Browse Topic: Regenerative braking

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Two-Channel Pressure Control Using an Electric Cylinder and a Solenoid valve for Electronically Controlled Brake Systems2026-01-06384/7/2026
With the rapid proliferation of electrified vehicles (xEVs), maximizing regenerative energy recovery has become a crucial challenge in realizing zero-emission mobility. In front-wheel-drive (FWD) vehicles, regenerative braking acts only on the front axle, resulting in a braking-force distribution biased toward the front. When uniform hydraulic pressure is applied to both axles, excessive braking force on the front wheels may cause premature wheel lock and hinder the intended regenerative braking effect. To address this issue, it is essential to implement an independent pressure control strategy (two-channel pressure control) that appropriately reduces front pressure according to regenerative force while independently maintaining adequate rear pressure. This study proposes a new two-channel pressure control architecture utilizing a simple and reasonable actuator set consisting of one electric cylinder and one solenoid valve. The electric cylinder generates hydraulic pressure by
Kaneko, Shosuke, Deno, Yoshitomo, Kobayashi, Tatsushi, Kawamura, Hikaru
Characterizing Regenerative Braking of the Tesla Model 3 Using Chassis Dynamometer Testing2026-01-04534/7/2026
Regenerative braking has a strong influence on the energy efficiency and drivability of battery-electric vehicles. This study establishes an empirical baseline analysis under controlled conditions of the regenerative braking behavior of the 2020 Tesla Model 3 to support the interpretation of on-road performance and serve as a reference for subsequent testing and analysis. The tests were performed on a four-wheel-drive chassis dynamometer at Argonne National Laboratory, combining Multi Cycle Testing (MCT) to simulate real world driving patterns (city, highway) with coast-down tests to isolate periods where the motor is operating in regen mode and compare the behavior across different parameters. Vehicle data was collected from the vehicle using taps in the Controller Area Network (CAN) bus as well as a high-resolution power analyzer. The vehicle displayed the highest efficiency during simulated city driving conditions (3.62 miles/kWh followed by highway (3.40 miles/kWh) and aggressive
Pierce, Benjamin Branch, Di Russo, Miriam, Das, Debashis, Zhan, Lu, Stutenberg, Kevin
Backlash Evasion Strategy for Enhancing Vehicle Cornering Performance2026-01-06404/7/2026
This study presents a torque distribution control strategy for EVs with e4WD powertrain to overcome the trade-off between ensuring vehicle acceleration and deceleration responsiveness and mitigating backlash shock in the driving system. The deterioration of the drivability which occurs from the intrinsic hardware characteristics of the drivetrain is prevented by designing a response-priority drive mode in which neither front or rear motor torque is allowed to change its sign. Instead, in such drive mode, the front motor torque is only allowed to perform regenerative braking while the rear motor torque is only allowed to produce positive acceleration torque. In order to avoid sacrificing the maximum acceleration by applying such strategy, the mode transition function is implemented as well. In addition, in order to prevent backlash impact due to drivetrain compliance, variable offset torque based on drivetrain compliance model is evaluated in real time and applied to each motor command
Oh, JIWON, Lee, Ho Wook
Embedded Real-Time Control of a Distributed Trailer Propulsion System with Regenerative Braking for Net Neutral Load Towing2026-01-00654/7/2026
Towing imposes substantial efficiency penalties on both battery-electric vehicles (BEVs) and internal combustion engine (ICE) vehicles, reducing range by 30-50%. This paper presents a proof-of-concept embedded control architecture for distributed trailer propulsion that actively regulates drawbar force to reduce towing loads. Unlike proprietary e-trailer systems requiring specialized hardware, the proposed implementation demonstrates feasibility using commercial off-the-shelf (COTS) components and open-source software. The distributed architecture employs dual Raspberry Pi 4B single-board computers communicating via ROS 2 at 20 Hz. The trailer-mounted controller executes a Simulink-generated control node coordinating load cell acquisition (HX711 ADC), motor CAN bus telemetry, and throttle commands to a 5 kW BLDC traction motor powered by a 5 kWh LiFePO4 battery pack. A vehicle-mounted controller logs OBD-II/CAN validation data. The control pipeline implements cascaded EWMA/Hampel
Joshi, Gaurav, Adelman, Ian, Liu, Jun, Donnaway, Ruthie
Quantifying the Impact of Towing on BEV Energy Use: Instrumented On Road Testing and Chassis Dynamometer Reproduction2026-01-04314/7/2026
Electrification is rapidly entering all vehicle classes, including light- and heavy-duty trucks designed for heavy towing capabilities. Still, the quantitative impact of towing on battery-electric vehicle (BEV) energy use and range remains under-characterized. We conducted controlled towing tests with a Ford F-150 Lightning using two trailers of different sizes and varying payloads to isolate aerodynamic and mass effects and to span the full range of towable payloads within the vehicle’s rated capacity. The vehicle was instrumented at the CAN bus level, capturing motor power, torque, speed, and related internal signals from different control modules. On-road testing consisted of repeated back-and-forth passes on level, straight road segments at set speeds focusing on highway operation, where aerodynamic drag is stronger and real-world towing use cases occur. From these data, we extracted road load equations and dynamometer coefficients for each trailer combination, then reproduced
Timermans Ladero, Inigo
An Adaptive Brake Force Allocation Strategy for Rear-Wheel Driven EVs2026-01-06364/7/2026
Due to changed requirements compared to conventional propulsion concepts, electromobility demands new and innovative strategies for energy-efficient vehicle motion control. For example, the challenge in purely rear-wheel drive (RWD) electric vehicles (EVs) is to achieve a maximum of regenerative braking power in order to increase energy recovery and to ensure, that this does not impair the braking stability. Within this conflict between energy efficiency and braking dynamics, it is necessary to design an intelligent strategy to optimise recuperation. This paper presents such a strategy, which improves an existing approach formerly presented by the authors, but specifically optimised to overcome weaknesses. The previous approach had two major limitations: First, the efficiency map of the in-wheel machines (IWMs) was not considered. Second, there was no possibility of switching flexibly between different brake force distributions to guarantee both, maximized recovery potential and high
Mitsching, Thomas, Heydrich, Marius, Ivanov, Valentin
Predictive Assessment of Drum Brake Squeal Utilizing Advanced Time-Domain CAE Synthesis2026-01-02214/7/2026
With the growing trend of electric vehicles (EVs) incorporating regenerative braking systems, many compact SUVs, including hybrids and EVs, still utilize drum brakes on the rear wheels to strike a balance between cost, performance, and durability. Drum brake squeal remains a complex and persistent challenge in the field of vehicle noise, vibration, and harshness (NVH). This issue stems from dynamic instability caused by time–dependent friction forces. Traditional linear modal analysis has been used to study the mechanisms behind drum brake squeal, focusing on harmonic vibrations in large–scale models. However, these methods often fail to accurately correlate with real world behavior due to the presence of extra, non-physical modes. To address this, time–domain analysis approaches have been explored, incorporating detailed friction models and contact mechanics. These methods consider different root causes for high and low–frequency squeal and have shown promising results in accurately
Song, Gavin, Kazimierczyk, Stanislaus, Vlademar, Michael, Venugopal, Narayana
Scalable and Modular Data-Driven Hybrid Chassis Dynamometer Framework for EV Powertrain Evaluation2026-26-03631/16/2026
In its conventional form, dynamometers typically provide a fixed architecture for measuring torque, speed, and power, with their scope primarily centered on these parameters and only limited emphasis on capturing aggregated real-time performance factors such as battery load and energy flow across the diverse range of emerging electric vehicle (EV) powertrain architectures. The objective of this work is to develop a valid, appropriate, scalable modular test framework that combines a real-time virtual twin of a compact physical dynamometer with world leading real-time mechanical and energy parameters/attributes useful for its virtual validation, as well as the evaluation of other unknown parameters that respectively span iterations of hybrid and electric vehicle configurations, ultimately allowing the assessment of multiple chassis without having to modify the physical testing facility's test bench. This integration enables a blended approach, using a live data source for now, providing
Kumar, Akhilesh, V, Yashvati
Enhancing Range Prediction Accuracy for the BEV: Bridging the Gap between Simulation and Real-World Testing2026-26-05211/16/2026
Accurate range estimation in battery electric vehicles (BEVs) is essential for optimizing performance, energy efficiency, and customer expectations. This study investigates the discrepancies between physical test data and simulation predictions for the BEV model. A detailed range delta analysis identifies key contributors to the observed deviations, including regenerative braking inefficiencies, increased propulsion demand, auxiliary loads, and estimated drivetrain losses within the Electric Drive Module (EDM) during traction and regen. Results indicate that the test vehicle exhibits lower regenerative braking efficiency, higher traction forces and lower regen energy than predicted by simulations, primarily due to EDM inefficiencies and friction brake usage during regeneration. The study underscores the importance of refining simulation methodologies by integrating real-world, test based EDM loss maps to improve accuracy and better align predictive models with actual vehicle
Mahajan, Prasad, Kesarkar, Sidhesh, Ali, Shoaib
Predictive SoC Management for Enhanced Recuperation Efficiency in Electric Vehicles2026-26-01541/16/2026
In recent years, the automotive industry has been looking into alternatives for conventional vehicles to promote a sustainable transportation future having a lesser carbon footprint. Electric Vehicles (EV) are a promising choice as they produce zero tail pipe emissions. However, even with the demand for EVs increasing, the charging infrastructure is still a concern, which leads to range anxiety. This necessitates the judicious use of battery charge and reduce the energy wastage occurring at any point. In EVs, regenerative braking is an additional option which helps in recuperating the battery energy during vehicle deceleration. The amount of energy recuperated mainly depends on the current State of Charge (SoC) of the battery and the battery temperature. Typically, the amount of recuperable energy reduces as the current SoC moves closer to 100%. Once this limit is reached, the excess energy available for recuperation is discharged through the brake resistor/pads. This paper proposes a
Barik, Madhusmita, S, Sethuraman, Aruljothi, Sathishkumar
Simulation Research on Torque Vectoring, Braking, Chassis Control Strategies for Electric & Hybrid Vehicles using System Simulation2026-26-04231/16/2026
Electric Vehicles and Plug-in Hybrids alleviate the energy crisis but pose a unique challenge for vehicle dynamics. Though significant developments in motor control strategy and energy density management are evolving, we face significant challenges in torque management, with several ADAS features being an integral part of the EVs/xHEVs. It demands high-fidelity physical and control model exchanges between electric chassis, ride-handling, tire modelling, steering assist, powertrain, and validation using a 0D–1D platform. This paper explicates a unified strategy for improving overall vehicle performance by intelligently distributing and coordinating drive torque to enhance traction, stability, and drivability across diverse operating conditions through co-simulation. The co-simulation platform includes physical models in AMESIM, and control strategies integrated in MATLAB/Simulink. The platform features comprehensive representations of digital vehicles that require detailed modelling of
Eruva, Patrickxavier, Sarapalli Ramachandran, Raghuveeran, Chougule, Sourabh, Natanamani-Pillai, Siva Subramanian, Scheider, Clement, Leclerc, Cedric, Natarajasundaram, Balasubramanian
Optimization of Inverter Control Strategies for Improved Powertrain Efficiency Using E-Motor Emulation Platforms2026-26-05091/16/2026
As the brain and the core of the electric powertrain, the traction inverter is an essential part of electric vehicles (EVs). It controls the power conversion from DC to AC between the electric motor and the high-voltage battery to enable effective propulsion and regenerative braking. Strong and scalable inverter testing solutions are becoming more essential as EV adoption rises, particularly in developing nations like India. In India, traditional testing techniques that use actual batteries and e-motors present several difficulties, such as significant safety hazards, inadequate infrastructure, expensive battery prices, and a shortage of prototype-grade parts. This paper presents a comprehensive approach for traction inverter validation using the AVL Inverter TS™ system incorporating an advanced Power Hardware-in-the-Loop (PHiL) test system based on e-motor emulation technology. It enables safe, efficient, and reliable testing eradicating the need for actual batteries or mechanical
Mehrotra, Soumya, Chhabra, Rishabh
Regenerative Braking Control Strategy for Electric Commercial Bus under Indian Road Condition Using Artificial Neural Network2026-26-06451/16/2026
The main focus of this paper is to create a more efficient regenerative braking control strategy for electric commercial buses operating under Indian road conditions. The strategy uses Artificial Neural Networks (ANNs) to optimize regenerative braking process. Regenerative braking helps to recover energy that would otherwise be lost during braking and convert it back into usable power for the vehicle. The challenge is to design a system that works effectively on the diverse and often challenging road conditions found in India, such as varying gradients, traffic patterns, and road surface types. This study begins by collecting data (which includes vehicle speed, traffic condition, etc.) from real-world driving conditions and aims to train an Artificial Neural Network (ANN) using a large set of driving data which is collected under various conditions to predict the most efficient regenerative braking settings for different driving scenarios. This research brings a new approach to the
Saurabh, Saurabh, Bhardwaj, Rohit, Patil, Nikhil, Gadve, Dhananjay, Amancharla, Naga Chaithanya
Research on Methods for Quantitative Assessment of Vehicle Controllability Level2025-99-010111/11/2025
As one of the main indexes of functional safety evaluation, controllability is of critical significance. According to ISO26262 standard, by analyzing the impact of potential faults such as unexpected torque and regenerative braking force loss on vehicle controllability under different working conditions, this paper designs a vehicle controllability test scheme under abnormal motor function under multiple scenarios such as straights, lane changes and curves, and builds a test scheme under abnormal motor function. The mapping relationship between vehicle dynamic state data and controllability level provides a new idea for quantitative analysis of vehicle controllability.
Yang, Xuezhu, He, Lei, Li, Chao, Ren, Zhiqiang
Research on Low-Power Control of Offshore Wind Sail Stabilization Devices Based on Single Pendulum Control Simulation2025-99-013111/11/2025
To tackle persistent operational instability and excessive energy consumption in marine observation platforms under wave-induced disturbances, this paper introduces a novel ultra-low-power stabilization system based on pendulum dynamics. The system employs an innovative mechanical configuration to deliberately decouple the rotation axis from the center of mass, creating controlled dynamic asymmetry. In this behavior, the fixed axis serves as a virtual suspension pivot while the camera payload functions as a concentrated mass block. This configuration generates intrinsic gravitational restoring torque, enabling passive disturbance attenuation. And its passive foundation is synergistically integrated with an actively controlled brushless DC motor system. During platform oscillation, embedded algorithms detect angular motion reversals. In addition, their detection triggers an instantaneous transition from motor drive to regenerative braking mode, and transition facilitates bidirectional
Zhang, Tianlin, Liu, Shixuan, Xu, Yuzhe
Power Electronics: The Backbone of Sustainable Electrification2025-28-022811/6/2025
Power electronics are fundamental to sustainable electrification, enhancing energy, efficiency, integrating renewable energy sources, and reducing carbon emissions. In electric vehicles (EVs), power electronics is crucial for efficient energy conversion, management, and distribution. Key components like inverters, rectifiers, and DC-DC converters optimize power from renewable sources to meet EV system requirements. In EVs, power electronics convert energy from the lithium-ion battery to the electric vehicle motor, with sufficient propulsion and regenerative braking. Inverters is used to transfer DC power from the lithium-ion eEV battery to alternating current for the motor, while DC-DC converters manage voltage levels for various vehicle systems. These components maximize EV energy efficiency, reduce energy losses, and extend driving range. Power electronics also support fast and efficient battery charging, critical for widespread EV adoption. Advanced charging solutions enable rapid
Pipaliya, Akash Pravinbhai, Hatkar, Chetan
Evaluation of Alternative Cooling Method for High Performance Resistors in Zero-Emission Trucks2025-28-035910/30/2025
High Performance Resistors (HPR), also known as brake resistors are used in zero emission vehicles (ZEVs) to dissipate excess electrical energy produced during regenerative braking, as heat energy. It is necessary to use a suitable cooling technique to release this heat energy into the atmosphere in a regulated manner. Currently in most of the ZEVs, liquid cooled HPR with its dedicated heat exchanger and other auxiliaries such as pump, surge tank, Coolant and coolant lines, is used which increases the cost, packaging space and assembly time. This paper presents air cooling as a substitute heat-exchanging technique for high-performance resistors which eliminates the need of auxiliaries mentioned above, resulting in space optimization and reduction in assembly time. An air cooled HPR, designed for this study consists of a heat exchanger, which accommodates a resistor wire within its tubes. The design was made to fit commercial vehicle use, specific to trucks, due to packaging constraints
Menariya, Pravin Ganesh, Kumar, Vishnu, Arhanth, Mahima, Umesha, Sathwik, Jagadish, Harshitha
Comparative Evaluation of Energy Efficiency and Performance of Electric and Counterpart Diesel Tractors2025-01-041710/7/2025
The objective of this trial was to compare the energy efficiency and performance of battery electric and conventional diesel tractors. Controlled road tests replicating normal operations were conducted using two electric and two diesel day-cab tractors. The test protocol was based on the TMC - Type III RP 1103A and SAE J1526 test procedures. The tests were conducted on a 110 km long route that included a 59 km hilly portion with a maximum altitude difference of 307 m. The tractors were divided into test groups of two vehicles. Trailers and drivers were switched throughout the trial between the tractors in a test group. The tests found that the two electric trucks consumed 60% and 63% less energy than their counterpart diesel trucks, respectively. Considering the average emission factor for production of electricity in Canada, the electric trucks emitted on average 82% less GHG emissions than the conventional diesel-powered tractors. The two diesel trucks showed similar fuel consumption
Surcel, Marius-Dorin, Partington, Mark, Tanguay-Laflèche, Maxime, Schumacher, Richard
Optimal Control Strategy for Dual-Motor EVs with CVT: Comparison of Simulation of Steady-State and Dynamic Programming Methods2025-01-040710/7/2025
This study investigates an optimal control strategy for a battery electric vehicle (BEV) equipped with a high-speed motor and a continuously variable transmission (CVT). The proposed dual-motor powertrain model activates only one motor at a time, with Motor A routed through a CVT and Motor B through a fixed gear. To improve energy efficiency, two optimization methods are evaluated: a quasi-steady-state map-based approach and a dynamic programming (DP) method. The DP approach applies Bellman’s principle to derive the globally optimal CVT ratio and motor torque trajectory over the WLTC cycle. Simulation results demonstrate that the DP method significantly improves overall efficiency compared to traditional control logic. Furthermore, the study proposes using DP-derived maps to refine practical control strategies, offering a systematic alternative to conventional experimental calibration.
Zhao, Hanqing, Moriyoshi, Yasuo, Kuboyama, Tatsuya
Enhancing Capacitance of High-Rate Electric Double-Layer Capacitors with CO 2 -Activated Mesoporous Carbon Gel Electrodes2025-01-506410/2/2025
Electric double-layer capacitors (EDLCs) store charge by adsorbing ions at the electrode–electrolyte interface, offering fast charge–discharge rates, high power density, minimal heat generation, and long cycle life. These characteristics make EDLCs ideal for memory backup in electronic devices and power assistance in electric and hybrid vehicles, where rapid energy response and high-power delivery are critical. However, their energy density remains lower than that of batteries, requiring improvements in capacitance and operating voltage. Activated carbon with high surface area is commonly used as the electrode material, but its microporous structure limits ion transport at high rates, reducing power performance. This limitation is especially critical in automotive motor drive systems. Recent research has shifted toward mesoporous carbon materials, which improve ion diffusion and accessibility. In this study, resorcinol–formaldehyde carbon cryogels (RFCCs) with controlled mesoporous
Cheng, Zairan, Okamura, Tsubasa, Ohnishi, Yuto, Nakagawa, Kiyoharu
Enhanced Vehicle Capability Through Innovative High Voltage Power Solutions2025-01-05069/16/2025
Increasing the mission capability of ground combat and tactical vehicles can lead to new concepts of operation that enhance safety and effectiveness of warfighters. High-temperature power electronics enabled by wide-bandgap semiconductors such as silicon carbide can provide the required power density to package new capabilities into space-constrained vehicles and provide features including silent mobility, boost acceleration, regenerative braking, adaptive cooling, and power for future protection systems and command and control (C2) on the move. An architecture using high voltage [1] would best satisfy the ever-increasing power demands to enable defense against unmanned aerial systems (UAS) and offensive directed energy (DE) systems for advanced survivability and lethality capabilities.
Eddins, R., Lambert, C., Habic, D., Haynes, A., Spina, J., Schwartz, E.
Bolstering Driver Braking Confidence – Considerations for “Deceleration Adder” Technologies2025-01-03539/15/2025
Over the life of a typical vehicle (often estimated as 15 years or 300,00 km), an average driver can be expected to apply the brakes about 1.6 million times – almost 9 times per mile and over 290 times per day, and an “exuberant” driver can be expected to do this over 2.2 million times. Without question, the driver becomes accustomed to how the vehicle responds to braking control (and all of the normal variation around it), and even develops expectations for how it will respond the next time the brakes are employed. In the rare event of a failure or malfunction in the brake system resulting in an appreciably different vehicle response to the brake input, this can be surprising and even alarming to the driver, sometimes to the extent of causing hesitation in braking. Fortunately, with the rise of mechatronic braking actuators in the 1980’s and 1990’s paved the way for features such as “Driver Brake Assist” (which provides additional pressure beyond what the primary brake actuator can at
Antanaitis, David
A Study on the Development of Optimal Brakes for Electric Vehicles Using Simulation2025-01-03459/15/2025
As the ICE vehicle changes into the EV, we can use regenerative brake. It can improve not only the energy consumption but also reduce the hydraulic brake usage. The less hydraulic brake usage mitigates the heat loading on the brake disc. From this reason, the lightweight brake can be used in the EV. However, when the lightweight brake is applied, the brake NVH can be increased. The optimization design of the lightweight brake should be done to prevent the brake NVH. In this paper, the optimal brake disc thickness and brake interfaces are determined by using of disc heat capacity analysis. The lightweight brake should be optimized by using of the brake squeal analysis. We can verify the results from both analysis and test. Finally, we can have the lightweight brake, which is competitive in terms of cost, weight and robust to the brake NVH.
Kim, Sungho, Kim, Jeongkyu, Hwang, Jaekeun, Kang, Donghoon
An Eco-Charging Strategy for Heavy-Duty Electric Vehicles via Graph Optimization2025-24-01169/7/2025
An optimization framework for trip and charging planning for electric heavy-duty vehicles is proposed in this paper. Building upon and extending previous work on light-duty vehicles, our approach models energy-aware routing by constructing a state-augmented graph that jointly captures geographic position and battery state-of-charge. We refine the route model to include detailed vehicle dynamics and speed constraints specific to heavy-duty vehicles, and introduce an alternative graph construction method that avoids the computational complexity of lexicographic products by generating only feasible nodes. The resulting framework enables efficient trip planning that accounts for driving behavior, road characteristics, and charging infrastructure. Simulation results demonstrate the effectiveness of the approach in reducing energy consumption and ensuring operational feasibility for long-haul freight transport.
Zonetti, Daniele, Sciarretta, Antonio, De Nunzio, Giovanni
Simulation-Based Investigation and its Experimental Validation of the Thermal Behaviour of a Battery Electric City Bus2025-01-02667/2/2025
Electrification of city busses is an important factor for decarbonisation of the public transport sector. Due to its strictly scheduled routes and regular idle times, the public transport sector is an ideal use case for battery electric vehicles (BEV). In this context, the thermal management has a high potential to decrease the energy demand or to increase the vehicles range. The thermal management of an electric city bus controls the thermal behaviour of the components of the powertrain, such as motor and inverters, as well as the conditioning of the battery system and the heating, ventilation, and air conditioning (HVAC) of the drivers’ front box and the passenger room. The focus of the research is the modelling of the thermal behaviour of the important components of an electric city bus in MATLAB/Simscape including real-world driving cycles and the thermal management. The heating of the components, geometry and behaviour of the cooling circuits as well as the different mechanisms of
Schäfer, Henrik, Meywerk, Martin, Hellberg, Tobias
Kinetic Energy Recovery: Assessment on the impact of Permanent Magnet Synchronous Motor and Battery Dynamic models2025-01-03037/2/2025
This paper examines the influence of a detailed dynamic model of a Surface Permanent Magnet Synchronous Motor (SPMSM) on the accurate evaluation of kinetic energy recovery during braking in a mild hybrid vehicle. The model, implemented in MATLAB Simulink, is based on the motor’s DQ equivalent circuit, accounting for transient effects, inductance variability, and magnetic saturation. Also, a 2nd Order Thevenin Equivalent model of the battery is used in order to take into account the bus voltage variability. Simulations reveal that the dynamic model predicts significant variations in energy recovery potential, with differences of up to 25% compared to static models under specific braking conditions. These discrepancies are particularly pronounced during high-speed high-torque transitions, where transient electrical behaviors strongly influence energy recovery. The model’s accuracy enhances the reliability of energy simulations, especially in scenarios involving frequent or intense
Lombardi, Simone, Federici, Leonardo, Tribioli, Laura, Bella, Gino
Electric Bus NVH Challenges and Refinement Using Innovative Approach2025-01-00805/5/2025
The trend towards electrification propulsion in the automotive industry is highly in demand due to zero-emission and becoming more significant across the world. Battery electric vehicles have lower overall noise as compared to conventional I.C Engine counterparts due to the absence of engine combustion and mechanical noise. However, other narrowband and tonal noises are becoming dominant and are strongly perceived inside the cabin. With the ongoing push towards electrification, there is likely to be increased focus on the noise impact of gearing required for the transmission of power from the electric motor to the road. Direct coupling of E-motors with Axle has resulted in severe tonal noises from the driveline due to instant e-motor torque ramp up from 0 rpm and reverse torque on driving axle during regenerative braking. The tonal noises from the rear axle during vehicle running become very critical for customer perception. For automotive NVH engineers, it has become a challenge to
Doshi, Sohin, Kalsule, Dhanaji, Sawangikar, Pradeep, Suresh, Vineeth, Sharma, Manish
Development of an Imperceptible Brake Failure Control Technology and Real Vehicle Application10-09-02-00154/26/2025
With the advancement of control technology in the automotive field, there is a possibility of cross-system redundant control between various actuators. As for the braking system, current brake-by-wire system often uses mechanical backup braking methods to give the vehicle a certain braking capacity after failure. However, in the mechanical backup braking mode, the brake master cylinder is connected to the supporting wheel cylinder, and the brake assist is lost, which leads to an increase in brake pressure and makes it difficult for the driver to step on the brake pedal. Meanwhile, due to the limitation of the brake master cylinder stroke, the maximum braking deceleration of the vehicle is only 3 m/s2 after the driver fully presses the brake pedal. The above two defects greatly affect the safety of the vehicle during backup braking. To solve the above problems, this article takes electric vehicles as the research object, designs a new type of hydraulic circuit for the braking system
Tian, Boshi, Li, Liang, Liao, Yinsheng, Lv, Haijun, Hu, Zhiming, Sun, Yue, Qu, Wenying
Study on Emergency Obstacle Avoidance Lateral Stability Control of Tractor Semitrailer Vehicles2025-01-82964/1/2025
As a crucial component of highway freight systems, tractor semitrailer vehicles play a key role in the transportation industry. However, their complex vehicle structure can lead to significant lateral instability during emergency obstacle avoidance, posing challenges to the vehicle's dynamic stability and safety. To enhance the emergency obstacle avoidance lateral stability of tractor semitrailer vehicles, a direct yaw moment lateral stability control strategy based on differential driving/braking is proposed. First, a 3-degree-of-freedom ideal linear dynamic model of the tractor-semitrailer is established, and its accuracy is validated. Then, a lateral stability control strategy for emergency obstacle avoidance is proposed. The upper-layer controller employs an improved feedforward differential model-free adaptive control (IMFAC) method to track the target yaw rate and vehicle sideslip angle, while the lower-layer controller focuses on optimizing tire load rate. Additionally, a drive
Guo, Shaozhong, Dou, Jingyang
Research on Energy Recovery Strategy in Braking of Electric Tractor-Semitrailer2025-01-82904/1/2025
Tractor-semitrailers play an important role in the transportation industry. However, global warming and the rapid advancement of energy technologies have driven the transformation of high-emission vehicles, such as tractor-semitrailers, to be powered by new energy sources in order to achieve goals related to energy conservation, emission reduction, and cost savings. By using the motor as the primary driving force, the energy recovered during braking or coasting can be converted into electricity and stored in the battery for later use. While much research has been conducted on braking control and energy recovery for passenger cars, there is limited research on tractor-semitrailers. Additionally, the jackknife is a critical factor to consider under high-speed conditions. To investigate the braking energy recovery of electric tractor-semitrailers, tire and motor models were developed based on the turning and braking conditions of such vehicles. Taking into account the load transfer effect
Chen, Runping, Duan, Yupeng
Evaluation and Prevention of Brake Drum Freezing by Aerodynamic Measures2025-01-87754/1/2025
The use of drum brakes in Battery Electric Vehicles (BEVs) offers numerous benefits, including energy efficiency, reduced brake dust emissions, and reliable performance under challenging weather conditions. The capability of regenerative braking reduces the friction brake application frequency in BEVs and therefore the brakes can be prone to corrosion and performance degradation especially considering conventional disc brake systems. The closed design of a drum brake prevents corrosion of the friction-components by sealing out water, dirt or snow. A common sealing concept is performed with a labyrinth between the gap of the rotating drum and the axle mounted backplate. A hermetical isolation of water and snow ingress into the drum cannot be achieved with this concept, so additional aerodynamic measures are necessary to deflect the air/water path and protect the inner brake components. Additionally, interfaces like wheel cylinders, electric park brake parts, brake shoe pins, and axle
Hennicke, Tim, Kuthada, Timo, Bernhard, Adrian, Reichhart, Leander, Weber, Eugen, Moers, Michael, Rettig, Marc
Stability Control for Distributed Drive Electric Vehicles Using Particle Filter and Fuzzy Integral Sliding Mode Control2025-01-88114/1/2025
The Distributed Drive Electric Vehicles (DDEVs) offer advantages such as independently controllable driving and braking forces at each wheel, rapid response, and precise control. These features enable effective electronic stability control (ESC) by appropriately distributing torque across each wheel. However, traditional ESC systems typically employ single-wheel hydraulic differential braking, failing to fully utilize the independent torque control capabilities of DDEVs. This study proposes a hierarchical control strategy for distributed driving and braking ESC based on particle filter (PF) and fuzzy integral sliding mode control (FISMC). First, the vehicle state estimation layer uses a three-degree-of-freedom vehicle model and the PF to estimate sideslip angle and vehicle speed. Next, the target torque decision layer includes a target speed tracking controller and a yaw moment decision controller. The yaw moment decision controller uses the FISMC to determine additional yaw moment by
Li, Xiaolong, Zheng, Hongyu, Kaku, Chuyo
Smart Boosting: A Control Strategy for Optimized Energy Management with Boost Converter in Hybrid Electric Vehicles2025-01-85804/1/2025
In hybrid electric vehicles (HEVs), optimizing energy management and reducing system losses are critical for enhancing overall efficiency and performance. This paper presents a novel control strategy for the boost converter in hybrid electric vehicles (HEVs), aimed at minimizing energy losses and optimizing performance by modulating to a higher boost converter voltage only when necessary. Traditional approaches to boost converter control often lead to unnecessary energy consumption by maintaining higher voltage levels even when not required. In contrast, the proposed strategy dynamically adjusts the converter's operation based on real-time vehicle demands, such as driver input, Engine Start-Stop (ESS) events, Active Electric Motor Damping (AEMD), entry and exit transitions for Engine Fuel Cut-Off (DFCO), Noise-Vibration-Harshness (NVH) events like lash-zone crossing and other specific operational conditions. The control strategy leverages predictive algorithms and real-time monitoring
Basutkar, Ameya, Huo, Shichao, Sullivan, Claire, Berger, Daniel, Tischendorf, Christoph
An Integrated Data-Driven and Physics-Based Approach for Dynamic Operation Simulation of Electric Vehicles2025-01-86044/1/2025
To address the challenges of complex operational simulation for Electric Vehicles (EVs) caused by spatial-temporal variations and driver behavior heterogeneity, this study introduces a dynamic operation simulation model that integrates both data-driven and physics-based principles, referred to as the Electric Vehicle-Dynamic Operation Simulation (EV-DOS) model. The physics-based component encompasses critical aspects such as the powertrain energy transfer module, heat transfer module, charge/discharge module, and battery state estimation module. The data-driven component derives key features and labels from second-by-second real-world vehicle driving status data and incorporates a Long Short-Term Memory (LSTM) network to develop a State-of-Health (SOH) prediction model for the EV power pack. This model framework combines the interpretability of physical modeling with the rapid simulation capabilities of data-driven techniques under dynamic operating conditions. Finally, this study
Jing, Hao, HU, Jianyao, Ouyang, Jianheng, Ou, Shiqi(Shawn)
Bi-Level Control Co-Design for Parallel Electric-Hydraulic Hybrid Vehicles2025-01-85824/1/2025
This study presents a control co-design method that utilizes a bi-level optimization framework for parallel electric-hydraulic hybrid powertrains, specifically targeting heavy-duty vehicles like class 8 semi-trailer trucks. The primary objective is to minimize battery energy consumption, particularly under high torque demand at low speed, thereby extending both battery lifespan and vehicle driving range. The proposed method formulates a bi-level optimization problem to ensure global optimality in hydraulic energy storage sizing and the development of a high-level energy management strategy. Two nested loops are used: the outer loop applies a Genetic Algorithm (GA) to optimize key design parameters such as accumulator volume and pre-charged pressure, while the inner loop leverages Dynamic Programming (DP) to optimize the energy control strategy in an open-loop format without predefined structural constraints. Both loops use a single objective function, i.e. battery energy consumption
Taaghi, Amirhossein, Yoon, Yongsoon
Mercedes proposes ‘in-drive brakes’ for better EVs25AUTP03_103/1/2025
From humble Chevrolet Bolts to six-figure Lucid Airs, every EV can reverse its electric motors to slow the vehicle while harvesting energy for the battery, the efficient tag-team process known as regenerative braking. Today's EVs do this so well that traditional friction brakes, which clamp onto a spinning wheel rotor or drum, can seem an afterthought. Witness Volkswagen's decision to equip its ID.4 with old-fashioned rear drum brakes, with VW claiming drums reduce EV rolling resistance and offer superior performance after long periods of disuse.
Ulrich, Lawrence
Refining Control, Charging, and Battery Chemistry for CO 2 e Savings in Heavy-Duty Off-Road Plug-In Series Hybrid14-14-02-00092/27/2025
With current and future regulations continuing to drive reductions in carbon dioxide equivalent (CO2e) emissions in the on-road industry, the off-road industry is also likely to be regulated for fuel and CO2e savings. This work focuses on converting a heavy-duty off-road material handler from a conventional diesel powertrain to a plug-in series hybrid, achieving a 49% fuel reduction and 29% CO2e reduction via simulation. Control strategies were refined for energy savings, including a regenerative braking strategy to increase regenerative braking and a load-following hydraulic strategy to decrease electrical energy consumption. The load-following hydraulic control shuts off the hydraulic electric machine when it is not needed—an approach not previously seen in a load-sensing, pressure-compensated system. These strategies achieved a 24.1% fuel savings, resulting in total savings of 61% in fuel and 41% in CO2e in the plug-in series compared to the conventional machine. Beyond control
Goodenough, Bryant, Czarnecki, Alexander, Robinette, Darrell, Worm, Jeremy, Subert, David, Kiefer, Dylan, Heath, Matthew, Brunet, Bob, Kisul, Robert, Latendresse, Phil, Westman, John, Black, Andrew
Niobium Alloyed Ferritic Nitrocarburized Brake Rotors2024-01-30319/8/2024
Niobium (Nb) alloyed Grey cast iron in combination with Ferritic Nitrocarburize (FNC) case hardening heat treatment is proposed to improve wear resistance and reduce brake dust generation of brake rotors. Standard Eutectic and Hypereutectic Grey irons alloyed with Niobium were evaluated in comparison to baseline unalloyed compositions. Brake speed snub sensitivity tribological testing was performed on a matrix including Niobium alloyed, Unalloyed, FNC, Non FNC, Non-Asbestos Organic (NAO) friction and Low metallic (Low Met) friction materials. Full size brake rotors were evaluated by Block Wear and Corrosion Cleanability. Improved wear, corrosion resistance and reduced brake dust debris were demonstrated by the Niobium alloyed FNC brake rotor combinations. Corrosion is an important consideration when evaluating brake performance. Combining cyclic corrosion and brake rotor testing provides the best comparison with field exposure.
Holly, Mike
Brake Heat Capacity Prediction Using a Machine-Learned Friction Coefficient Model and Virtual Wheel Brake2024-01-30549/8/2024
Recently, the increasing complexity of systems and diverse customer demands have necessitated the development of highly efficient vehicles. The ability to accurately predict vehicle performance through simulation allows for the determination of design specifications before the construction of test vehicles, leading to reduced development schedules and costs. Therefore, detailed brake thermal performance predictions are required both for the front and rear brakes. Moreover, scenarios requiring validation, such as alpine conditions that apply braking severity to xEV with the regenerative braking system, have become increasingly diverse. To address this challenge, this study proposes a co-simulation method that incorporates a machine-learned brake pad friction coefficient prediction model to enhance the accuracy of brake thermal capacity predictions within the vehicle simulation environment. This innovative method allows for the simultaneous prediction of both front and rear-wheel brakes
Cho, Sunghyun, Baek, SangHeum, Kim, Min Soo, Hong, Incheol, Kim, Hyun Ki, Kim, Gwichul, Lee, Jounghee
Optimization-Based Battery Thermal Management for Improved Regenerative Braking in CEP Vehicles2024-01-29747/2/2024
The courier express parcel service industry (CEP industry) has experienced significant changes in the recent years due to increasing parcel volume. At the same time, the electrification of the vehicle fleets poses additional challenges. A major advantage of battery electric CEP vehicles compared to internal combustion engine vehicles is the ability to regenerate the kinetic energy of the vehicle in the frequent deceleration phases during parcel delivery. If the battery is cold, the maximum regenerative power of the powertrain is limited by a reduced chemical reaction rate inside the battery. In general, the maximum charging power of the battery depends on the state of charge and the battery temperature. Due to the low power demand for driving during CEP operation, the battery self-heating is comparably low. Without active conditioning of the battery, potential of regenerating energy is partially lost because the friction brake needs to absorb kinetic energy whenever the cold battery’s
Rehm, Dominik, Krost, Jonathan, Meywerk, Martin, Czarnetzki, Walter
Control System for Regenerative Braking Efficiency in Electric Vehicles with Electro-Actuated Brakes10-08-02-00155/1/2024
This article presents the design and the analysis of a control logic capable of optimizing vehicle’s energy consumption during a braking maneuver. The idea arose with the purpose of enhancing regeneration and health management in electric vehicles with electro-actuated brakes. Regenerative braking improves energy efficiency and allows a considerable reduction in secondary emissions, but its efficiency is strongly dependent on the state of charge (SoC) of the battery. In the analyzed case, a vehicle equipped with four in-wheel motors (one for each wheel), four electro-actuated brakes, and a battery was considered. The proposed control system can manage and optimize electrical and energy exchanges between the driveline’s components according to the working conditions, monitoring parameters such as SoC of the battery, brake temperature, battery temperature, motor temperature, and acts to optimize the total energy consumption. The solution devised allows first to maximize the effects of
Tempone, Giuseppe Pio, de Carvalho Pinheiro, Henrique, Imberti, Giovanni, Carello, Massimiliana
Enhancing Regenerative Energy Capture in Electric Vehicles: Braking Performance through Integral Sliding Mode Control10-08-02-00124/18/2024
This article focuses on the development of an active braking control system tailored for electric vehicles. The essence of this system lies in its ability to regulate the slip coefficient to optimize traction during braking, thereby maximizing energy recuperation. In the context of the simulation on enhancing regenerative energy capture in electric vehicles, the use of integral sliding mode control (ISMC) as an alternative for regulating braking performance can be understood through a comparison of two key output variables in braking control systems: wheel deceleration and wheel slip. Traditionally, wheel deceleration has been a controlled variable in braking systems, and it is still utilized in some anti-lock braking systems (ABS). It can be easily measured using a basic wheel encoder. However, the dynamic performance of wheel deceleration control may suffer when there are rapid changes in the road surface. On the contrary, regulating wheel slip offers high robustness from a dynamic
Direm, Chaima, Hartani, Kada
Real-Time Deployment Strategies for State of Power Estimation Algorithms2024-01-21984/9/2024
Lithium-ion cells operate under a narrow range of voltage, current, and temperature limits, which requires a battery management system (BMS) to sense, control, and balance the battery pack. The state of power (SOP) estimation is a fundamental algorithm of the BMS. It operates as a dynamic safety limit, preventing rapid ageing and optimizing power delivery. SOP estimation relies on predictive algorithms to determine charge and discharge power limits sustainable within a specified time frame, ensuring the cell design constraints are not violated. This paper explores various approaches for real-time deployment of SOP estimation algorithms for a high-power lithium-ion battery (LIB) with a low-cost microcontroller. The algorithms are based on a root-finding approach and a first-order equivalent circuit model (ECM) of the battery. This paper assesses the practical application of the algorithm with a focus on processor execution time, flash memory and RAM allocation using a processor-in-the
Schommer, Adriano, Araujo Xavier, Marcelo, Morrey, Denise, Collier, Gordana
Fatigue Analysis and Rapid Design Process of Anti-vibration Rubber Parts for Automobiles2024-01-22554/9/2024
In recent years, an increase in vehicle weight due to the electrification of automobiles, specifically EVs, has increased the input loads on anti-vibration rubber parts. Moreover, the characteristics of these loads have also changed due to the rotational drive of electric motors, regenerative braking, and other factors. When designing a vehicle, in advance it is necessary to set specifications that take into account the spring characteristics and durability of the anti-vibration rubber parts in order to meet functional requirements. In this study, the hyperelastic and fatigue characteristics (S-N diagram and Haigh diagram) of Rubbers which is widely used for anti-vibration rubber parts, were experimentally obtained, and structural and fatigue analyses using FEM (Finite Element Method) were conducted in conjunction with spring and fatigue tests of anti-vibration rubber parts to determine the correlation between their spring and fatigue characteristics. Parameter studies were conducted
Sugimoto, Nao
Innovative Zero-Emissions Braking System: Performance Analysis Through a Transient Braking Model2024-01-25534/9/2024
This paper presents the analysis of an innovative braking system as an alternative and environmentally friendly solution to traditional automotive friction brakes. The idea arose from the need to eliminate emissions from the braking system of an electric vehicle: traditional brakes, in fact, produce dust emissions due to the wear of the pads. The innovative solution, called Zero-Emissions Driving System (ZEDS), is a system composed of an electric motor (in-wheel motor) and an innovative brake. The latter has a geometry such that it houses MagnetoRheological Fluid (MRF) inside it, which can change its viscous properties according to the magnetic field passing through it. It is thus an electro-actuated brake, capable of generating a magnetic field passing through the fluid and developing braking torque. A performance analysis obtained by a simulation model built on Matlab Simulink is proposed. The model is able to simulate the transient 1D motion of an electric vehicle equipped with four
Tempone, Giuseppe Pio, Imberti, Giovanni, de Carvalho Pinheiro, Henrique, Carello, Massimiliana
An Adaptive Clamping Force Control Strategy for Electro-Mechanical Brake System Considering Nonlinear Friction Resistance2024-01-22824/9/2024
The Electronic Mechanical Braking (EMB) system, which offers advantages such as no liquid medium and complete decoupling, can meet the high-quality active braking and high-intensity regenerative braking demands proposed by intelligent vehicles and is considered one of the ideal platforms for future chassis. However, traditional control strategies with fixed clamping force tracking parameters struggle to maintain high-quality braking performance of EMB under variable braking requests, and the nonlinear friction between mechanical components also affects the accuracy of clamping force control. Therefore, this paper presents an adaptive clamping force control strategy for the EMB system, taking into account the resistance of nonlinear friction. First, an EMB model is established as the simulation and control object, which includes the motor model, transmission model, torque balance model, stiffness model, and friction model. Subsequently, a cascaded clamping force controller, consisting
Xu, Zelin, Wu, Jian, Bi, Gongyuan, Hou, Jie, Zheng, Wenbo, Li, Lun, Gao, Shang, Chen, Zhicheng
Optimal Control Co-Design of a Parallel Electric-Hydraulic Hybrid Vehicle2024-01-21544/9/2024
This paper presents an optimal control co-design framework of a parallel electric-hydraulic hybrid powertrain specifically tailored for heavy-duty vehicles. A pure electric powertrain, comprising a rechargeable lithium-ion battery, a highly efficient electric motor, and a single or double-speed gearbox, has garnered significant attention in the automotive sector due to the increasing demand for clean and efficient mobility. However, the state-of-the-art has demonstrated limited capabilities and has struggled to meet the design requirements of heavy-duty vehicles with high power demands, such as a class 8 semi-trailer truck. This is especially evident in terms of a driving range on one battery charge, battery charging time, and load-carrying capacity. These challenges primarily stem from the low power density of lithium-ion batteries and the low energy conversion efficiency of electric motors at low speeds. To address these issues, a recent development is the electric-hydraulic hybrid
Taaghi, Amirhossein, Yoon, Yongsoon
Fuzzy Control of Regenerative Braking on Pure Electric Garbage Truck Based on Particle Swarm Optimization2024-01-21454/9/2024
To improve the braking energy recovery rate of pure electric garbage removal vehicles and ensure the braking effect of garbage removal vehicles, a strategy using particle swarm algorithm to optimize the regenerative braking fuzzy control of garbage removal vehicles is proposed. A multi-section front and rear wheel braking force distribution curve is designed considering the braking effect and braking energy recovery. A hierarchical regenerative braking fuzzy control strategy is established based on the braking force and braking intensity required by the vehicle. The first layer is based on the braking force required by the vehicle, based on the front and rear axle braking force distribution plan, and uses fuzzy controllers. Achieve one-time distribution of the front axle braking force; the second layer, according to the magnitude of the braking intensity, divides the braking conditions into light braking, moderate braking and emergency braking, and realizes braking under the three
Zhang, Yu
An Improved Semi-Transient Brake Cooling Simulation Method15-17-03-00112/5/2024
In this article, an improved brake cooling simulation method is introduced. By this method, the vehicle parameters, such as weight, height of the center of gravity, wheelbase, and the like can be included to calculate the braking thermal load under different operating conditions. The effect of the brake kinetic energy regeneration (BKER) on the braking thermal load can also be calculated by this method. The calculated braking thermal load is then input to a coupled 3D simulation model to conduct flow and thermal simulation to calculate brake disc temperature. It is demonstrated that by this simulation method, the difference between the brake disc temperatures obtained from simulation and vehicle test can be controlled below 5%.
Ni, Jun, Li, Bo, Yuan, Qingpeng, Ran, Xin, Liang, Changqiu, Liao, Huihong
A Study on Effect of Regenerative Braking on Vehicle Range and Axle Life2024-26-02401/16/2024
This paper aims at analysing the effect of regeneration braking on the amount of energy harnessed during vehicle braking, coasting and its effect on the drive train components like gear, crown wheel pinion, spider gear & bearing etc. Regenerative braking systems (RBS) is an effective method of recovering the kinetic energy of the vehicle during braking condition and using this to recharge the batteries. In Battery Electric Vehicles (BEV), this harnessed energy is used for controlled charging of the high voltage batteries which will help in increasing the vehicle range eventually. Depending on the type of the powertrain architecture, components between motor output to the wheels will vary, i.e., in an e-axle, motor is coupled with a gear box which will be connected with differential and the wheels. Whereas in case of a central drive architecture, motor is coupled with gearbox which is connected with a propeller shaft and then the differential and to the wheels. All the components
S, Srivatsa, Pethkar, Shivanand, Ghosh, Sandeep
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