Design-Method of a High Power Eddy Current Brake as a Retarder for Electric Trucks

Abstract

This paper explores a novel approach to braking in electric vehicles by integrating an eddy current brake (ECB) with an anisotropic material structure into the electric drive system as a retarder. Traditional regenerative braking methods, while effective, often require the battery to be undercharged to reserve capacity for braking energy, or the addition of a braking resistor, which increases system weight. The proposed ECB method offers a promising alternative by potentially reducing mechanical brake size, eliminating the need for a brake resistor, and allowing the battery to maintain a higher state of charge. It utilizes an anisotropic material structure within the ECB to enhance power density and improve heat distribution, thereby overcoming the typical limitations of lower power density in standard ECBs. This approach also aligns with the UN-ECE-13 directive for continuous braking function by effectively managing the braking energy without the typical drawbacks. The analysis includes optimization algorithms to determine the optimal size of the ECB under emergency braking conditions and continuous downhill scenarios, ensuring compliance with safety standards while enhancing vehicle efficiency and performance.