Braking Strategy Characterization for a Dual-Motor Battery Electric Vehicle and Regenerative Torque Limit Derivation

Recent research on braking control strategies for battery electric vehicles (BEVs) commonly limits the front-to-rear braking force distribution. However, no public evidence shows that production vehicles observe these limits. The present study evaluates this assumption through road tests and high-fidelity simulations for dual- and single-motor powertrains. On-road measurements acquired from a mass-produced BEV indicate that, under typical driving conditions, the force split can diverge safely from conventional design curves—including the ECE and the ideal curves. Building on these data, a comparative analysis quantifies the efficiency penalties associated with constrained braking (fixed ratios or ideal curve tracking) relative to an unconstrained, efficiency-oriented approach. In dual-motor configurations, removing the constraint recovers up to 6.8% more kinetic energy over a real-world cycle. A power loss-based method is proposed to establish a torque curve limiting regenerative braking at low-speed operation. Applied to a single-motor delivery-van model, the regenerative torque limitation increases energy recuperation by as much as 4.8% during moderate to intense decelerations. These findings provide guidance for future brake control designs, demonstrating that efficiency-focused regeneration can coexist with anti-lock braking systems to extend BEVs’ driving range without compromising vehicle stability.