Design of regenerative braking energy feedback system for ultracapacitor heavy-duty tractor
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摘要: 针对电动汽车制动能量再生回馈问题, 基于陕汽集团超级电容纯电动重型牵引原型车SX4186EV, 设计了一个新型的复合制动系统, 由独立的制动能量再生回馈与双回路气制动2个子系统并联构成。基于制动强度与实车载荷, 提出一种基于规则的再生制动力与气制动力分配策略。在上海码头牵引车实际行驶工况下, 检验复合制动系统的能量回收效率。试验结果表明: 在满载与空载制动工况下, 制动能量回收效率分别为14.534%与55.617%, 平均值为35.076%, 而铅酸电池与锂电池电动汽车实际回收效率一般仅约为10%, 因此, 超级电容纯电动汽车制动能量回收效率高。Abstract: In view of regenerative braking energy feedback problem for electric vehicle(EV), based on the SX4186EV prototype of ultracapacitor pure-electric heavy-duty tractor of Shaanxi Automobile Group Co., Ltd., a hybrid braking system was proposed. the system was made up of two independent subsystems, including energy recovery braking subsystem and double-loop air braking subsystem. Based on braking intensity and real load, a rule-based braking force allocation strategy for the subsystems was put forward. A road experiment under the actual running condition at Shanghai Dock was carried out to test the braking energy recovery efficiency of the system. Experimental result shows that the braking energy recovery efficiencies under full-loaded running condition and unloaded running condition are 14.534% and 55.617% respectively, and the average is 35.076%. The efficiencies of electric vehicles powered with lead-acid and lithium batteries are usually about 10%, so the ultracapacitor heavy-duty tractor has higher braking energy recovery efficiency.
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Key words:
- automotive engineering /
- electric vehicle /
- heavy-duty tractor /
- ultracapacitor /
- regenerative brake /
- energy recovery
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图 2 双回路气制动系统
1-空压机; 2-金属软管; 3-单向阀; 4-空气干燥器; 5-再生储气罐; 6-五通阀; 7-气包; 8-气压报警传感器; 9-三通阀; 10-手刹制动阀; 11-差动式继动阀; 12-气室; 13-制动器; 14-脚刹制动阀
Figure 2. Double-loop air braking system
图 4 行车过程中超级电容端电压、电流与功率
Figure 4. Terminal voltage, current and power of ultracapacitor during driving cycle
图 5 空载制动电容端电压、电流与功率
Figure 5. Terminal voltage, current and power of ultracapacitor under unloaded braking
图 6 满载制动电容端电压、电流与功率
Figure 6. Terminal voltage, current and power of ultracapacitor under full-loaded braking
表 1 电动机参数
Table 1. Parameters of motor
型式 三相异步交流电动机 额定电压/V 400 额定功率/kW 100 峰值功率/kW 160 额定转速/(r·min-1) 824 最高转速/(r·min-1) 4 500 额定扭矩/(N·m) 1 565 最大扭矩/(N·m) 2 300 
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表 2 超级电容参数
Table 2. Parameters of ultracapacitor
单体容量/F 160 000 储能电压/V 350~586 储能输出能量/(kW·h) 12 最大充电电流/A 400 充电停止电流/A 80~160 最大放电电流/A 600 电容最高使用温度/℃ 55
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表 3 逆变器参数
Table 3. Parameters of inverter
额定容量/(kV·A) 220 额定电压/V 340~650 额定输出电压/V 400 额定输出电流/A 320 工作频率/Hz 0~150
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表 4 增程测试结果
Table 4. Tested result of range-extended ratio
T/min W3/(kW·h) W1/(kW·h) W2/(kW·h) r/% 29.3 10.498 2.524 7.974 31.65
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表 5 回馈效率测试结果
Table 5. Tested result of recovery efficiency
制动模式 空载急刹车 空载中轻度刹车 满载急刹车 满载中轻度刹车 Ev/(kW·h) 0.181 583 0.179 311 0.498 565 0.505 607 W4/(kW·h) 0.047 060 0.152 983 0.055 743 0.090 435 R/% 25.916 85.317 11.181 17.887 平均回收效率/% 55.617 14.534 35.076
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