Ultracapacitor as selectable energy buffer in electric vehicle application

A method of ultracapacitor integration with a regenerative braking system for use in electric drive trains is presented in this paper. An ultracapacitor (UC) is an intermediary to store and provide energy on the DC bus in certain scenarios, such as during acceleration and regenerative braking. UC is used to avoid direct inrush loading on the battery, which the electric drive system may cause. The energy from UC is injected into the DC bus in compliment to the battery, for which a dedicated power source switch called the “Main Charge Controller” (MCC) is responsible. The charge discharge of UC is done through a bidirectional buck-boost converter (BDBBC). The use of UC to offload high energy demand from the battery and store energy recovered during regenerative braking helps improve the vehicle's life and per-charge range. The stored energy in UC can be obtained from the battery at the start. UC can also be charged at the time of charging. The design and the presented control are ideal for lightweight electric vehicles. The system uses a 39.9 kJ ultracapacitor, formed from market-available 50F 2.7 V units in a 52S configuration, storage, and a 6kWh battery. The simulated vehicle in battery only case provides a minimum of 154 km range in rough conditions, in best case scenario it provides a 200 km range. The proposed design provides an increased extended range compared to simple battery-based regenerative braking, in the case of this work the hybrid solution provides an addition of more than 30 km of additional range compared to a battery-only solution which is simulated for all the same conditions except without the addition of the UC and its control and handling system, resulting in a total range of 230 km. The speed control response achieved by the user is also very fast. Electric Vehicles have range limitations due to storage technology which is a high entry barrier for consumers looking for reliable vehicles without range anxiety, as storage technology progresses adoption will become easier. This work is an attempt at using hybrid storage and selective use of it, for improved range and sharper speed response. However, this work does not explore the aging of the storage components due to increased operational load and thermal stresses or application to alternate battery chemistries. This work is primarily focused on the vehicles that use lithium-based batteries.