Analysis of Single Pedal Regenerative Braking Efficiency of Coal Mine Electric Vehicles

doi:10.3969/j.issn.1004-132X.2025.02.003

Abstract

Abstract: A single-pedal regenerative braking control strategy was proposed based on the accelerator pedal for electric vehicles used in coal mine trackless auxiliary transportation, aiming to significantly enhance the regenerative braking energy recovery rate and energy utilization efficiency. Theoretical modeling of the regenerative braking process was conducted based on vehicle braking dynamics and the law of conservation of energy. Considering the structural characteristics of the driving system and accelerator pedal of mine trackless auxiliary electric transportation vehicles, a regenerative braking torque solution model was established based on the accelerator pedal opening. Furthermore, to meet the requirements of high-intensity braking conditions, a regenerative braking torque calculation model was developed for the transition from the accelerator pedal to the brake pedal. The working principles of the control strategy during vehicle acceleration, coasting, and braking were sequentially analyzed. For typical driving cycle conditions, an actual vehicle test was conducted on a chassis dynamometer to evaluate the energy consumption economy of the single-pedal regenerative braking control strategy. The results show that the driving range increases by 41.65 km and 35.86 km under the NEDC and WLTC conditions, respectively. Comprehensive on-road test results demonstrate a smooth transition of regenerative braking torque during the switching between the accelerator and brake pedals, ensuring a seamless acceleration and deceleration processes for the entire vehicles. This paper lays a technical foundation for the optimized development of regenerative braking systems and contributes to the promotion and popularization of coal mine electric vehicles.

Key words: , coal mine electric vehicle, accelerator pedal, regenerative braking, energy recovery, control strategy

摘要： 针对煤矿无轨辅助运输电动车辆提出了一种基于加速踏板的单踏板再生制动控制策略，以进一步提高再生制动能量回收率和能源利用效率。基于车辆制动动力学和能量守恒定律，对再生制动过程进行了理论建模。结合煤矿无轨辅助运输电动车辆驱动系统以及加速踏板的结构特征，建立了基于加速踏板开度的再生制动转矩求解模型，同时，为满足大强度制动工况需求，建立了由加速踏板切换至制动踏板时的再生制动转矩计算模型，对车辆加速、滑行及制动过程中控制策略的工作原理依次进行了分析。针对典型的驾驶循环工况，在底盘测功机上对单踏板再生制动控制策略的能耗经济性进行实车测试，结果显示NEDC和WLTC工况续驶里程分别增加了41.65 km和35.86 km。实车综合路试结果表明，加速、制动踏板切换过程中再生制动转矩过渡平稳，整车加减速过程平顺。研究结果为再生制动系统的优化开发奠定了技术基础，有利于煤矿电动车辆的推广和普及。

关键词: 煤矿电动车辆, 加速踏板, 再生制动, 能量回收, 控制策略

CLC Number:

U469
TP273

REN Zhiyong1, 2, 3, SHI Qin1, 4, YAN Kai2, 3. Analysis of Single Pedal Regenerative Braking Efficiency of Coal Mine Electric Vehicles[J]. China Mechanical Engineering, 2025, 36(02): 209-219.

任志勇1, 2, 3, 石琴1, 4, 闫凯2, 3. 煤矿电动车辆单踏板再生制动效能分析[J]. 中国机械工程, 2025, 36(02): 209-219.

References

［1］任志勇, 石琴. 矿用电动无轨辅助运输装备发展现状及关键技术［J］. 煤炭科学技术, 2021, 49(7)：118-123.
REN Zhiyong, SHI Qin. Development Status and Key Technologies on Mine-used Electric Auxiliary Trackless Transport［J］. Coal Science and Technology, 2021, 49(7)：118-123.
［2］任志勇. 纯电动防爆车辆续驶里程影响因素研究［J］. 煤炭科学技术, 2019, 47(2)：150-155.
REN Zhiyong. Research on Influence Factors Affecting Driving Range of Flame-proof Battery Electric Vehicles［J］. Coal Science and Technology, 2019, 47(2)：150-155.
［3］刘峰, 曹文君, 张建明, 等. 我国煤炭工业科技创新进展及“十四五” 发展方向［J］. 煤炭学报, 2021, 46(1)：1-15.
LIU Feng, CAO Wenjun, ZHANG Jianming, et al. Current Technological Innovation and Development Direction of the 14th Five-year Plan Period in China Coal Industry［J］. Journal of China Coal Society, 2021, 46(1)：1-15.
［4］刘志强, 濮晛. 电动汽车连续再生制动系统防抱死制动试验研究［J］. 汽车工程, 2018, 40(7)：804-811.
LIU Zhiqiang, PU Xian. An Experimental Study on Anti-lock Braking of Continuous Regenerative Braking System in Electric Vehicles［J］. Automotive Engineering, 2018, 40(7)：804-811.
［5］靳立强, 孙志祥, 王熠, 等. 基于模糊控制的电动轮汽车再生制动能量回收研究［J］. 汽车工程, 2017, 39(10)：1101-1105.
JIN Liqiang, SUN Zhixiang, WANG Yi, et al. A Research on Regenerative Braking Energy Recovery of Electric-wheel Vehicle Based on Fuzzy Control［J］. Automotive Engineering, 2017, 39(10)：1101-1105.
［6］刘坤, 杜长虹, 吴维, 等. 电驱动系统再生制动工况动力学特性研究［J］. 汽车工程, 2021, 43(8)：1121-1127.
LIU Kun, DU Changhong, WU Wei, et al. Research on Dynamic Characteristics of Electric Drive System under Regenerative Braking Condition［J］. Automotive Engineering, 2021, 43(8)：1121-1127.
［7］韩陌, 何洪文, 石曼, 等. 基于学习的无人驾驶车辆模型预测路径跟踪控制研究［J］. 汽车工程, 2024, 46(7)：1197-1207.
HAN Mo, HE Hongwen, SHI Man, et al. Research on Learning-based Model Predictive Path Tracking Control for Autonomous Vehicles［J］. Automotive Engineering, 2024, 46(7)：1197-1207.
［8］LIU Wei, QI Hongzhong, LIU Xintian, et al. Evaluation of Regenerative Braking Based on Single-pedal Control for Electric Vehicles［J］. Frontiers of Mechanical Engineering, 2020, 15(1)：166-179.
［9］YU Jiawei, ZHENG Songlin, PHAM H, et al. Reliability Modeling of Multi-state Degraded Repairable Systems and Its Applications to Automotive Systems［J］. Quality and Reliability Engineering International, 2018, 34(3)：459-474.
［10］QIU Chengqun, WANG Guolin. New Evaluation Methodology of Regenerative Braking Contribution to Energy Efficiency Improvement of Electric Vehicles［J］. Energy Conversion and Management, 2016, 119：389-398.
［11］任志勇, 石琴, 赵远, 等. 矿用双电机双轴驱动铰接车辆转矩协调控制［J］. 工程科学与技术, 2021, 53(3)：173-179.
REN Zhiyong, SHI Qin, ZHAO Yuan, et al. Torque Coordinated Control for Mine Articulated Vehicles Driven by Twin Motors and Twin Shafts［J］. Advanced Engineering Sciences, 2021, 53(3)：173-179.
［12］XU Guoqing, XU Kun, ZHENG Chunhua, et al. Fully Electrified Regenerative Braking Control for Deep Energy Recovery and Maintaining Safety of Electric Vehicles［J］. IEEE Transactions on Vehicular Technology, 2016, 65(3)：1186-1198.
［13］BUNYAEVA E V, SKORIK V G, VLASEVSKII S V, et al. A Method for Improving the Energy Efficiency of an Alternating Current Electric Locomotive in the Regenerative Braking Mode［J］. Russian Electrical Engineering, 2016, 87(2)：73-76.
［14］LYU Chen, ZHANG Junzhi, LI Yutong, et al. Mechanism Analysis and Evaluation Methodology of Regenerative Braking Contribution to Energy Efficiency Improvement of Electrified Vehicles［J］. Energy Conversion and Management, 2015, 92：469-482.
［15］WU Jianing, YAN Shaoze, ZUO M J. Evaluating the Reliability of Multi-body Mechanisms：a Method Considering the Uncertainties of Dynamic Performance［J］. Reliability Engineering & System Safety, 2016, 149：96-106.
［16］ZEFF S. My Electric Journey with a Nissan Leaf：a Classic Early-adopter Experience［J］. IEEE Consumer Electronics Magazine, 2016, 5(3)：79-80.
［17］TIE S F, TAN C W. A Review of Energy Sources and Energy Management System in Electric Vehicles［J］. Renewable and Sustainable Energy Reviews, 2013, 20：82-102.
［18］刘志更. 架线式无轨胶轮车在长距离大坡度巷道中的可行性研究与试验［J］. 煤炭工程, 2021, 53(2)：175-179.
LIU Zhigeng. Feasibility Study and Test of the Stringing Trackless Rubber-tyred Vehicle in Long Distance and Large Slope Roadway［J］. Coal Engineering, 2021, 53(2)：175-179.
［19］谢进. 防爆电动无轨胶轮车在神东矿区井下应用研究［J］. 煤炭科学技术, 2017, 45(增刊2)：87-91.
XIE Jin. Application of Explosion-proof Electric Trackless Rubber-wheel Vehicle in Underground Mine［J］. Coal Science and Technology, 2017, 45(S2)：87-91.
［20］王连柱, 张燕滨. 煤矿井下无轨辅助运输巷道设计研究［J］. 煤炭科学技术, 2020, 48(8)：70-75.
WANG Lianzhu, ZHANG Yanbin. Design and Research of Roadway for Trackless Auxiliary Transportation System in Underground Coal Mine［J］. Coal Science and Technology, 2020, 48(8)：70-75.
［21］刘隽宁, 苏功富. 电动防爆无轨胶轮材料运输车控制策略研究［J］. 煤炭科学技术, 2022, 50(增刊2)：345-351.
LIU Junning, SU Gongfu. Research on Control Strategy of Electric Explosion-proof Trackless Rubber-tyred Material Transport Vehicle［J］. Coal Science and Technology, 2022, 50(S2)：345-351.
［22］BRAVO R R S, de NEGRI V J, OLIVEIRA A A M. Design and Analysis of a Parallel Hydraulic-Pneumatic Regenerative Braking System for Heavy-duty Hybrid Vehicles［J］. Applied Energy, 2018, 225：60-77.
［23］ZHAO Di, CHU Liang, XU Nan, et al. Development of a Cooperative Braking System for Front-wheel Drive Electric Vehicles［J］. Energies, 2018, 11(2)：378.
［24］张传伟, 郭卫. 煤矿井下无轨胶轮电动车驱动控制策略研究［J］. 矿山机械, 2012, 40(9)：39-42.
ZHANG Chuanwei, GUO Wei. Study on Driving Control Strategies for Underground Trackless Rubber-tired Electric Vehicles［J］. Mining & Processing Equipment, 2012, 40(9)：39-42.
［25］LIU L, LIU X T, WANG X L, et al. Reliability Analysis and Evaluation of a Brake System Based on Competing Risk［J］. Journal of Engineering Research, 2017, 5(3)：150-161.
［26］余志生. 汽车理论［M］. 5版. 北京：机械工业出版社, 2009.
YU Zhisheng. Automobile Theory［M］. 5th ed. Beijing：China Machine Press, 2009.
［27］武仲斌, 谢斌, 迟瑞娟, 等. 电动拖拉机田间巡航作业驱动转矩管理模型［J］. 农业工程学报, 2019, 35(4)：88-98.
WU Zhongbin, XIE Bin, CHI Ruijuan, et al. Driving Torque Management Model for Electric Tractor in Field Cruise Condition［J］. Transactions of the Chinese Society of Agricultural Engineering, 2019, 35(4)：88-98.
［28］WU Zhongbin, XIE Bin, LI Zhen, et al. Modelling and Verification of Driving Torque Management for Electric Tractor：Dual-mode Driving Intention Interpretation with Torque Demand Restriction［J］. Biosystems Engineering,2019,182：65-83.
［29］王庆年, 杨阳, 贾一帆, 等. 基于电机参数设计的电动车辆经济性优化研究［J］. 汽车工程, 2018, 40(4)：375-381.
WANG Qingnian, YANG Yang, JIA Yifan, et al. A Research on Energy Economy Optimization of Electric Vehicle Based on Motor Parameter Design［J］. Automotive Engineering, 2018, 40(4)：375-381.
［30］方培俊, 蔡英凤, 陈龙, 等. 基于车辆动力学混合模型的智能汽车轨迹跟踪控制方法［J］. 汽车工程, 2022, 44(10)：1469-1483.
FANG Peijun, CAI Yingfeng, CHEN Long, et al. Trajectory Tracking Control Method Based on Vehicle Dynamics Hybrid Model for Intelligent Vehicle［J］. Automotive Engineering, 2022, 44(10)：1469-1483.
［31］武仲斌, 任志勇, 赵远, 等. 矿山辅运电动车辆加速踏板集成再生制动控制策略［J］. 煤炭学报, 2024, 49(8)：3677-3686.
WU Zhongbin, REN Zhiyong, ZHAO Yuan, et al. Integrated Regenerative Braking Control Strategy for the Accelerator Pedal of Mine Trackless Electric Vehicle for Auxiliary Transportation［J］. Journal of China Coal Society, 2024, 49(8)：3677-3686.

[1]	CHENG Aiguo1, WANG Chao1, YU Wanyuan2, HE Zhicheng1. Numerical and Experimental Study on Effects of Rivet Crack on Mechanics Properties of Self-piercing Riveted Joints [J]. China Mechanical Engineering, 2025, 36(02): 197-208.
[2]	XU Jialu1, LIU Xiaonan1, LI Pengchao2, LIU Zhenyu1. Kinematics Parameter Identification for Industrial Robots Based on Multi-strategy Fusion DBO Algorithm [J]. China Mechanical Engineering, 2025, 36(02): 294-304.
[3]	XIN Jiaming1, JI Xiaogang1, 2, SUN Rong1, SU Yilin1. Study on Bending Performance of Bionic High-strength and Lightweight Pipe Structures [J]. China Mechanical Engineering, 2025, 36(02): 333-341.
[4]	WANG Yongqing, AI Jingchao, LI Te, LAN Tian, LIU Haibo. High Precision Weld Grinding Method of In-pipe Robots Considering Stiffness Characteristics [J]. China Mechanical Engineering, 2025, 36(02): 351-358,368.
[5]	PAN Zhiyong, WANG Liang, JIN Jiamei, QIU Jianmin, FENG Haoren. Design and Experiments of Bonded-type Disc Stator M-DOF Ultrasonic Motors [J]. China Mechanical Engineering, 2025, 36(01): 38-46,58.
[6]	WU Shi, GAO Zengkuo, WANG Mingzhu, ZHAO Chengrui. Influences of Fractal Features of Helical Gear Surface Topography on Time-varying Contact Stiffness [J]. China Mechanical Engineering, 2025, 36(01): 59-68,77.
[7]	LI Jian1, DING Xiaohong1, ZHANG Yijie2, XIONG Min1, WANG Han1, ZHANG Heng1. Hybrid Optimization for Housing Structure Stiffener and Support Location [J]. China Mechanical Engineering, 2025, 36(01): 69-77.
[8]	WU Guanwu, WU Liqun, WANG Hongcheng, WANG Yaxing, GUO Jinshuai, ZHANG Zheng, WU Jiaxin, LI Liangliang. A Vortex Focused Transmission Method for Bearing Fault Acoustic Emission Signals [J]. China Mechanical Engineering, 2025, 36(01): 78-86.
[9]	LI Chilu1, XIONG Shiquan1, LEI Weijian2, LIU Shutong1, LI Yingmin2, YI Qian1, YI Shuping1. Research on Experience Feedback Graph of Nuclear Power Constructions Based on Multi-dimensional Cascading Knowledge Extraction [J]. China Mechanical Engineering, 2025, 36(01): 177-189.
[10]	LIU Hao1, HUANG Liang1, SUN Yiran1, ZHOU Wei1, TANG Tianyu1, MEN Xiangnan2, DENG Tao2, SU Hongliang2. Research on Coil Design and Forming Processes of 2024 Aluminum Alloy Conical Hole Electromagnetic Flanging [J]. China Mechanical Engineering, 2024, 35(12): 2149-2156.
[11]	XU Teng, DENG Chunyang, QIU Guoqiang, XIE Zefeng, RAN Jiaqi, GONG Feng. Strain Rate Effect and Formability Research of High-speed Stage Deep Drawing for Pure Tantalum Thin-wall Members [J]. China Mechanical Engineering, 2024, 35(12): 2157-2168.
[12]	ZHANG Qingzheng1, JIANG Chen1, GAO Rui2, JIANG Jinxin1. Simulation Analysis and Process Study of Scribing Processes for GaAs Cleavage Processing [J]. China Mechanical Engineering, 2024, 35(12): 2203-2210.
[13]	WANG Lei1, 2, FANG Zichen1, WANG Zhentao1, SUN Liang1, 2, YU Gaohong1, 2, CUI Rongjiang3. Mixed Multi Pose Synthesis Method and Applications of Unequal Velocity Planetary Gear Trains [J]. China Mechanical Engineering, 2024, 35(12): 2211-2220.
[14]	LI Jimeng, WANG Ze, SHI Qingxin, MENG Zong. Rolling Bearing Fault Diagnosis of Wind Turbines Based on Frequency Domain Group Sparse Model with Graph Regularization Constraints [J]. China Mechanical Engineering, 2024, 35(11): 1909-1919.
[15]	LI Hao1, JIAO Yanchao1, ZHANG Yuyan1, ZHANG Hao1, XING Hongwen2, WEN Xiaoyu1, WANG Haoqi1, YE Guoyong1, GUAN Xiao2. Research on Station Optimization of Aircraft Assembly Laser Trackers Based on Digital Twins [J]. China Mechanical Engineering, 2024, 35(11): 1986-1994.