Electronic – Regenerative braking at any speed below maximum – how is it done

motor

My mobility scooter has a motor controller with regenerative braking – but regeneration seems to take place even at low speeds, well under the maximum! I know it does this because if I reduce throttle at low speed going down a hill, I see the current reverse on the ammeter and the battery voltage start to climb – considerably higher than with no load.

How does the controller achieve this? Normally, charging can only take place when the motor's generated voltage exceeds that of the battery – and this cannot happen at low speed. I ask because I want to build one from scratch.

Best Answer

The short answer is that regenerative braking is not based only on the back EMF of the motor. It's based on also using the motor's inductance (and/or an external inductor) as the key element of a boost-mode switchmode power converter that can convert the output voltage of the motor (when used as a generator) to a level that can be used to charge the battery.

Since PWM speed controllers already contain the necessary high-current switching elements connected between the battery and the motor, switching between "driving" and "braking" is really just a matter of changing the timing of the control signals to those switching elements.