Accelera, the zero-emissions unit of Cummins, has unveiled its new integrated brake chopper resistor (iBCR), which includes robust cyber security features with improved performance and reliability. The new iBCR is a versatile system designed to address two critical aspects of electric commercial vehicle performance—electrical endurance braking and energy efficiency.
Acting as an electrical equivalent of a mechanical retarder, the excess energy generated from braking is redirected to the liquid-cooled resistor, where it dissipates as heat. This innovative approach ensures efficient energy management and improved braking performance.
“Our new iBCR transforms traditional electric drive systems by integrating enhanced efficiency, safety and cost-effectiveness. By harnessing regenerative braking and optimizing energy management, we’re driving innovation while shaping a cleaner, greener mobility landscape.”
Brian Wilson, GM of eMobility at Accelera
Key features
- Enhanced regenerative braking: Electric commercial vehicles benefit from regenerative electric braking, where the electric motor acts as a generator during braking. The iBCR captures surplus energy and converts it into heat, which can be used to heat the vehicle’s cabin or to temper the battery system. This not only enhances efficiency, but also contributes to overall energy savings.
- Cost-effective compliance: By integrating with a liquid-cooled resistor, the compact iBCR offers an economical solution to meet the UN ECE R 13 European regulatory standards. It helps optimize battery size and avoids the need to carry buffer capacity. The iBCR also helps relieve strain on friction brakes to enable improved durability and reduce maintenance efforts.
- Safety improvements: The iBCR has increased responsiveness and provides immediate room for uninterrupted endurance braking, with the ability to dissipate excess energy as heat up to 150-kilowatt (kW) output power. This makes it suitable for heavy-duty applications that require endurance-braking ability. The iBCR plays a crucial role in maintaining safety within electric drive systems, providing reliable performance in demanding scenarios.
