CONTROL OF A MODULAR MULTILEVEL DC/DC CONVERTER FOR REGENERATIVE APPLICATIONS

CHAPTER-5

REGENERATIVE BRAKING
5.1 INTRODUCTION:
In preceding sections, explained about the seven-level MMC controlling with PI
controller and in the fallowing section about the regenerative braking principle and the
benefits which are used as a application in electrical vehicles using MMC and the storage
elements (supercapacitor).
In recent years, EV (electric vehicles) has attracted much concentration as a
remedy to traditional vehicles running with non-renewable fossil fuels which can take
power by internal combustion engines. This paying attention mainly on ecological and
economic concern connected to the utilization of fossil-based oil as fuel in ICE (internal
combustion engine) vehicles. Now, EVs are becoming promising solution for running in
long distances. Plug-in EVs make use of a battery structure will recharged through
regular power outlets. So, the characteristics of electric vehicles have become comparable
due to which stores wastage energy released by vehicle during braking will be catches
and take it to high voltage batteries which are not possible with the conventional vehicles.
The process of RB ( Regenerative braking)taking energy from drive motor which is
connected on the load side back into the battery connected in high voltage side during
process of braking, when inertia of vehicles rushes the motor drive from motor mode to
generator mode.

Electric vehicles are showing extraordinary attention in the unstable market prices
and view of retreating supply of fuel. Advancement in technology for battery sector, and
important improvements in motor (electrical) efficiency made EV (electric vehicles) an
attractive option, particularly for small distance commutes. The application of BLDC
(Brushless DC motor) technology in hybrid vehicle gives special importance in
regenerative braking. Brushless DC motor are being encounter more periodically in
electric vehicles due to its high efficiency and toughness, therefore brushless DC motor
requires a quite composite control to manage with the flow of energy reversal in the
period of transition to regenerative braking from motoring action.

DEPARTMENT OF EEE, RGMCET 40 | P a g e

 CONTROL OF A MODULAR MULTILEVEL DC/DC CONVERTER FOR REGENERATIVE APPLICATIONS

5.2 PRINCIPLE OF REGENERATIVE BRAKING:

EVs use their drive motors to convert kinetic energy into electromagnetic energy
Motors and generators operate under the same principle and can be used interchangeably.
The First Law of Thermodynamics dictates that the EV will slow down as this occurs.
The generated electrical energy can be dissipated through a resistive network (Dynamic
Braking) or stored (Regenerative braking).
Vehicle has forward momentum. The wheels are coupled to the rotors of electric
traction motors in an EV Instead of a current being applied to the motor to turn the rotors,
the rotors are turned by the wheels of the EV. The rotors experience opposing torque as
current is induced in the motor coils. This opposing torque slows the vehicle. The
generated electrical energy is stored.

5.3 CIRCUIT OF BRAKE CONTROL:

Complex electronic circuits that handle braking functions Coordinates motor and
friction brakes under a wide range of situations. The controller will take the following
parameters into account and determines how the vehicle will break Speed of vehicle.
Driver input (pedals) Storage medium state-of-charge Routes and regulates generated
power. Depending on the desired output, the brake controller must be able to supply
vehicle batteries or capacitors with the proper polarity, current, and voltage for safe
charging (depends on battery state of charge).

Fig. 5.1. Basic block diagram of electric vehicle

DEPARTMENT OF EEE, RGMCET 41 | P a g e

 CONTROL OF A MODULAR MULTILEVEL DC/DC CONVERTER FOR REGENERATIVE APPLICATIONS

5.4 ELEMENTS OF REGENERATIVE BRAKING:

There are 5 elements of regenerative braking (RB) which are coordinated, but
before uncomplaining these it is significant to talk about deceleration modes.
There are two deceleration modes
i. Foot off choke but not on brake handle, in this mode partial charging will occur
and vehicle will decelerate gradually.
ii. Foot on brake handle, in this mode privileged amount of deceleration will be
allowable and vehicle will stop more quickly. During light braking pedal
applications generator will sluggish the car, if heavier brake pedal are applied the
frictional brakes will also come into play.
Brake Pedal
Braking force is used by driver on brake pedal.
Hydraulic Booster Unit
It consists of master cylinder and regulator it responds in two steps. 1st it sends
some(electronic) signal to Electronic Control Unit (ECU) that barking force has been
demand, next the master cylinder exert hydraulic pressure on pedal stroke stimulator and
the regulator feeds fluid to hydraulic pressure control unit.

Brake Electronic Control Unit

It senses braking insist and sends a frictional demand to regenerative braking
(RB). It also calculates the force essential to complete braking demand and inculcate
hydraulic pressure control unit to pass on an equivalent amount of hydraulic fluid.
Pedal Stroke Stimulator
It absorbs a quantity of hydraulic pressure from master cylinder that corresponds
to the amount of braking force functioned by the regenerative braking (RB).
Hydraulic pressure control unit:
It passes equivalent amount of hydraulic fluid into a four way cylinder.

DEPARTMENT OF EEE, RGMCET 42 | P a g e

 CONTROL OF A MODULAR MULTILEVEL DC/DC CONVERTER FOR REGENERATIVE APPLICATIONS

Motor as generator:
In an electric vehicle (EV) motor is used to power vehicle, this motor may be 3
phase ac motor or dc motor. As rotating magnetic field (RMF) is incessantly rotating in
Stator with synchronous speed (Ns,) the rotor is always trying to catch up the Ns.
The communication of magnetic field torque, the amount of torque shaped is
related to relative position of rotor field to stator field. Since, the stator field is always in
advance of rotor field when the accelerator is pressed, the rotor is always whirling to
catch up Ns and it is continuously produce torque. When driver foliage the accelerator
knob, the power electronics module instantly changes the position of stator field to
following the rotor. Now rotor must slow down to side with its field with the stator field.
The current direction in the switches of stator changes its direction and energy flows
through the power electronic module and then back to the battery. This is called energy
regeneration.
In case of DC motor during regenerative braking, power cycle is inverted.
Suppose we have very trouble-free DC motor add power to its brushes, motor will spin,
eliminate the power and spin the motor shaft it will produce electricity nothing is
reversed except the fact that the relay sending power to motor is now collecting power
from motor.

5.5 ENERGY STORAGE OPTIONS:

Recharging vehicle battery packs
a) Circumstances of charge influences safety storage of current from generation.
b) Omnipresent method for hybrid cars.
Charging an selection of capacitors/supercapacitors(SC)
a) Very high charging/discharging rate (high power density).
b) Energy density is much lower than batteries.
c) Allows for regenerative braking if batteries are at a high condition of charge.
d) Implement on some buses.

DEPARTMENT OF EEE, RGMCET 43 | P a g e

 CONTROL OF A MODULAR MULTILEVEL DC/DC CONVERTER FOR REGENERATIVE APPLICATIONS

5.6 BENEFITS OF REGENERATIVE BRAKING:

1. Increase of overall energy efficiency of a vehicle
2. Increases the lifespan of friction braking systems
3. Fuel economy gets incremented.
4. Reduction of emission will be decremented.
5. Provide plenty drive power and power for unexpected acceleration.
6. Improve the efficiency of the engine and the overall wealth of the car.
7. Improved concert.
8. Reduction in Engine wears.

5.7 APPLICATION OF REGENERATIVE BRAKING:

1. During breaking process the kinetic energy will be wasted and that can be
regained.
2. Regenerative braking is used in some winch and crane hoist motors.
3. Regenerative Braking Systems are also used in electric railway applications.

Fig. 5.2. Simulation diagram of two-level MMC for

regenerative braking applications

DEPARTMENT OF EEE, RGMCET 44 | P a g e

 CONTROL OF A MODULAR MULTILEVEL DC/DC CONVERTER FOR REGENERATIVE APPLICATIONS

Fig. 5.3. Simulation results of inductor current of two-level MMC for regenerative
braking applications

Fig. 5.4. Simulation results of supercapacitor current of two-level MMC for

regenerative braking applications

Fig. 5.5. Simulation results of supercapacitor voltage of two-level MMC for

regenerative braking applications

DEPARTMENT OF EEE, RGMCET 45 | P a g e

 CONTROL OF A MODULAR MULTILEVEL DC/DC CONVERTER FOR REGENERATIVE APPLICATIONS

The above results represent that when bidirectional dc/dc converter used in
regenerative braking applications has current flows in bidirectional and the voltage in
unidirectional. So, the inductor current and supercapacitor current flows from
supercapacitor to load and from load to supercapacitor in regular intervals of time
through diodes and IGBT’s depending on the switching states of the switches and the
supercapacitor voltage has charging and discharging.

5.8 Summary:

In section 5.1 explained about the introduction of the RB, section 5.2 about the
principle of RB, section 5.3 about the circuit model, section 5.4 elements in Electric
vehicle, section 5.5 about the energy storage elements, 5.6 about the benefits, in section
5.7section about the application of RB, and in section 5.8 about the results of
regenerative braking.

DEPARTMENT OF EEE, RGMCET 46 | P a g e