Regenerative Braking

REGENERATIVE BRAKING
Table of Contents
Submitted by: .................................................................................................................................... 1
In ...................................................................................................................................................... 1
Electrical engineering ........................................................................................................................ 1
ATMIYA INSTITUTE OF TECHNOLOGY AND SCIENCE ...................................................... 1
RAJKOT (GUJARAT) ...................................................................................................................... 1
October- 2018 ................................................................................................................................... 1
CHAPTER I ......................................................................................................................................... 1
1 INTRODUCTION ......................................................................................................................... 1
1.1 GENERATION OF ENERGY ................................................................................................... 2
1.2 ENERGY CONSERVATION LAW ............................................................................................ 2
1.3 HISTORY ............................................................................................................................. 3
2 AIM & OBJECTIVE....................................................................................................................... 3
3 NEED OF REGENERATIVE BRAKING............................................................................................. 4
4 LITERATURE REVIEW .................................................................................................................. 5
CHAPTER II ........................................................................................................................................ 6
5 BRAKING.................................................................................................................................... 6
6 TYPE OF BRAKING ...................................................................................................................... 7
6.1 DYNAMIC BRAKING ............................................................................................................ 7
6.2 PLUGGING.......................................................................................................................... 7
6.3 REGENERATIVE BRAKING.................................................................................................... 8
CHAPTER III ....................................................................................................................................... 9
7 REGENERATIVE BRAKING ........................................................................................................... 9
8 TYPES OF REGENERATIVE BRAKING .......................................................................................... 10
8.1 ELECTRIC REGENERATIVE BRAKING .................................................................................. 10
8.2 HYDRAULIC REGENERATIVE BRAKES ................................................................................. 12
CHAPTER IV ..................................................................................................................................... 13
10 COMPONENTS USED IN MODEL OF REGENERATIVE BRAKING AND DESCRIPTION OF EACH
COMPONENT................................................................................................................................... 13
10.1 UNIVERSAL MOTOR ............................................................................................................. 13
10.2 SHAFT .............................................................................................................................. 13
10.3 FLYWHEEL ........................................................................................................................ 14
ATMIYA INSTITUTE OF TECHNOLOGY &

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10.4 PULLY ............................................................................................................................... 14

10.5 BRAKING WHEEL .............................................................................................................. 14
10.6 LED PANEL ....................................................................................................................... 15
10.7 SWITCH ............................................................................................................................ 15
10.8 AUTO TRANSFORMER / STEP DOWN TRANSFORMER ....................................................... 15
10.9 CVT CONTINIOUS VARIABLE TRANSMISSION .................................................................... 15
CHAPTER V ...................................................................................................................................... 16
11 WORKING ............................................................................................................................ 16
12 DESIGN ................................................................................................................................ 17
13 TOTAL EXPENDITURE OF PROJECT ........................................................................................ 18
CHAPTER VI ..................................................................................................................................... 19
14 MERITS OF REGENERATIVE BRAKING.................................................................................... 19
15 DEMERITS OF REGENERATIVE BRAKING ............................................................................... 20
16 FUTURE SCOPE..................................................................................................................... 21
CHAPTER VII .................................................................................................................................... 22
17 SNAPS OF THE PROJECT ................................................................................................. 22
CHAPTER VIII ................................................................................................................................... 23
CHAPTER VIII…………………………………………………………………………………………………………………………………..23
18 DESIGN ENGINEERING SHEETS………………………………………………………………………………………………23
18.1 EMPHATY MAPPING CANVAS……………………………………………………………………………………………….23
18.2 PRODUCT DEVELOPMENT CANVAS……………………………………………………………………………………….24
18.3 IDEATION CANVAS………………………………………………………………………………………………………………..25
18.4 LEARNING NEEDS MATRIX…………………………………………………………………………………………………….26
18.5 AEIOU SUMMARY…………………………………………………………………………………………………………………27
CHAPTER IX……………………………………………………………………………………………………………………………………..28
19 CONCLUSION…………………………………………………………………………………………………………………………..28

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ACKNOWLEDGEMENT
We have taken efforts in this project. However, it would not have been possible
without the kind support and help of many individuals. We would like to extend
our sincere thanks to all of them.
We are highly indebted to MR. DHAVAL RAVAL for their guidance and
constant supervision as well as for providing necessary information regarding
the project and also their support in completing the project.
We would like to express our gratitude to our parents and family members for
their kind co-operation and encouragement which help us in completion of this
project.
We would also like to thank the other faculty members specially Mr. DHAVAL
VORA for their kind suggestions.
Our thank Appreciation also go to our colleague in developing the project and
people who have willingly helped us out with their abilities.
This project would not be possible without the grace of almighty GOD.

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ABSTRACT
Regenerative Braking System (RBS) is an efficient system to reduce the

vehicle emission and fuel consumption. RBS is a system which converts
mechanical energy to electrical energy during braking action. It will become
an important system for future vehicle such as hybrid and electric car. Using
regenerative braking when braking, improves the efficiency of an electric
vehicle as it recovers energy that could go to waste if mechanical brakes
were used. The main concept is that when the back EMF Ebof the motor is
greater than that of the supply voltage V, which reverses the direction of the
motor armature current. The motor begins to operate as an electric generator.

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CHAPTER I
1 INTRODUCTION
 When a conventional vehicle applies its brakes, kinetic energy is
converted to heat as friction between the brake pads and wheels.
This heat is transfers away in the weather and the energy is
effectively wasted. The total amount of energy lost in this way
depends on how often, how hard and for how long the brakes are
applied. Regenerative braking refers to a process in which a portion
of the kinetic energy of the vehicle is stored by a short term storage
system. Energy normally dissipated in the brakes is directed by a
power transmission system to the energy store during deceleration.
 That energy is held until required again by the vehicle, whereby it

is converted back into kinetic energy and used to accelerate the
vehicle. In the center of city and in heavy traffic, driving involves
many more braking events resulting a much higher energy loss
Since regenerative braking results in an increase in energy output
for a given energy input to a vehicle, the efficiency is improved,
the amount of work done by the engine of the vehicle is reduced,
which in turn reducing the amount of prime energy required to
propel the vehicle. The energy storage unit must be compact,
durable and capable of handling high power levels efficiently.

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1.1 GENERATION OF ENERGY
Electricity generation is the process of generating electric power from

other sources of primary energy. The fundamental principles of
electricity generation were discovered during the 1820s and early
1830s by the British scientist Michael Faraday.
1.2 ENERGY CONSERVATION LAW

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The law of conservation of energy states that the total energy of an

isolated system remains constant; it is said to be conserved over
time. Energy can neither be created nor destroyed; rather, it
transforms from one form to another.
1.3 HISTORY
The “energy regenerative brake” system was developed in 1967 by
American Motors Corporation (amc) in co-operation with gulton
industries. The energy regeneration braking idea was later
commercialized by the japanese and the companies like Ford and
Chevrolet licensed it from toyota for use in their domestic built hybrid
vehicles. During the late 2000s, an electronic control unit used by
company BMW that engages the alternator during braking.
2 AIM & OBJECTIVE
The main aim of this project was to develop a product that stores the energy
which is normally lost during braking, and reuses it. The use of regenerative
braking system in automobiles provides us the means to balance the kinetic
energy of the vehicle to some extent which is lost during the process of
braking. The regenerative braking system used in the vehicles satisfies the
purpose of saving a part of the energy lost during braking.
The drive to use less fossil fuel has Developed the design of engines,
transmissions and control systems for decades. Now, it is pushing the
development of completely different technologies for generating power.
In spite of all these truly marvelous improvements, the energy efficiency of
the most modern production car is still less than 20 percent. Most of the
energy used to move the vehicle at any speed over any distance is literally
thrown away as heat. About half of that wasted energy goes through the
brakes. Today, almost every manufacturer is developing ways to recover a
significant portion of that wasted energy with regenerative braking.

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3 NEED OF REGENERATIVE BRAKING
 The Need for Regenerative Braking Systems In the years following

the energy crisis of the early 70's numerous researchers have
studied the feasibility and practicality of implementing hybrid
power trains incorporating regenerative braking which have the
potential to improve the fuel economy of vehicles operating under
urban driving conditions.
 The price increase of petroleum based fuel in the past few years
has also given rise to various research and development efforts for
energy conservation. However, reduced fuel consumption and
therefore operating cost and reduced gaseous emissions including
primarily carbon dioxide (hence global warming) are the major
driving forces behind commercial considerations of such systems.
 Regenerative braking only promises significant advancement in
town driving since 62.5% of energy is dissipated in the
Metropolitan cycle due to frequent braking. If all brake energy
could be regenerated with no loss in the regenerative system, fuel
consumption would be improved by 33%. Alternative sources state
that the addition of regenerative energy storage systems, the motor
vehicles can achieve theoretical fuel savings of up to 23% in a
vehicle on a level road urban driving schedule. This relative saving
is reduced as the weight of the vehicle reduces.
 Ultra-Low Emission Vehicles (ULEV) are expected to provide a
role for hybrid drive vehicles which is why manufacturers interest
is sensitive at present. It is widely believed that most of the
electric-hybrid vehicles sold are likely to be second or third
vehicles used specifically for local commuting and not needing to
provide the same all round performance as conventional cars.

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4 LITERATURE REVIEW
Yimin Gao and MehrdadEhsani, 2001

In this methodology for designing a RBS has been described. Three
RBS’s were built and tested, first using a HIL test bed and then installed
on an operation hybrid electric city bus. For the serial RBS, a key
problem of how to adjust the friction braking force has been solved.
Some factors have been taken into account for increasing the energy
regeneration efficiency. How the RBS reacts with the ABS has been
analyzed to ensure the vehicle’s longitudinal stability. The results indicate
that the serial RBS has high energy regeneration efficiency while
retaining acceptable vehicle drivability and stability needed to ensure
passenger safety.
Pratibha Patel (2016)

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. The results from some of the test conducted show that
around 30% of the energy delivered can be recovered by the system.
Regenerative braking system has a wide scope for further development
and the energy savings. The use of more efficient systems could lead to
huge savings in the economy of any country. It can be operating at high
temperature range and are efficient as compare to conventional braking
system. The regenerative braking system in vehicle satisfies the purpose
of saving apart of the energy loss during braking. It can be operated at
high temperature range and are efficient as compared to conventional
braking system.

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CHAPTER II
5 BRAKING
The term braking comes from the term brake. We know that brake is an
equipment to reduce the speed of any moving or rotating equipment, like
vehicles, locomotives. The process of applying brakes can be termed as
braking. i) mechanical braking and the ii) electrical braking. In
mechanical braking the speed of the machine is reduced solely by
mechanical process but electrical braking is far more interesting than that
because the whole process is depended on the flux and torque directions.

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BRAKING
ELECTRIC MECHANICAL
BRAKING BRAKING
DYNAMIC REGENERATIVE
PLUGGING
BRAKING BRAKING
6 TYPE OF BRAKING
6.1 DYNAMIC BRAKING

Another method of reversing the direction of torque and braking the
motor is dynamic braking. In this method of braking the motor which is at
a running condition is disconnected from the source and connected across
a resistance. When the motor is disconnected from the source, the rotor
keeps rotating due to inertia and it works as a self-excited generator.
When the motor works as a generator the flow of the current and torque
reverses. During braking to maintain the steady torque sectional
resistances are cut out one by one.
6.2 PLUGGING
In this method the terminals of supply are reversed, as a result the
generator torque also reverses which resists the normal rotation of the
motor and as a result the speed decreases. During plugging external
resistance is also introduced into the circuit to limit the flowing current.
The main disadvantage of this method is that here power is wasted.

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6.3 REGENERATIVE BRAKING
In this method when the braking is applied the motor acts as a generator
and it generates the power which can be utilized immediately or can be
stored for future use. This method is the most promising method of
braking and is explained in detail hence further.

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CHAPTER III
7 REGENERATIVE BRAKING
Regenerative braking takes place whenever the speed of the motor

exceeds the synchronous speed. This baking method is called
regenerative braking because here the motor works as generator and
supply itself is given power from the load, i.e. motors. The main criteria
for regenerative braking is that the rotor has to rotate at a speed higher
than synchronous speed, only then the motor will act as a generator and
the direction of current flow through the circuit and direction of the
torque reverses and braking takes place. The only disadvantage of this
type of braking is that the motor has to run at super synchronous speed
which may damage the motor mechanically and electrically, but
regenerative braking can be done at sub synchronous speed if the variable
frequency source is available.

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8 TYPES OF REGENERATIVE BRAKING

Based on the mode of storage of energy some of the system developed
can be listed they are
 Electric Regenerative Braking
 Hydraulic Regenerative Braking
8.1 ELECTRIC REGENERATIVE BRAKING

In an electric system which is driven only by means of electric motor
the system consists of an electric motor which acts both as generator
and motor. Initially when the system is cruising the power is supplied
by the motor and when the there is a necessity for braking depending
upon driver’s applied force on the brake pedal the electronic unit
controls the charge flowing through the motor and due to the
resistance offered motor rotates back to act as a generator and the
energy is energy is stored in a battery or bank of twin layer capacitors
for later use. In hybrid system motor will be coupled to another power
source normally I.C Engines as shown in the below (figure)
 The main components of this system are

Engine
Motor/generator
Batteries

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Electronic control system.
 During acceleration, the Motor/generator unit acts as electric motor

drawing electrical energy from the batteries to provide extra driving
force to move the car as (Shown in fig2). With this help from the motor,
the car’s internal combustion engine that is smaller and with lower peak
power can achieve high efficiency. During braking electric supply from
the battery is cut off by the electronic system. As the car is still moving
forward, the Motor/ Generator unit is acts as electric generator
converting kinetic energy into electrical and store in the batteries (shown
in fig 3) for later use.
Fig (3) showing charging of battery when brake

Fig (2) showing energy consumption from battery
applied

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8.2 HYDRAULIC REGENERATIVE BRAKES

Hydrostatic Regenerative Braking (HRB) system uses
electrical/electronic Components as well as hydraulics to improve
vehicle fuel economy. An alternative regenerative braking system
is being developed by the Ford Motor Company and the Eaton
Corporation. It's called Hydraulic Power Assist or HPA. With
HPA, when the driver steps on the brake, the vehicle's kinetic
energy is used to power a reversible pump, which sends hydraulic
fluid from a low pressure accumulator (a kind of storage tank)
inside the vehicle into a high pressure accumulator. The pressure
is created by nitrogen gas in the accumulator, which is
compressed as the fluid is pumped into the space the gas formerly
occupied. This slows the vehicle and helps bring it to a stop. The
fluid remains under pressure in the accumulator until the driver
pushes the accelerator again, at which point the pump is reversed
and the pressurized fluid is used to accelerate the vehicle,
effectively translating the kinetic energy that the car had before
braking into the mechanical energy that helps get the vehicle back
up to speed.
When the vehicle accelerates, the stored hydraulic energy is

applied to the transmission reducing the energy that the
combustion engine has to provide. An electronic controller and a
hydraulic valve manifold control the process. At present, these
hydraulic regenerative brakes are noisy and prone to leaks
however, once all of the details are ironed out, such systems will
probably be most useful in large trucks.

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CHAPTER IV
10 COMPONENTS USED IN MODEL OF REGENERATIVE

BRAKING AND DESCRIPTION OF EACH COMPONENT
10.1 UNIVERSAL MOTOR
Modern low-cost universal motor in which Field windings are copper
colored, toward the back, on both sides. The rotor's laminated core is gray
metallic, with darker slots for winding the coils. The universal motor is so
named because it is a type of electric motor that can operate on AC or DC
power. It is a commutated series-wound motor where the stator's field coils
are connected in series with the rotor windings through a commutator. It is
often referred to as an AC series motor.
Universal motors have high starting torque, can run at high speed, and are
lightweight and compact. They are commonly used in portable power tools
and equipment, as well as many household appliances. They're also
relatively easy to control. However, the commutator has brushes that wear,
so they are much less often used for equipment that is in continuous use. In
addition, partly because of the commutator, universal motors are typically
very noisy.
10.2 SHAFT
A shaft is a rotating machine element, usually
circular in cross section, which is used
to transmit power from one part to another, or
from a machine which produces power to a
machine which absorbs power. The various
members such as pulleys and gears are mounted
on it. FIG :- SHAFT

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10.3 FLYWHEEL
In this system, the translational energy of the vehicle is transferred into

rotational energy in the, which stores the energy until it is needed to accelerate
the vehicle. The benefit of using flywheel
technology is that more of the forward
inertial energy of the car can be captured
than in batteries, because the flywheel
can be engaged even during relatively
short intervals of braking and
acceleration. In the case of batteries, they
are not able to accept charge at these FIG: - FLYWHEEL
rapid intervals, and thus more energy is lost to
friction. Another advantage of flywheel technology is that the additional power
supplied by the flywheel during acceleration substantially supplements the
power output of the small engine that hybrid vehicles are equipped with.
10.4 PULLY
A pulley is a wheel on an axle or shaft that is designed to support
movement and change of direction of a taut cable or belt along its
circumference. Pulleys are used in a variety of ways to lift loads, apply
forces, and to transmit power. In nautical contexts, the assembly of wheel,
axle, and supporting shell is referred to as a "block." A pulley may also be
called a sheave or drum and may have a groove or grooves between
two flanges around its circumference. The drive element of a pulley system
can be a rope, cable, belt, or chain that runs over the pulley inside the
groove or grooves.
10.5 BRAKING WHEEL

As we mentioned, this is almost always caused by a problem with the
rotors. Other causes of a vibrating steering system would generally cause
shaking all the time, not just when braking. With that in mind, we'll focus
this section on the most common rotor problems and their solutions.

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10.6 LED PANEL

A light-emitting diode (LED) is a two-lead semiconductor light source. It is
a p–n junction diode, which emits light when activated. When a
suitable voltage is applied to the leads, electrons are able to recombine
with electron holes within the device, releasing energy in the form
of photons. This effect is called electroluminescence, and the color of the
light (corresponding to the energy of the photon) is determined by the
energy band gap of the semiconductor.
10.7 SWITCH
In electrical engineering, a switch is an electrical component that can break
an electrical circuit, interrupting the current or diverting it from one
conductor to another. The mechanism of a switch may be operated directly
by a human operator to control a circuit. Switches are made to handle a
wide range of voltages and currents; very large switches may be used to
isolate high-voltage circuits in electrical substation
10.8 AUTO TRANSFORMER / STEP DOWN TRANSFORMER
An autotransformer also called an

electrical transformer with only one
winding. The "auto" prefix refers to the
single coil acting alone and not to any
kind of automatic mechanism. In an
autotransformer, portions of the same
winding act as both the primary and
secondary sides of the transformer.
Autotransformers are often used to step
down voltages in the 110-115-120 V
FIG: - AUTO TRANSFORMER range.
10.9 CVT CONTINIOUS VARIABLE TRANSMISSION

The energy storage unit requires a transmission that can handle torque and
speed demands in a steeples manner and smoothly control energy flow to
and from the vehicle wheels.

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CHAPTER V
11 WORKING
 Here we have mentioned the list of components which are

used in this model. First of all, the 220V A.C. supply is
given to the auto transformer in which the voltage is stepped
down as 220/110. That lowered voltage is then given to the 1
phase universal motor.
 A pushbutton switch is connected in series to the universal

motor to provide the supply whenever needed. A shaft is
mounted on the “U” shape metal strip. That metal strip is
fixed rigidly with the wooden sheet. In that shaft there are 2
wheels which act as a driving wheel and a braking wheel
respectively.
 There is a pully fixed in the center of the shaft which couples

the universal motor and the shaft/crank with the help of a
belt. Another motor is kept on wooden rod which is fixed in
a see-saw position known as braking paddle. This is used for
braking purpose. This motor creates friction between itself
and the braking wheel which in turns reduces the speed of
the driving wheel.
 This dc motor acts as a generator. The power generated can

be utilized by either storing it or using it immediately by
connecting it to the load(LED). In larger traction system the
larger generator is kept which can also fed the power back to
the transmission line.

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12 DESIGN
With all of these considerations taken into account, the mass of the flywheel
should be as small as possible and should be distributed as much as possible
on the outer radius, then the radius should be made as large as can fit on the
bike, and the rest of the energy will be in the rotational speed, which
hopefully is not too high to get significant friction losses. First, the problem
of how much energy will be stored in the flywheel will be solved without
the complication of friction between the road and the bike.

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13 TOTAL EXPENDITURE OF PROJECT
The total cost of all the materials and the components which include
universal motor, small dc motors, shaft, running wheel, braking wheel,
wooden sheet, belt, metal strip, wires, and LEDs is about
Sr.no Product description Rate
1 Wooden Board (1 X 2) 200
2 Universal motor (220V) 750
3 Small dc motor (20 V) 30
4 Wheels (both) 60
5 Pully 30
6 Belt 20
7 Shaft / crank 80
8 LED panel 60
9 Metal strip 50
10 Wire 10
11 Braking paddle 50
12 Bolts, screw, clamps 30
TOTAL 1340

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CHAPTER VI
14 MERITS OF REGENERATIVE BRAKING

The advantages of regenerative braking are clear-cut as effectively drivers
can enjoy “something for nothing”. They will notice no difference to regular
braking and yet enjoy better fuel economy, reduced CO 2 emissions and
know that they are saving energy.
Effectively the electric motor works in reverse during the process of
regenerative braking. The motor acts as the generator to recharge batteries
with the energy that would normally be lost. This reduces the reliance on
fuel, boosting economy and lowering emissions
 Improved Fuel Economy- Dependent on duty cycles, power train design,

control strategy, and the efficiency of individual components.
 Increases the lifespan of friction braking system.
 Reduction in Engine wears-An electric vehicle also allows for
regenerative breaking which increases Efficiency and reduces wear on the
vehicle brakes.
 Approximately 20-25% saving in fuel consumption.
 Reduction in Brake Wear- Reducing cost of replacement brake linings
cost of labor to install them, and vehicle down time.
 Emissions reduction- engine emissions reduced by engine decoupling,
reducing total engine revolutions and total time of engine operation.
 Operating range is comparable with conventional vehicles- a problem not
yet overcome by electric vehicles.

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15 DEMERITS OF REGENERATIVE BRAKING

 Only work for wheels connected to motors.
 Aided complexity of brake control system.
 Friction brakes are still necessary for safety.
 Main disadvantage of this system when compared to dynamic brake is
needed to closely match the electricity generated with the supply. With
DC supply this requires the voltage to be closely controlled and it is
only with the development of power electronics that it has been possible
with AC supply where the supply frequency must also be matched.

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16 FUTURE SCOPE
Regenerative braking systems require further research to develop a better
system that captures more energy and stops faster. As the time passes,
designers and engineers will perfect regenerative braking systems, so
these systems will become more and more common. All vehicles in
motion can benefit from these systems by recapturing energy that would
have been lost during braking process. Future technologies in
regenerative brakes will include new types of motors which will be more
efficient as generators new drive train designs which will be built with
regenerative braking in mind, the world needs is a method or a
technology that saves energy from getting wasted. Also it can be operated
at high temperature range and are efficient as compared to conventional
braking system.

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CHAPTER VII
17 SNAPS OF THE PROJECT

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CHAPTER IX
19 CONCLUSION
The energy efficiency of a conventional brake is only about 20 percent,
with the remaining 80 percent of its energy being converted to heat
through friction. The miraculous thing about regenerative braking is that
it may be able to capture as much as half of that wasted energy and put it
back to work. This reduces fuel consumption by 10 to 25 percent. Hence
regenerative braking plays an important role in fuel consumption and also
in the field of speed. Specific energy consumption reduces as frequency
of braking decreases and vice versa.

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ATMIYA INSTITUTE OF TECHNOLOGY &

10.4 PULLY ............................................................................................................................... 14

18 DESIGN ENGINEERING SHEETS………………………………………………………………………………………………23

18.1 EMPHATY MAPPING CANVAS……………………………………………………………………………………………….23

18.2 PRODUCT DEVELOPMENT CANVAS……………………………………………………………………………………….24

18.3 IDEATION CANVAS………………………………………………………………………………………………………………..25

18.4 LEARNING NEEDS MATRIX…………………………………………………………………………………………………….26

18.5 AEIOU SUMMARY…………………………………………………………………………………………………………………27

ATMIYA INSTITUTE OF TECHNOLOGY &

ATMIYA INSTITUTE OF TECHNOLOGY &