Simulation of Regenerative Brake Blending Using Hardware-in-the-Loop on an Inertia Dynamometer

Current standards like the SAE J2789 have provisions for adjusting the brake inertia for regenerative braking systems. However, a comprehensive method to implement the correct brake blending during inertia dynamometer testing in real-time remains elusive. With Hybrid and Battery Electric Vehicles (BEV) propulsion systems on the rise, the need to develop the corresponding friction couples and braking systems is ever increasing. To better understand new phenomena related to low-temperature burnish, corrosion, brake balance, NVH, and brake emissions, the automotive industry needs to rely on laboratory testing using inertia dynamometers. The main innovation on the approach presented is the ability to have an actual (ego) brake corner in the test environment to provide real-time torque and temperature response during testing. This oral-only presentation elaborates on critical aspects of HiL simulation for BEV brake blending. What makes this work unique is the focus on the development of working software and working hardware using software ECUs for the battery controller, commercially available hardware (HiL and standards dynamometer platforms), and application to real-life cases and driving cycles. The work presents the software and hardware modules; the algorithms to control the ego brake corner; the communication packets; events, and scenario triggers; and the automation of a test cycle � with practical examples. These developments can support early system evaluation, simulation of static and dynamic scenarios, and expand to include multiple ego brake corners.