION STRATEGY FOR A REGENERATIVE BRAKING SYSTEM, DURING ANTI-LOCK BRAKE SYSTEM OPERATION.pdf : Master of Science in Engineering Thesi