Regenerative braking control system and method

• US 9,254,825 B2
• Filed: 01/12/2014
• Issued: 02/09/2016
• Est. Priority Date: 01/12/2014
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Lee, Jinkoo, Crombez, Dale Scott, Gabor, Daniel A., Lauffer, Scott J., Joyce, John P.
• Primary Examiner(s): To, Tuan C.
• Assistant Examiner(s): Kan, Yuri
• Application Number:
  US14/153,048
• Publication Number:
  US 20150197227A1
• Time in Patent Office: 758 Days
• Field of Search: 701/70, 701/22, 701/54, 303/3, 303/9.63, 303/151, 303/6.01, 188/159
• US Class Current: 1/1
• CPC Class Codes: B60L 15/2009 for braking
• CPC Class Codes: B60L 2240/423 Torque
• CPC Class Codes: B60L 2250/26 by pedal actuation
• CPC Class Codes: B60L 7/12 for vehicles propelled by dc motors
• CPC Class Codes: B60L 7/18 Controlling the braking effect B60L7/12, B60L7/14, B60L7/16 take precedence
• CPC Class Codes: B60L 7/22 Dynamic electric resistor braking, combined with dynamic electric regenerative braking
• CPC Class Codes: B60T 1/10 by utilising wheel movement for accumulating energy, e.g. driving air compressors
• CPC Class Codes: B60T 11/103 in combination with other control devices conjoint control of brake system and at least another sub-unit B60W10/188
• CPC Class Codes: B60T 11/16 Master control, e.g. master cylinders master cylinders associated with vacuum boosters B60T13/565
• CPC Class Codes: B60T 13/586 the retarders being of the electric type
• CPC Class Codes: B60T 7/042 by electrical means, e.g. using travel or force sensors
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility

Abstract

A vehicle regenerative braking control system includes a brake pedal; a brake pedal angle sensor interfacing with the brake pedal; a vehicle braking system interfacing with the brake pedal angle sensor, the vehicle braking system adapted to implement friction braking and regenerative braking responsive to receiving a brake pedal angle input signal from the brake pedal angle sensor; and at least one of a brake pedal switch and a brake master cylinder pressure sensor interfacing with the brake pedal and the vehicle braking system. The vehicle braking system is further adapted to implement friction braking and regenerative braking responsive to input from the at least one of a brake pedal switch and a brake master cylinder pressure sensor in the event that the vehicle braking system does not receive the brake pedal angle input signal from the brake pedal angle sensor. A regenerative braking control method is also disclosed.

Claims

1. A vehicle regenerative braking control system, comprising:

at least one controller comprising computer instructions stored in non-transitory memory, the at least one controller configured to implement friction braking and regenerative braking responsive to input from at least one of a brake pedal switch and a brake master cylinder pressure sensor as backup inputs causing the at least one controller to implement parallel regenerative braking and friction braking in the absence of a brake pedal angle input signal from a brake pedal angle sensor, the at least one controller configured to receive a brake pedal angle sensor signal from the brake pedal angle sensor including through an initial range of motion of the brake pedal corresponding to traversal of a brake pedal gap, the absence of the brake pedal angle input signal further causing the at least one controller to implement only friction braking during traversal of the brake pedal gap, the at least one controller further configured to apply series regenerative braking during traversal of the brake pedal gap and apply parallel regenerative braking and friction braking following traversal of the brake pedal gap if the brake pedal angle sensor signal is available.

2. The vehicle regenerative braking control system of claim 1 further comprising a brake system control module comprising computer instructions stored in non-transitory memory, the brake system control module interfacing with the at least one of a brake pedal switch and a brake master cylinder pressure sensor, and the brake system control module is configured to implement friction braking.

3. The vehicle regenerative braking control system of claim 2 further comprising friction brakes interfacing with the brake system control module and at least one vehicle axle interfacing with the friction brakes.

4. The vehicle regenerative braking control system of claim 3 wherein the vehicle braking system further comprises a powertrain control module comprising computer instructions stored in non-transitory memory, the powertrain control module interfacing with the brake system control module, and the powertrain control module is configured to implement regenerative braking.

5. The vehicle regenerative braking control system of claim 4 further comprising a traction motor interfacing with the powertrain control module and drivingly engaged by the at least one vehicle axle and a traction battery interfacing with the traction motor.

6. The vehicle regenerative braking control system of claim 1 wherein the at least one of a brake pedal switch and a brake master cylinder pressure sensor interfacing with a brake pedal and a vehicle braking system comprises the brake pedal switch interfacing with the brake pedal and the vehicle braking system.

7. The vehicle regenerative braking control system of claim 1 wherein the at least one of a brake pedal switch and a brake master cylinder pressure sensor interfacing with a brake pedal and a vehicle braking system comprises the brake master cylinder pressure sensor interfacing with the brake pedal and the vehicle braking system.

8. The vehicle regenerative braking control system of claim 1 wherein the at least one of a brake pedal switch and a brake master cylinder pressure sensor interfacing with a brake pedal and a vehicle braking system comprises the brake master cylinder pressure sensor and the brake master cylinder pressure sensor interfacing with the brake pedal and the vehicle braking system.

9. A regenerative braking control method by least one controller executing programmed instructions stored in non-transitory memory, comprising:

at least one controller executing programmed instructions stored in non-transitory memory to implement friction braking and regenerative braking responsive to input from at least one of a brake pedal switch and a brake master cylinder pressure sensor as backup inputs causing the at least one controller to implement parallel regenerative braking and friction braking in the absence of a brake pedal angle input signal from a brake pedal angle sensor, the at least one controller configured to receive a brake pedal angle sensor signal from the brake pedal angle sensor including through an initial range of motion of the brake pedal, the at least one controller further configured to initially apply series regenerative braking if the brake pedal angle sensor signal is available; and

developing a time-based torque request responsive to obtaining at least one of a brake pedal switch position and a brake master cylinder pressure and prior to performing at least one of parallel regenerative braking and friction braking.

10. The regenerative braking control method of claim 9 further comprising performing at least one of parallel regenerative braking and friction braking if the brake pedal angle input signal is available.

11. The regenerative braking control method of claim 9 further comprising developing a filtered torque request responsive to obtaining at least one of a brake pedal switch position and a brake master cylinder pressure and prior to performing at least one of parallel regenerative braking and friction braking.

12. The regenerative braking control method of claim 9 wherein performing at least one of parallel regenerative braking and friction braking comprises performing parallel regenerative braking and friction braking.

13. The regenerative braking control method of claim 9 wherein obtaining at least one of a brake pedal switch position and a brake master cylinder pressure if the brake pedal angle input signal is unavailable comprises obtaining a brake pedal switch position and a brake master cylinder pressure.

14. A regenerative braking control method by least one controller executing programmed instructions stored in non-transitory memory, comprising:

at least one controller executing programmed instructions stored in non-transitory memory to apply friction braking as a vehicle brake pedal traverses a brake pedal gap corresponding to an initial segment of a brake pedal torque range; and

performing at least one of parallel regenerative braking and friction braking, after the vehicle brake pedal traverses the brake pedal gap, based upon at least one of a brake pedal switch position and a brake master cylinder pressure as backup inputs causing the at least one controller to implement parallel regenerative braking and friction braking if a brake pedal angle sensor signal is unavailable, the at least one controller configured to receive a brake pedal angle sensor signal from the brake pedal angle sensor including through an initial range of motion of the brake pedal, the at least one controller further configured to initially apply series regenerative braking if the brake pedal angle sensor signal is available; and

developing a filtered torque request responsive to obtaining at least one of a brake pedal switch position and a brake master cylinder pressure and prior to performing at least one of parallel regenerative braking and friction braking.

15. The regenerative braking control method of claim 14 further comprising performing at least one of parallel regenerative braking and friction braking if the brake pedal angle sensor signal is available.

16. The regenerative braking control method of claim 14 further comprising developing a time-based torque request responsive to obtaining at least one of a brake pedal switch position and a brake master cylinder pressure and prior to performing at least one of parallel regenerative braking and friction braking.

17. The regenerative braking control method of claim 14 wherein performing at least one of parallel regenerative braking and friction braking comprises performing parallel regenerative braking and friction braking.

18. The regenerative braking control method of claim 14 wherein obtaining at least one of a brake pedal switch position and a brake master cylinder pressure if the brake pedal angle sensor signal is unavailable comprises obtaining a brake pedal switch position and a brake master cylinder pressure.