DEVELOPMENT OF

R E G E N E R AT I V E
BRAKING SYSTEM
U S I N G F LY W H E E L
Mini-Project Review
 PRESENTED BY
ANUP NIRMAL ABRAHAM 1MV20ME007
1MV20ME008
BHARATHA H S 1MV20ME025
1MV20ME036
MAYUR PRAKASH

SHOAIB AFFANUnder
M the Guidance of
Mr. K Ejaz Ahmed
Associate Professor
Department of Mechanical Engineering
Sir M Visvesvaraya Institute of Technology,
Bengaluru
TA B L E O F C O N T E N T S
Chapters Slide Nos.

1. Introduction 1. 4 – 8

2. Literature Survey 2. 9 – 10

3. Problem Statement 3. 11

4. Objectives 4. 12

5. Methodology 5. 13 – 19

6. Results 6. 20

7. Conclusion 7. 21

8. References 8. 22-23
 INTRODUCTIO
N
Regenerative braking systems (RBS) are a
groundbreaking advancement in the automotive
industry that allows vehicles to recover and
reuse kinetic energy generated during braking.
Instead of dissipating this energy as heat, RBS
converts it into electrical energy and stores it for
later use, enhancing overall efficiency and
reducing environmental impact. Benefits include
improved fuel efficiency, reduced emissions,
extended lifespan of braking components, lower
maintenance costs, and enhanced range for
hybrid and electric vehicles. RBS is applicable
across various vehicle types and has been
facilitated by advancements in energy storage
systems like batteries and supercapacitors.
T Y P E S O F R E G E N E R AT I V E B R A K I N G
SYSTEMS

 Electric Motor-Based Regenerative Braking System : Electric motor-based regenerative braking

systems are commonly used in electric vehicles. The system converts kinetic energy into electrical energy
during braking, storing it in the battery for later use, allowing the vehicle to recover and reuse energy that
would be lost in traditional braking systems.

 Hydraulic Regenerative Braking System: Hydraulic regenerative braking systems, or hydraulic hybrid
systems, utilize a hydraulic pump/motor and accumulator to capture and store energy during braking. This
stored hydraulic energy can be used for propulsion or to power auxiliary systems, improving overall energy
efficiency in vehicles.
T Y P E S O F R E G E N E R AT I V E B R A K I N G
SYSTEMS
 Flywheel Based Regenerative Braking System : Flywheel-based regenerative braking systems store
kinetic energy in a rotating flywheel during braking, which is then released to assist the electric motor during
acceleration. These systems are ideal for applications that involve frequent braking and acceleration, offering
fast response times and high-power density, ultimately improving the vehicle's efficiency.

 Ultracapacitor-Based Regenerative Braking System : Ultracapacitor-based regenerative braking

systems capture and store electrical energy during braking, utilizing the high power density and fast
charge/discharge capabilities of ultracapacitors. These systems are well-suited for high-performance electric
vehicles, as they efficiently handle frequent charge and discharge cycles, extending the lifespan of the battery
pack.
A D VA N T A G E S , L I M I T A T I O N S O F
R E G E N E R AT I V E B R A K I N G S Y S T E M
ADVANTAGES LIMITATIONS

1. Energy Efficiency. 1. Limited Energy Recovery.

2. Extended Battery Life. 2. Cost and Complexity.
3. Enhanced Performance. 3. Weight and Space Considerations.
4. Reduced Environmental Impact.
A P P L I C AT I O N S
1. Electric Vehicles (EVs).
2. Hybrid Electric Vehicles
(HEVs).
3. Public Transportation.
4. Heavy-Duty Vehicles.
 L I T E R AT U R E S U R V E Y
✓ Siddharth K Sheladia, et al, studied ‘A Review on Regenerative Braking Methodology in Electric Vehicle’, International
Journal of Creative Research Thoughts, Volume 6, Issue 1 (2018). 2320-2882. In this paper, it is mentioned that Regenerative
braking can save up to 5% to 8% of waste energy. The systems have been enhanced with advanced power electronic
components such as ultra-capacitors, DC-DC converters (Buck-Boost) and flywheels.
✓ Anchal Kumar, et al, studied (Regenerative Braking system (RBS) future Braking system) (May 2014) Vol.2, Issue 5:
Regenerative braking systems (RBS). The main aim of this project was to develop a product that stores the energy which is
normally lost during braking, and reuses it. Also, Electric Motor is used to convert Kinetic Energy into electrical energy.
✓ A. Eswaran, S Ajith, et al, studied ‘Design and Fabrication of Regenerative Braking System’, International Journal of
Advance Research and Innovative Ideas in Education-Vol-4 Issue-3 (2018), pg 2395-4396. In this paper, the regenerative
braking system used in the vehicles satisfies the purpose of saving a part of the energy lost during braking. Also, it can be
operated at a high temperature range and is efficient as compared to conventional braking systems.
✓ Sanket Rajendra Sathe, et al, studied. “Regenerative Braking System: A Review” Volume 10, Issue 5, May 2022. This study
presents data concerning the principles and properties of regenerative braking systems. Several automation, mechanical
devices, and constructive studies are allotted during this field to spice up recovered energy potency and cut back in operation
prices.
 L I T E R AT U R E S U R V E Y
 Ketan Warake, et al, studied ‘Design & Development of Regenerative Braking System at Rear Axle’, International Journal of
Advanced Mechanical Engineering. Volume 8, Number 2 (2018), pg 2250-3234. In this paper, the regenerative braking system
used in the vehicles satisfies the purpose of saving a part of the energy lost during braking. The regenerative braking system is
designed to partially recover the battery charge wasted in braking of the vehicle, showing that minimum 11% battery energy
can be recovered.

 Tako Nama, et al, studied, ‘Design, Modelling and Hardware Implementation of Regenerative Braking for Electric Two-
Wheelers for Hilly Roads’ (December 2022). This paper has proposed a regenerative braking circuit that is modular and can be
integrated into existing electric scooters which uses mechanical braking, which can be very effective in hilly regions.

 Y. Luo, D. Huang and X. Gao’s "Research on energy recovery for electric vehicle based on motor-generator integration
system".
In this paper they took the electric vehicle as a research object and concentrated on its energy recovery system.
The power produced during the motor braking torque can be exerted through the transmission of the during wheel brake,
resulting in braking force.
P R O B L E M S TAT E M E N T
• At this century, automotive industry has posted a great challenge in order to reduce the
vehicle fuel consumption and emission, this is due to the shortage of fuel resources and
worsen air pollution problem. According to figures released by the US Environmental
Protection Agency (EPA), conventional ICE vehicles currently contribute 40-50% of ozone,
80-90% of carbon monoxide, and 50-60% of air toxins found in urban areas.
• A study shows that, one third (20 to 25%) energy is consumed during braking. The invention
if Regenerative Braking System is viewed as a solution to these 4 problems, as it recovered
wasted energy and restored to another form of useful energy. Although the valuable and
positive effect brought by Regenerative Braking System is realized, it still has its issue or
problem to be solved; one of the major problems is observed as the suitable battery to be
used in this type of vehicle.
OBJECTIVES
1. Energy Efficiency: Regenerative braking systems can recover and reuse up to 70% of braking
energy, resulting in a substantial improvement in vehicle energy efficiency.
2. Extended Battery Life: Regenerative braking systems extend electric vehicle battery life by 25%,
increasing sustainability and driving range.
3. Cost Reduction: Regenerative braking systems can result in up to 30% cost reduction in
maintenance and replacement expenses for brake components, offering significant long-term
savings for both vehicle owners and manufacturers.
4. Environmental Impact Reduction: The objective is to minimize greenhouse gas emissions and air
pollution by maximizing energy efficiency and reducing energy waste during braking. According
to current research and development, emissions produced can be reduced by up to 23% on
average.
METHODOLOGY
A thorough literature research was conducted
in the field of Regenerative Braking Systems
(RBS) and its related aspects. Based on the
literature review, mechanical, electrical and
hydraulic regenerative braking systems were
found to be viable options for the chosen
application. The Flywheel or the mechanical
regenerative braking system was selected for
further development and its various
configurations were explored. This type of
mechanism was selected due to its ability to
efficiently generate energy while keeping costs
at a minimum in comparison to the other
methods for regenerative braking.
WORKING PRINCIPLE
1. Initial Momentum: The vehicle possesses kinetic 5. Brake release: Upon acceleration, the stored energy is
energy due to its motion. released from the flywheel.

2.Braking Initiation: When the brakes are applied, the 6. Power supplementation: The released energy
regenerative braking system activates. supplements power from the engine or electric motor.

3. Kinetic energy conversion: Kinetic energy is 7. Repeated cycling: The process of regenerative braking
transferred from the wheels to the flywheel. and energy storage can be repeated multiple times during
a drive.
4. Energy storage: The flywheel stores the converted
kinetic energy as rotational energy.
Regenerative braking utilizes the motor to
slow down the car when the brake pedal
is pressed, with the motor operating in
reverse and recharging the batteries. This
process significantly reduces fuel
reliance, enhances fuel economy, and
lowers emissions. In urban settings and
stop-and-go driving scenarios,
regenerative braking proves particularly
effective. The system allows the motor to
act as a generator, extracting energy from
the battery during normal running
conditions and recharging it during
braking.
C O M P O N E N T S S P E C I F I C AT I O N
SL NO TITLE SPECIFICATION

1 BATTERY 12V, 4.5 A

2 MAIN FRAME 280*190 *190

3 WORM GEAR MOTOR 12V, 4.5 A

4 ELECTRIC GENERATOR 20 WATT

5 FLYWHEEL 250mm Diameter

6 DIODE IN4007 (3 AMPS)

7 SHAFT 20mm Diameter, 230 mm Length

B I L L O F M AT E R I A L S
SL NO MATERIAL/PROCESS COSTS (IN RS)
1 BATTERIES 150
2 MAIN FRAME AND FABRICATION 500
3 WORM GEAR MOTOR 1000
4 ELECTRIC GENERATOR (BLDC) 250
5 FLYWHEEL 1250
6 DIODE 10
7 SHAFT 150
8 LED 20
TOTAL COSTS: 3330
 E N E R G Y E Q U AT I O N S
1. Ohm’s Law: 3. Output mechanical power of the motor:
I=V/R
Pout = τ * ω
Where, I – current, measured in amperes (A)
where, Pout – output power, measured in watts (W)
V – applied voltage, measured in volts (V)
R – resistance, measured in ohms (Ω) τ – torque, measured in Newton meters (N-m)

ω – angular speed, measured in radians per second (rad/s)

2. The consumed electrical power of the motor: 4. Efficiency of the motor:

Pin = I * V E = Pout / Pin
Where, Pin – input power, measured in watts (W)
where, Pout – output power, measured in watts (W)
I – current, measured in amperes (A)
Pin – input power, measured in watts (W)
V – applied voltage, measured in volts (V)
E – Efficiency of the motor (%)
C A L C U L AT I O N S
I=V/R

I = 12 / R Pout = τ * ω

R= 12/1.2 ω = 63 * 2π / 60 = 6.5973 rad/s

R= 10 Ohms Pout = 18.5 *6.5973 = 122.05 W
Pin = I * V

Pin = 12 * 12 E = (Pout / Pin)*100

Pin = 144 W E = 122 / 144 = 0.847 * 100 = 84.7 %

 RPM Angular Speed (ω) (rad/s) Output Power (Pout) (W) Efficiency (E) (%)
R E S U LT S
It can be seen from the result tables 40 4.1888 77.2448 53.6111

that the efficiency of the regenerative 45 4.7124 86.9506 60.2431

50 5.2360 97.064 67.3403

braking systems using D.C Motors
55 5.7596 106.2786 73.7876
increases as the angular velocity of the
60 6.2832 115.4932 80.2465
motor increases and hence the 63 6.5973 122.05 84.7
regenerative braking systems are more
efficient as higher angular velocities
and the recoverable energy increases
with increase in the motor speed. The
losses are higher at lower speed
because the motors are inefficient at
lower speeds, whereas the losses at
higher speeds are mainly mechanical
losses like friction losses and air drag.
CONCLUSION
The regenerative braking system effectively captures and recovers a portion of the energy lost
during braking in vehicles. It addresses the issue of wasted battery charge dissipated as heat by
friction brakes, instead utilizing it to rotate the generator's rotor and convert mechanical energy
into useful battery charge. While it cannot bring the vehicle to a complete stop, experimental
findings reveal that using a DC motor with gears yields higher voltage generation compared to
stepper or servo motors. Implementing this system in actual vehicles can recover a minimum of
11% of battery energy, increasing the distance traveled between successive charging
requirements by 10 to 15% and reducing energy wastage.
REFERENCES
1. Sayed Nashit, Sufiyan Adhikari, Shaikh Farhan, Srivastava Avinash and Amruta Gambhire, ‘Design,
Fabrication and Testing of Regenerative Braking Test Rig for BLDC Motor’, 2016, pg 1881-84.
2. Khushboo Rahim, and Mohd. Tanveer, ‘Regenerative Braking System: Review Paper’, International
Journal on Recent and Innovation Trends in Computing and Communication, 5.5 (2018), pg 736-39.
3. Tushar L. Patil, Rohit S. Yadav, Abhishek D. are, Mahesh Saggam, Ankul Pratap, ‘Performance
Improvement of Regenerative braking system’, International Journal of Scientific & Engineering Research
Volume 9, Issue 5, (2018), pg 2229-5518
4. Siddharth K Sheladia, Karan K Patel, V raj D Savalia, Rutvik G Savaliya, ‘A Review on Regenerative
Braking Methodology in Electric Vehicle’, International Journal of Creative Research Thoughts, Volume 6,
Issue 1 (2018), pg 2320-2882.
5. Anchal Kumar, Pulkit Gupta, Sandeepan Deb & Shay Pohjuy (Regenerative Braking system (RBS) future
Braking system) (May 2014) Vol.2, Issue 5: Regenerative braking systems (RBS).
REFERENCES
6. A. Eswaran, S Ajith, V Karthikeyan, P Kavin, S Loganandh, ‘Design and Fabrication of Regenerative
Braking System’, International Journal of Advance Research and Innovative Ideas in Education-Vol-4
Issue-3 (2018), pg 2395-4396,
7. Ketan Warake, Dr. S. R. Bhahulikar, Dr. N. V. Satpute, ‘Design & Development of Regenerative
Braking System at Rear Axle’, International Journal of Advanced Mechanical Engineering. Volume 8,
Number 2 (2018), pg 2250-3234.
8. Tako Nama, Prosenjit Mondal, Praveen Tripathy, Ravindranath Adda, and Anup Kumar Gogoi
(December 2022), Design, Modeling and Hardware Implementation of Regenerative Braking for Electric
Two-Wheelers for Hilly Roads.
9. Y. Luo, D. Huang and X. Gao’s "Research on energy recovery for electric vehicle based on motor-
generator integration system,"
10. Sanket Rajendra Sathe, Saurabh Sharad Masal, Samadhan Laxman Kakade, Suyash Yelatwar, Prof. S.
J. Jagtap. ‘Regenerative Braking System: A Review’ Volume 10, Issue 5, May 2022.
THANK YOU