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Regenerative Braking Experimental Tests and Results for Formula Student Car

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Document pages: 12 pages

Abstract: In thispaper, the tuning process of a regenerative braking system for a full electricFormula Student car is reported. Experimental results will be discussed andrecovered energy will be measured. In order to obtain the best tuning somepreliminary requirements have been decided: no-slipmotion of traction wheels during braking phase, no over current and over voltageof Li-ion cells and the best feeling from the braking pedal for the driver. Themain target of the regenerative braking system is to obtain the maximum recoveredenergy during the Endurance event in a typical Formula Student Competition (FSGermany, Hockenheim ring). First, an accurate estimation of the admissiblebraking torques with the tires used was carried out, starting from the magicformula of Pacejka of the tires. The maximum electric braking torque that theinstalled engine can provide at various speeds was then estimated, compatiblywith the charging currents allowed by the storage system. Subsequently, amechanical regulating device for regenerative braking was designed anddescribed here, installed directly on the gear lever system that connects thebrake pedal to the brake pumps. The proposed system is able to appropriatelydelay the entry into action of the hydraulic brake pumps and this delay ismechanically adjustable by acting on threaded pins. In this way, the intervalof actuation of the brake pedal which activates only the electric braking canbe adjusted and tuned. Finally, the overall project was tested on the track, inorder to validate the hypotheses previously calculated and determine thesetting capable of optimizing the energy recovered during a test equivalent tothe Endurance event, compatibly with the constraints of the installed systemson board.

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