SOLUTION
OK guys, I spent a few hours this afternoon calculating this out using numeric methods. My time deltas in calculating these numbers were anywhere from about 0.01s to 0.05s, so the numbers should be reasonably good. (Note--I've already shown very good agreement with analytical solutions for the coasting case, discussed above).
First, let me share the results. I believe they are very interesting.
Interesting Result #1: Coasting is Not Always More Efficient
I will share some numbers that I've calculated, but I think I've proven that coasting is not always more efficient. I will show you several examples in which, given that you cover the same
distance, using regen you'll have more energy in your pack than if you coasted (as I suspected initially).
Interesting Result #2: This is Complicated
Also as suspected, the answer is not cut and dry. It requires this sort of calculation to figure out whether you're better off using regen. However, we may be able to come up with some "Hypermile" rules of thumb using my data.
Interesting Result #3: The faster your final target speed, the larger the differential between your starting and final speed must be to get a regen benefit.
For example, if your target speed is 40 mph, you must start out going at least about 67.5 mph to get a benefit from regen. Any slower than 67.5 mph and it's better to coast. Any faster, and you're (much) better off using regen.
If your target speed is 55 mph, you must start out going at least 84 mph to get a benefit from regen.
If your target speed is 75 mph, you must start out going at least about 106 mph to get a benefit from regen.
Interesting Result #3
The improvement in regen over coasting is probably not going to be very noticable in the real world unless you're going from highway speeds down to surface streets (like 35 mph)...and even then we're gaining a fraction of a mile of range. You probably don't do this much--so you probably won't actually notice much improvement unless you're in a hypermiling competition
Real World Conclusion
In all cases where regen puts out about 60 kw (about 40 MPH and above-ish), your initial speed must be somewhere in the ballpark of about 30 mph faster than your target speed to get a benefit from regen. This is a decent rule of thumb to use.
So, if you're going 70 mph and you're dropping to 40 mph,
USE REGEN.
If you're going 75 mph and you're dropping to 55 mph (as in my initial post), COAST.
If you're going highway speed and you're dropping down to a 35 mph surface street,
USE REGEN.
This is particularly interesting because there are some experienced hypermilers here for whom this changes their game plan!
OK, so there are the results. Obviously, these rules of thumb change with higher altitudes (which favor coasting), colder temperatures (which favor using regen), etc. But these are good starting estimates.
Note that it's possible that something like mass doesn't even matter. I didn't take the numerics far enough to look into this, but I'll provide my spreadsheet so someone here can. (Gotta tend to my kids!) Also, feel free to experiment with different air densities, masses, regen efficiencies, etc. to see how it affects things.
Here's the techincal stuff. I'll try to be brief.
Assumptions:
-Constant regen of 60kW going into the battery (so target speed of 40 mph or higher)
-Regen efficiency of 85%
-Power production efficiency of 92% (opposite of regen)
-I Included drag, rolling resistance, and drivetrain losses. (Estimating the drivetrain losses).
-Ignored other power uses (HVAC, accessories, etc). Except for HVAC, they are minimal compared to the energies we're talking about here. You could take it a bit further to include HVAC based on the difference in times for regen vs. coasting--but I suspect it's not too drastic of a difference.
Basic Methodology
2 Cases:
Coasting: Go from speed A to B by coasting only. This takes a certain amount of distance. There is no net change to the energy in the battery.
Regen: Apply full regen at Speed A. When speed B is reached (which is at a shorter distance than when coasting), maintain speed until you cover the same distance covered in the coasting case. Take the energy gain from the regen and the energy loss from maintaining speed for the remaining distance to get a net change in battery energy.
In general, the numeric method is as follows:
1. Use numerical methods to calculate drag force, rolling resistance, and drivetrain resistance at the starting speed.
2. Use the sum of these forces and the mass of the car to calculate instantaneous acceleration.
3. Use the instantaneous acceleration to calculate a new speed at a new time t + dt, where dt is small (0.01-0.05 sec) Use the speed and the dt to calculate the distance covered in this small time dt.
4. Lather, rinse, repeat.
Here are some numbers. Note in all cases than for coasting, the energy change in the battery is zero--so if regen gives a gain of energy as listed below, it's better than coasting.
65 to 55 MPH: Regen LOSES about 30,000 Joules of energy.
85 to 55 MPH: Regen GAINS about 8,000 Joules of energy.
105 to 55 MPH: Regen GAINS about 150,000 Joules of energy.
50 to 40 MPH: Regen LOSES about 24,000 Joules of energy.
60 to 40 MPH: Regen LOSES about 22,500 Joules of energy.
70 to 40 MPH: Regen GAINS about 10,000 Joules of energy.
90 to 40 MPH: Regen GAINS about 155,000 Joules of energy (about 43 Wh, or about 0.15 mi of range).
Here's my spreadsheet for those who want to fiddle:
http://www.sendspace.com/file/r4l4t7
OK, there ya go guys. Don't know if this makes me a hero, a nerd, or both
. Anyway, gotta get back to being a father. Question answered!