REGENERATIVE BRAKING SYSTEM

A PROJECT REPORT

Submitted By

HARIBABU M.

INDIRAN V.

JAABIR SULTAN

in partial fulfilment for the award of the degree

of

BACHELOR OF ENGINEERING

In

MECHANICAL ENGINEERING

VELTECH MULTITECH DR. RANGARAJAN DR.SAKUNTHALA

ENGINEERING COLLEGE, AVADI

ANNA UNIVERSITY:: CHENNAI 600 025

JULY 2021
 BONAFIDE CERTIFICATE

Certified that this report “REGENARATIVE BRAKING SYSTEM” is the bonafide

work of HARIBABU M. (113118114015), INDHIRAN V. (113118114017) and
JAABIR SULTAN (113118114018) who carried out the project work under my
supervision.

SIGNATURE SIGNATURE

Mr. M. Selvam. M.E., (Ph.D.) Dr. S. Palani. ME., Ph.D.

HEAD OF DEPARTMENT SUPERVISOR

Assistant Professor Associate Professor

Mechanical Engineering Mechanical Engineering

Vel Tech Multi Tech Dr. Rangarajan Vel Tech Multi Tech Dr. Rangarajan

Dr. Sakunthala Engineering College Dr. Sakunthala Engineering College

AVADI, Chennai 600 062 AVADI, Chennai 600 062

CERTIFICATE OF EVALUATION

COLLEGE CODE/NAME: 1131/ Vel Tech Multi Tech Dr. Rangarajan Dr.
 Sakunthala Engineering College

DEPARTMENT : Mechanical Engineering

SEM/YEAR : 6th / 3rd

SUBJECT CODE/NAME : ME 6612 / Design and Fabrication Lab

S. Names of Students Title of the Project Name of Internal Guide

NO

1 HARIBABU M.

(113118114015) DESIGN AND Dr. S. PALANI., ME., Ph.D.

FABRICATION OF ASSOCIATE PROFESSOR, Department
2 INDHIRAN V. REGENERATIVE of Mechanical Engineering
BRAKING SYSTEM
(113118114017)

3 JAABIR SULTAN

(113118114018)

This is to certify that the project entitled “DESIGN AND FABRICATION OF

REGENERATIVE BRAKING SYSTEM” is the bonafide record of work done by the
above students who carried out the project work under our guidance during the year 2020 –
2021 in partial fulfilment of the award of Bachelor of Engineering degree in Mechanical
Engineering of Anna University Chennai.

Submitted for the Viva-voce held on ………………………………… at Vel Tech Multi Tech
Dr. Rangarajan Dr. Sakunthala Engineering College, AVADI – 600062.

INTERNAL EXAMINER EXTERNAL EXAMINER

ACKNOWLEDGEMENT
At this moment of culminating our project, we express our deep gratitude to God
almighty who guided us to make this project a success.

We are greatly indebted to our beloved Founder and Chairman Col. Prof. Vel. Shri.
Dr. R. RANGARAJAN B.E (ELEC)., B.E (MECH)., M.S (AUTO)., our Vice-
chairman Dr. Mrs. R. SAKUNTHALA RANGARAJAN M.B.B.S for providing us
with excellent environment and infrastructure at our college Vel Tech Multi Tech Dr.
Rangarajan Dr. Sakunthala Engineering College. We thank our principal Dr. V.
RAJAMANI M.E., Ph.D., for being a source of moral encouragement and providing
us with his valuable support.

We thank our Head of the Department Mr. M.SELVAM, M.E., (Ph.D.) for his
guidance and encouragement at each and every stage of our project work and also
guiding us properly throughout the reviews.

Our sincere thanks to project guide Dr.S.PALANI. M.E., Ph.D., Department of

Mechanical Engineering for his valuable suggestions and guidance at the time of need.

We would like to express our heartfelt gratitude to all the faculty members,
Department of Mechanical Engineering for the help they extended for completion of
project.

This project is dedicated to our parents and friends who sacrificed a lot and extended
their full support to us.

ABSTRACT

 We are slowly reaching the era of electric vehicles. One of the most important
issues we might face is battery charging time and lack of charging stations.
Regenerative braking system provides an easy solution to address both
problems to an extent.
 This system allows the vehicle to generate energy every time brakes are
applied. The power generated is directly proportional to the usage of the brake.
 A simple engineering concept involving mechanical and electrical prowess
provides an elegant solution that may have caused serious issues under certain
conditions.
 The Objective of this project is to increase battery capacity of any regular
electric car battery.
 This system coverts wasteful energy into usable power for the battery.
 This system involves friction lining arrangement inside brake drum
 When the drum rotates, the friction lining does not touch the drum.
 However when the brake is applied, friction line touches the drum from inside
and moves the motor connected to lining in same direction.
 Thus it generated electricity using the motor itself as dynamo.
 The system allows for charging car battery each time brakes are applied, hence
providing regenerative braking system.

ADVANTAGES

 The Objective of this project is to increase battery capacity of any regular

electric car battery.
 This system coverts wasteful energy into usable power for the battery.
 This system involves friction lining arrangement inside brake drum
 When the drum rotates, the friction lining does not touch the drum.
 However when the brake is applied, friction line touches the drum from inside
and moves the motor connected to lining in same direction.
 Thus it generated electricity using the motor itself as dynamo.
 The system allows for charging car battery each time brakes are applied, hence
providing regenerative braking system.

FLOW CHART:
 TABLE OF CONTENTS

TITLE PAGE

BONAFIDE CERTIFICATE

CERTIFICATE OF EVALUATION

ACKNOWLEDGEMENT

TABLE OF CONTENT
LIST OF FIGURES

LIST OF TABLES

LIST OF SYMBOLS

CHAPTER 1: INTRODUCTION 1-9

1.1 Introduction 1

1.2 Working Principle 3

1.3 Types of Regenerative Braking System 4

1.4 Problem statement 6

1.5 Applications 7

1.6 Advantages 7

1.7 Disadvantages 8

1.8 Future Scope 8

1.9 Organization of the thesis 9

CHAPTER 2: LITERATURE REVIEW 10-18

2.1 History 10

2.2 Literature review 15

CHAPTER 3: METHODOLOGY 19-38

3.1 Fabrication 26
3.2 Methods 34

CHAPTER 4: RESULTS AND DISCUSSION 39-40

4.1 Result 39

4.2 Discussion
CHAPTER 5: CONCLUSION AND RECOMMENDATIONS 41-42

5.1 Conclusion 41

5.2 Recommendations 42

REFERENCES 43
APPENDICES

LIST OF TABLES

Table 3.1 List of Materials used in Fabrication 26

Table 3.2 Properties of Mild Steel 27

Table 4.2 Result Table 39

List of Figures Page no.

Fig 1.2.1: Normal forward driving condition. 3 Fig
1.2.2: Regenerative action during braking. 3 Fig 2.1:
A Flybrid Systems kinetic energy recovery system. 10 Fig
2.2: A KERS flywheel. 11 Fig
3.1: Initialization of project. 20 Fig
3.2: Design of frame. 21 Fig 3.3
: Design of pulley. 21 Fig 3.4
: Design of motor. 22 Fig 3.5
: Design of bearing. 22 Fig 3.6
: Assembly Dialog box. 23 Fig 3.7
: Assembly of the component. 24 Fig 3.8
: Final assembly with belt drive mechanism. 25 Fig 3.9
: Square Bar. 26 Fig
3.10 : Solid Shaft. 27 Fig
3.11 : Plummer Block. 28 Fig
3.12 : Wheel. 29 Fig
3.13 : Brake Wheel. 29 Fig
3.14 : Brake Spindle. 30 Fig
3.15 : Sewing Machine Motor. 30 Fig
3.16 : Pulley. 31 Fig
3.17 : Pulley Rope. 31 Fig
3.18 : LED. 32 Fig
3.19 : Wires. 32 Fig
3.20 : Brushed D.C Motor. 33 Fig
3.21 : Drilling Machine. 34 Fig
3.22 : Hacksaw. 35 Fig
3.23 : Angle chip from the square bar. 35 Fig
3.24 : Basic Welding Circuit. 36 Fig

CHAPTER 1

1.1 Introduction

In recent years, there is the lack of reliable alternative energy sources, increasing
efficiency and reducing exhaust gas emissions has become the focus of the modern
automotive research. Commercial vehicles such as refuse trucks and delivery vehicles
lose a tremendous amount of kinetic energy during frequent braking and constant
drive at low speeds on designated city routes, which results in higher fuel
consumption and Green House Emission Gas (GHG) emission than other on-road
vehicles. Numerous attempts have been made to improve type of vehicles. The
technological combination of Exhaust Gas Recirculation (EGR) and Diesel
Particulate Filter (DPF) after treatment is one of the effective ways to solve the
vehicle emission, especially for NOx and soot. However, this method is not able to
reduce the GHG emission since the low temperature combustion of this technology
results in increasing the fuel penalty. Sacrificing engine efficiency in exchange for
reduced pollutants cannot fundamentally solve the energy crisis. In order to achieve
overall GHG reduction targets, a strong reduction is needed particularly for
commercial vehicles. Regenerative energy technology is one of the key features of
electrified vehicles. It allows the vehicle to capture a tremendous amount of the
kinetic energy lost during braking or decelerating for reuse. That is saying, energy
recovery technology can significantly bring down the energy consumption of
electrified vehicle, particularly in urban operated route. Generally, there are two
regenerative energy approaches which have been applied to commercial vehicles:
Regenerative Braking System and Boost Recuperation System. The former is usually
applied in series hybrid 2 architecture; the latter in the parallel architecture. The
regenerative braking system is equipped in the driven axle to recuperate the braking
energy loss. The boost recuperation system is parallelly coupled with the mechanical
propulsion system to recuperate kinetic energy during the deceleration process. Both
technologies allow commercial vehicles to have a significant improvement of
reducing fuel consumption as well as emissions. However, few researchers have
addressed the regenerative energy rate of hybrid commercial vehicles. The more
energy the regenerative braking recuperates; the less fuel is consumed. Typical hybrid
commercial vehicles are generally designed as rear drive and the regenerative braking
system is equipped in rear driven axle(es) to recuperate the braking energy loss. Due
to the change of the center gravity in the vehicle under different load conditions,
braking energy loss may vary in both front and rear axles. Current braking research
indicates that around 50-80% of braking energy loss of commercial vehicles occurs in
the front axle and the braking energy loss varies slightly under different load states.
Therefore, the majority of the regenerative energy potential is not taped.

1.2 Working Principle

Regenerative braking is a braking method that utilizes the mechanical energy from
the motor by converting kinetic energy into electrical energy and fed back into the
battery source. Theoretically, the regenerative braking system can convert a good
fraction of its kinetic energy to charge up the battery, using the same principle as an
alternator.

Fig 1.2.1: Normal forward driving condition Fig 1.2.2: Regenerative action during braking

In regenerative braking mode, it uses the motor to slow down the car when the driver
applies force to the brake pedal then the electric motor works in reverse direction thus
slowing the car. While running backwards, the motor acts as the generator and
recharge the batteries as shown in figure (1.2.2). Meanwhile in figure (1.2.1) shows
the car in normal running condition whereas the motor turning forward and taken
energy from the battery. By using regenerative braking, it vastly reduces the reliance
on fuel, boosting fuel economy and lowering emissions. These types of brakes work
effectively in driving environment such as stop-and-go driving situations especially in
urban city.

1.3 Types of Regenerative Braking System

There are multiple methods of energy conversion in Regenerative Braking System

including spring, flywheel, electromagnetic and hydraulic. More recently, an
electromagnetic-flywheel hybrid Regenerative Braking System has emerged as well.
Each type of Regenerative Braking System utilizes a different energy conversion or
storage method, giving varying efficiency and applications for each type. The Types
are as follows:

1.3.1 Electromagnetic

1.3.2 Flywheel
1.3.3 Electromagnetic flywheel

1.3.4 Spring

1.3.5 Hydraulic

1.3.1 Electromagnetic

In Electromagnetic system, the drive shaft of the vehicles is connected to an electric

generator, which uses magnetic fields to restrict the rotation of the drive shaft,
slowing the vehicle and generating electricity. In the case of electric and hybrid
vehicles, the electricity generated is sent to the batteries, giving them a recharge. In
gas powered vehicles, the electricity can be used to power the cars electronics or sent
to a battery where it can later use to give the vehicle an extra boost of power. This
technique is currently used in some Le Mans Prototype racing cars.

1.3.2 Flywheel

In Flywheel Regenerative Braking System, the system collects the kinetic energy of
the vehicle to spin a flywheel that is connected to the drive shaft through a
transmission and gear box. The spinning flywheel can then provide torque to the
drive shaft, giving the vehicle a power boost.

1.3.3 Electromagnetic flywheel

Electro flywheel regenerative brake is a hybrid model of electromagnetic and

flywheel Regenerative Braking System. It shares the basic power generation methods
with the electromagnetic system; however, the energy is stored in a flywheel rather
than in batteries. In this sense, the flywheel serves as a mechanical battery, where
electrical energy can be stored and recovered. Due to the long life of flywheel
batteries compared to lithium-ion batteries, electric flywheel Regenerative Braking
System is the more cost-effective electricity storage method.

1.3.4 Spring

The spring-loaded regenerative braking system is typically used on human powered

vehicles, such as bicycles or wheelchairs. In spring Regenerative Braking System, a
coil or spring is winded around a cone during braking to store energy in the form of
elastic potential. The potential can then be returned to assist the driver while going
uphill or over rough terrain.

1.3.5 Hydraulic

The Hydraulic Regenerative Braking System slows the vehicle by generating

electricity which is then used to compress a fluid. Nitrogen gas is often chosen as the
working fluid. Hydraulic Regenerative Braking Systems have the longest energy
storage capability of any system, as compressed fluid does not dissipate energy over
time. However, compressing gas with a pump is a slow process and severely limits
the power of the hydraulic Regenerative Braking System.

1.4 Problem statement

At this century, automotive industry has posted a great challenge in order to reduce
the vehicle fuel consumption and emission, these 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 brake. The invention of 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.

1.5 Applications

❖ Kinetic energy recovery mechanism.

❖ Regenerative braking systems are used in electric elevators and crane lifting
motors.

❖ Also used in electric and hybrid cars, electric railway vehicles, electric bicycles,
etc.
❖ Could be used in an industry that uses a conveyor system to move material from
one workstation to another and halts at a certain distance after a prescribed interval.

1.6 Advantages

❖ Better Performance.

❖ Cuts down on pollution related to supply generation.

❖ Efficient Fuel Economy–The fuel consumption is reduced, dependent on the

machine cycles, vehicle design, automation control plan, and the individual
component’s efficiency.

❖ Reduced wear and tear of Engines.

❖ Reduced Brake Wear– Cutting down the replacement brake linings cost, the cost
of labor for installation, and machine downtime.

❖ Reduced emissions–Cuts down on pollution related to power generation, engine

decoupling reduces the total number of revolutions and thus engine emissions.

❖ Smaller accessories – reducing fuel tank size and thus the weight of the vehicle.

1.7 Disadvantages

In practice, the regenerative brakes take the time to slowdown a vehicle, hence most
of the vehicles that use them, also have friction brakes working alongside. This is one
reason why regenerative brakes don't save 100 percent of braking energy.

❖ High cost of components, engineering, and installation.

❖ As compared to dynamic brakes, regenerative brakes are needed to match the

power produced by the input supply (D.C. and A.C. supplies), and it is achieved only
with the help of development of power electronics.
❖ A Regenerative braking safety is limited when the batteries storing the recovered
energy are 100 % charged. The excessive charge would cause the voltage of the
battery to rise above a safe level.

❖ Added maintenance – Dependent on the complexity of the design. 1.8 Future

Scope Future developments, however, such as ultra-capacitors, flywheels and
hydraulic systems could have much higher power capacities, which could open up the
possibility to rely more heavily on the regenerative braking system, even for high
speed, high stops and the opportunity to downsize or even eliminate the friction-
braking system.

1.9 Organization of the thesis

This thesis is structured in five correlated chapters in following order.

Chapter 1 provides brief introduction on Regenerative Braking System. Chapter 2

discusses the literature review on Regenerative Braking System. Chapter 3 describes
methodology and materials used in regenerative braking system.

Chapter 4 interprets the obtained results.

Chapter 5 concludes the research and presents summary of research findings.

Regenerative Braking system is a useful technology to restore the kinetic energy

which will fade away in heat produced during friction. This system is useful in
improving the fuel economy of the vehicle and also in increasing the efficiency of the
system. Nowadays, Most of the car manufacturing companies use this system to
increase the vehicle’s parts life and to limit the emissions.

CHAPTER 2 LITERATURE REVIEW

2.1 History
 Fig 2.1: A Flybrid Systems kinetic energy recovery system

The first of these systems to be revealed was the Flybrid. This system weighs 24 kg
and has an energy capacity of 400 kJ after allowing for internal losses. A maximum
power boost of 60 kW (81.6 PS, 80.4 HP) for 6.67 seconds is available. The 240 mm
diameter flywheel weighs 5.0 kg and revolves at up to 64,500 rpm. Maximum torque
is 18 Nm (13.3 ft lbs). The system occupies a volume of 13 litre.

Auto part makers

Bosch Motorsport Service is developing a KERS for use in motor racing. These
electricity storage systems for hybrid and engine functions include a lithium-ion
battery with scalable capacity or a flywheel, a four to eight-kilogram electric motor
(with a maximum power level of 60 kW or 80 hp), as well as the KERS controller for
power and battery management. Bosch also offers a range of electric hybrid systems
for commercial and light-duty applications.

Carmakers

Automakers including Honda have been testing KERS systems. At the 2008 1,000
km of Silverstone, Peugeot Sport unveiled the Peugeot 908 HY, a hybrid electric
variant of the diesel 908, with KERS. Peugeot planned to campaign the car in the
2009 Le Mans Series season, although it was not capable of scoring championship
points. Peugeot plans also a compressed air regenerative braking power train called
Hybrid Air [8]. Vodafone McLaren Mercedes began testing 13 of their KERS in
September 2008 at the Jerez test track in preparation for the 2009 F1 season; although
at that time it was not yet known if they would be operating an electrical or
mechanical system. In November 2008 it was announced that Free scale
Semiconductor would collaborate with McLaren Electronic Systems to further
develop its KERS for McLaren's Formula One car from 2010 onwards. Both parties
believed this collaboration would improve McLaren's KERS system and help the
system filter down to road car technology. Toyota has used a super capacitor for
regeneration on Supra HV-R hybrid race car that won the 24 Hours of Tokachi race
in July 2007. BMW has used regenerative braking on their E90 3 Series as well as in
current models like F255 Series under the Efficient Dynamics moniker. Volkswagen
have regenerative braking technologies under the Blue Motion brand in such models
as the MK7 Golf and MK7 Golf Estate/Wagon models, other VW group brands like
SEAT, Skoda and Audi.

Motorcycles

KTM racing boss Harald Bartol has revealed that the factory raced with a secret
kinetic energy recovery system (KERS) fitted to Tommy Koyama's motorcycle
during the 2008 season-ending 125cc Valencian Grand Prix. This was against the
rules, so they were banned from doing it afterwards.

Races

Automobile Club de l'Ouest, the organizer behind the annual 24 Hours of Le Mans
event and the Le Mans Series is currently "studying specific rules for LMP1 that will
be equipped with kinetic energy recovery system." Peugeot was the first
manufacturer to unveil a fully functioning LMP1 car in the form of the 908 HY at the
2008 Auto sport 1000 km race at Silverstone.

2.2 Use in civilian transport

Bicycles

Regenerative braking is also possible on a non-electric bicycle. The EPA, working

with students from the University of Michigan, developed the Hydraulic
Regenerative Brake Launch Assist (RBLA). It is available on electric bicycles with
direct-drive hub motors.

Cars

Many electric vehicles employ regenerative braking since the first used in the US by
the AMC Amitron concept car [14]. Regenerative braking systems are not able to
fully emulate traditional brake function for drivers, but there are continuing
advancements [15]. The calibrations used to determine when energy will be
regenerated and when friction braking is used to slow down the vehicle affects the
way the driver feels the braking action. Examples of cars include:

• Audi e-tron

• Ford Fusion Hybrid

• Hyundai Kona Electric

• Nissan Leaf

• Tesla Model 3

• Toyota Prius

2.3 Literature Review

Sayed Nashit, Sufiyan Adhikari, Shaikh Farhan, Srivastava Avinash and Amruta
Gambhire, ‘Design, Fabrication and Testing of Regenerative Braking Test Rig for
BLDC Motor’, 2016, 1881- 84. In this paper a test bench for testing of regenerative
braking capability of a Brushless DC Motor is design and then fabricated. The project
creates awareness to engineers towards energy efficiency and energy conservation. It
concludes that the regenerative braking systems are more efficient at higher speed
and it cannot be used as the only brakes in a vehicle. The definite use of this
technology described as in the project in the future automobiles can help us to a
certain level to sustainable and bright future of energy efficient world as a part of
power that is lost can be regained by using the regenerative braking system.
Khushboo Rahim, and Mohd. Tanveer, ‘Regenerative Braking System: Review
Paper’, International Journal on Recent and Innovation Trends in Computing and
Communication, 5.5 (2018), 736-39. In this paper the advantages of regenerative
braking system over conventional braking system has been mentioned. Regenerative
braking systems can work at the high temperature ranges and are highly efficient
when compared to the conventional brakes. They are more effective at higher
momentum. The more frequently a vehicle stops, the more it can benefit from this
braking system. Large and heavy vehicles that moves at high speeds builds up lots of
kinetic energy, so they conserve energy more efficiently. It has broad scope for
further advancements and the energy conservation. 16 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). 2229-5518 In this paper the techniques to
increase the efficiency of the regenerative braking system is mentioned. The
technique mentioned was to reduce the weight of the automobile which increase
performance, using super capacitor also improves the conversion rate of energy in
regenerative braking system, making the automobile compact also tends to increase
the efficiency of the system. C. Jagadeesh Vikram, D. Mohan Kumar, Dr. P. Naveen
Chandra, ‘Fabrication of Regenerative Braking System’, International Journal of Pure
and Applied Mathematics Volume 119, (2018). 9973-9982. In this paper the
Fabrication process on the Regenerative Braking System had been implemented as
per the prescribed measures has been taken and the future enhancements should be
processed on basis of the need of the study. The Implementation of the regenerative
braking system be quite essential in automotive transportation with maximized
performance in braking. 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). 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
high temperature range and are efficient as compared to conventional braking system.
Regenerative braking systems 17 require further research to develop a better system
that captures more energy and stops faster. All vehicles in motion can benefit from
these systems by recapturing energy that would have been lost during braking
process. The use of more efficient systems could lead to huge savings in the economy
of any country. 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), 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. The
energy is converted into heat by friction brake which is dissipated to the environment.
This Energy is utilized to rotate the rotor of generator converting mechanical energy
of wheels into useful charge of battery. The regenerative braking system cannot be
used as main braking system of vehicle as it cannot bring the vehicle to rest.
Experimentation shows that minimum 11% battery energy can be recovered using the
regenerative braking system which would otherwise be wasted to heat in friction
brakes. Hence the distance travelled between two successive charging requirements
can be increase to 10 to 15 % using this regenerative braking, when installed in actual
vehicles. 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). 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 18 ultra-capacitors, DC-DC converters (Buck-Boost) and
flywheels. Ultra-capacitors, which help improve the transient state of the car during
startup, provide a smoother charging characteristic of the battery and improve the
overall performance of the electric vehicle system. Buck-boost converters help
maintain power management in regenerative braking systems, such as boosting
acceleration. Finally, flywheels are used to improve the power recovery process
through automotive wheels. We have learnt the recommendation and conclusion from
the previous researcher and then we have utilized in our experiment. We have also
changed the components and methods as the researcher suggested to make the
experiment more practical and efficient.

Objectives

• To control the speed of the vehicle as well as to stop it quickly and efficiently
without sticking.

• To reduce the reaction time of braking by using regenerative braking and generating
power by converting kinetic energy into electrical energy.

CHAPTER 3

METHODOLOGY

3.1 DESIGN

3.1.1 Design consideration

 Regenerative braking system may not suffice the basic requirement of braking
system alone. This is because of limitation of energy dissipation at very high power.
The storage and generation systems may not be capable to operate at those levels due
to design limitations. Due to critical level of safety involved with the system,
reliability becomes debatable and it necessitates a frictional braking system to co-
exist with electrical regenerative braking system. This forms a hybrid braking system,
which means:

1. Just like hybrid propulsion systems, there can be many design configurations
and control strategies.

2. Design and control of system should be such that they ensure vehicle’s
desired braking performance while at the same time capturing as much energy as
possible.

During developing strategies, a careful consideration of braking behavior and

its characteristics with respect to speed, braking power, deceleration rate etc. must be
made.

3.2 FABRICATION

3.2.1 List of Materials used in Fabrication

3.2.1.1 Square Bar

These were used in order to build a frame. The Solid bar was of mild steel and was
welded into a square frame

Fig 3.9: A Square Bar

3.2.2 A Solid Shaft

Solid shaft used was also of mild steel and were used in order to make the base for
the wheel and the brake spindle. The wheel was fitted on the shaft. One of the shafts
was connected to the electric motor with the help of pulley and pulley rope. Once the
motor starts the motion is transferred from the motor to the pulley and from the
pulley to the shaft which rotates the wheel.

Fig 3.10: Solid Shaft.

3.2.3 Plumber Block

Plummer block is a device with an anti-friction bearing in it, which helps any
solid shaft to have rotational movement while holding the outer ring in stationary
position. The Plummer block used in the project is of inner diameter 12 mm. The
solid shaft is inserted in the bearing which is used for rotational movement in the
shaft.
3.3 Equipments used in Fabrication:

❖ Drilling Drilling is a metal removal process that uses a drill bit to cut or enlarge a
hole of circular crosssection in solid materials. The drill bit is a rotary cutting tool,
often multipoint. The bit is pressed against the work piece and rotated at rates from
hundreds to thousands of revolutions per minute. This forces the cutting edge against
the work piece, cutting off chips from what will become the hole being drilled.

Fig 3.11: Plumber Block

3.2.5 Brake Wheel

The brake wheel is used to stop the movement of the shaft. The brake wheel is
connected on the shaft and has internal dia. of 12mm.The Brake wheel is made of
Polyvinyl Chloride (PVC).
 Fig 3.13: Brake Wheel

3.2.6 Brake Spindle

The brake spindle contains a small gear mounted in the tip of the motor. The gear on
the brake spindle meshes with another gear on the brake wheel gear and then slows
down the movement of the shaft.

3.2.7 Sewing Machine Motor

The Sewing Machine Motor is of 220V A.C having the max. speed of 9500 rpm. The
tip of the motor has small pulley where the belt is connected. The motor has an
acceleration system which is used to increase and decrease the speed as per
requirements.
 Fig 3.15: Sewing Machine Motor

3.2.8 Pulley

The pulley is used in order to transfer the rotatory motion of the motor to the shaft.
The pulley used has an internal diameter of 12 mm. Pulleys are connected through the
belt.
 Fig 3.16: Pulley

3.2.9 Pulley Rope

The pulley rope is used to transfer the power from the motor to the shaft.

Fig 3.17: Pulley rope

3.2.1.10 LEDs

These are used in order to show the power generated from the regenerative
brakes.

Fig 3.18: LED

3.2.10 Electrical Wires

The inner wire is made of copper and it is insulated. They are used in order to
transfer the power from the motor to the LEDs.
 Fig 3.19: Wire

3.2.11 Brushed D.C Motor

This motor is used as Dynamo. The motor tip is connected to the gear and when the
gear meshes with the brake wheel gear, the motor spindle rotates. The rotating
spindle has kinetic energy and due electro-magnetic force the kinetic energy is
converted into electrical energy. The motor has the capacity of 12v.
 Fig 3.20: Brushed D.C Motor

3.3 Equipment used in Fabrication:

❖ Drilling

Drilling is a metal removal process that uses a drill bit to cut or enlarge a hole of
circular crosssection in solid materials. The drill bit is a rotary cutting tool, often
multipoint. The bit is pressed against the work piece and rotated at rates from
hundreds to thousands of revolutions per minute. This forces the cutting edge against
the work piece, cutting off chips from what will become the hole being drilled.
 Fig 3.21: Drilling Machine

❖ Metal-Cutting

Metal cutting is a process by which the excess metal is removed by the workpiece in
the form of chips. There process we used in order to get the workpiece of the required
dimension was by using a hacksaw blade.

Fig 3.22: Hacksaw.

The square bar was cut in angle at 45° to join the bar and create a frame which is later
welded together to form the base of the model.

Fig 3.23: Angle chip from the square bar.

❖ Arc-Welding

Arc welding is the fusion of two pieces of metal by an electric arc between the pieces
being joined to the work pieces by an electrode that is guided along the joint between
the pieces. The electrode is either a rod that simply carries current between the tip and
the work, or a rod or wire that melts and supplies filler metal to the joint. The basic arc
welding circuit is an alternating current (AC) or direct current (DC) power source
connected by a “work” cable to the work piece and by a “hot” cable to an electrode.
When the electrode is positioned close to the work piece, an arc is created across the
gap between the metal and the hot cable electrode. An ionized column of gas develops
to complete the circuit.
Basic Welding Circuit

Fig 3.24: Basic Welding Circuit

The arc produces a temperature of about 3600°C at the tip and melts part of the metal
being welded and part of the electrode. This produces a pool of molten metal that
cools and solidifies behind the electrode as it is moved along the joint. There are two
types of electrodes.

❖ Consumable electrode tips melt, and molten metal droplets detach and mix into the
weld pool.

❖ Non-consumable electrodes do not melt. Instead, filler metal is melted into the
joint from a separate rod or wire.

The strength of the weld is reduced when metals at high temperatures react with
oxygen and nitrogen in the air to form oxides and nitrides. Most arc welding processes
minimize contact between the molten metal and the air with a shield of gas, vapor or
slag. Granular flux, for example, adds deoxidizers that create a shield to protect the
molten pool, thus improving the weld.
PROCEDURE

❖ First the square bar is cut into an angle of 45 degree and then welded together in
order to form a square frame.

❖ The square bar is welded at each corner to form a table like structure. ❖ The flat
mild steel plate is drilled and welded in the square bar to hold the solid shaft for brake
spindle.

❖ The Plummer block is fitted over the flat plate welded on the square frame. ❖
Solid shaft is inserted in the Plummer block upon which the wheel and brake wheel
and pulley are fitted.

❖ On the Frame the motor is welded.

❖ The power of the motor is transmitted to the wheel by the joining the pulley and
motor with a belt.

❖ The brake wheel is fixed at the tip of the Geared D.C motor which is fixed upon
the brake spindle.

❖ The L.E.Ds is fixed on the square frame.

❖ The output of the Geared D.C motor is connected to L.E.Ds through copper wire.
❖ The small wheels are placed on the legs to give movements to the Assembly.

❖ The Entire Assembly is coloured with Red and black Paint to protect form Rust.

Precautions to be taken during Fabrication

❖ The Apron is worn at every process during Fabrication.

❖ Face shield and welding gloves are used during the welding process.

❖ Proper coolant is supplied during the Drilling process.

❖ Gloves are used to project hands during the Grinding process.

❖ The materials were handled very carefully during the Fabrication.

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