PRODUCT DEVELOPMENT PROJECT

Rudra Prasad Patra , 119ME0367

Prof. S.K. Sahoo HOD, Department of Mechanical

Engineering
PRIMARY FISHBONE DIAGRAM

Problems in regenerative Problems in traditional

braking braking

Wastage of energy due

Not sufficient force for to friction
sudden braking
Implementing regen Wearing of brake
braking in vehicles such components
as E-Bicycles

Disadvantages of braking system

Moisture and temperature can affect

brake fluid
Leakage issues

Problems with hydraulic

systems
SECONDARY FISHBONE DIAGRAM

Implementing regen braking

in vehicles such as Not sufficient force for
E-Bicycles sudden braking

Regen braking only retards the motor at a

Requirement of direct limited speed
drive motor
Very small fraction of energy
Absence of freewheeling causing recovered
generator drag

Disadvantages of Regenerative braking system

Additional weight of Periods of high current rate which

complex components might damage the Li-ion battery
Difficulty in Overheating of Li ion
modulation battery

Designing components
Battery damage while energy recovery during
associated with Regen
regenerative braking
braking
NEED STATEMENT
Problem : Implementing regenerative braking in E-bicycles (for purposes such as providing power to safety flashers)

Limitations : Hub motors which facilitate regen braking produce worst RPM / direct drive motors may damage aluminium
chassis due to force produced by them and add to its weight. Regen systems are difficult to modulate.

IDEA GENERATION
Idea 1:Use of regenerative braking only
Use of regenerative braking only to stop the vehicle.

Idea 2: Simultaneous use of regenerative and friction braking

Regenerative and friction braking system always act together when applied to give effective braking.
Idea 3: Stepwise activation of regenerative braking followed by regenerative braking
First regenerative braking is applied to retard the cycle at lower speeds followed by friction braking at
higher speeds/ sudden braking.
 Cost Time to Maintenance Lifespan Effectiveness TOTAL
(0.5) Develop (0.5) (0.3) (0.8)
(0.1)

Idea 1 7x0.5 6x0.1=0.6 6 x 0.5= 3 6 x 0.3 3 x 0.8 = 2.4 11.3

=3.5 =1.8

Idea 2 5x0.5= 6x0.1=0.6 4 x 0.5 = 2 4 x 0.3 7 x 0.8 = 5.6 11.9

2.5 = 1.2

Idea 3 4x0.5= 5x0.1=0.5 4 x 0.5 = 2 5 x 0.3 9 x 0.8 = 7.2 13.2

2 = 1.5

Conclusion :
Idea 3 seems more feasible because
(i) It tactically uses both braking methods hence maximising energy recovery
(ii)It is the most effective and sustainable scheme .
MORPHOLOGICAL ANALYSIS
MORPHOLOGICAL MATRIX

Alternative 1 Alternative 2 Alternative 3 Alternative Alternative 5

4

Friction Rubber Ceramic Organic Semi -

Brake pad metallic
material

Motor Type Hub Direct drive Brushless Brushless Permanent

integrated asynchronou DC Motor Magnet
s induction Synchronous
Motor

Battery Type Li ion Ni - Cd Li Polymer Lead acid Ultracapacitors

Choice of semi Germanium Silicon Gallium Thyristor
conductor in
rectifier arsenide

Number of possible products = 4 x 5 x 5 x 4 =400

 Evaluation of Possible Products

Parameters to consider product evaluation :

(i) Cost

(ii) Efficiency

(iii) Maintenance

(iv) Effectiveness

Cost(0.5) Efficiency(0.6) Maintenance(0.3) Effectiveness(0.8) Total

PP -1 8 3 8 9 15.4

PP-2 7 6 4 2 9.9

PP-3 6 9 7 8 16.9

PP-4 6 5 4 3 9.6
Suitability of product :

1. Objective Tree

Effective implementation of
Regenerative braking in E
bicycles

Maximising Effectiveness and

Lesser maintenance
efficiency of system safety

More Less wear Less Effective

Cost Safe at any
energy and tear heating of for
effective situautional
saving battery ; sudden
braking for
increases and slow
drivers
battery life braking
SWOT ANALYSIS

1. Efficient 1. Not effective

2. Effective in at low speeds
all braking 2. Heating of
scenarios battery
3. Lesser reduces it life
maintenance

1. New method of 1. Overheating of

brake application battery
2. Innovative design 2. Non bio degradable
of brake battery components
callipers 3.
3. Mass
implementation
in E bicycles
Detail Functional Design Tree
Hybrid Braking in E
Bicycles

Regen Braking
Friction Braking

Specially Direct Drive Storage Battery

designed brake motor
calliper
Drawings and detail specifications
PATENT WRITING
THE PATENT ACT 1970
(39 OF 1970)
&
The Patent Rules , 2003
COMPLETE SPECIFICATION
Title of invent :

Hybrid Braking System for E Bicycles

APPLICANT
(a) NAME : RUDRA PRASAD PATRA
(b) NATIONALITY : INDIAN
(c) ADDRESS : Sector 1, Rourkela, Odisha
The following specification particularly describes and contains the nature of this
Invention and the manner in which it is to be performed

COMPLETE SPECIFICATION
Hybrid Braking System for E Bicycles
Technical field of innovation:

1.STATEMENT OF INVENTION:

The present invention discloses / relates to design of system for Hybrid braking of E bicycles.

2. Background of Invention and any problem with prior art:

Slowing or stopping. operations on bicycles are dissipative. Friction pads applied to the rotating rim of the, tire. convert kinetic energy of the cyclist and
bicycle into heat, which is irrecoverably lost to the atmosphere by conduction and forced convection. This energy could instead be converted into electrical
energy and stored for future use.Though not widely used, hub-integrated and tire contact generators that power bicycle headlamps and rear
flashers are currently available for consumer purchase. Both types require additional physical exertion from the cyclist, as they must be
engaged continuously to power bicycle headlamps and flashers. This reports the results for a series of tests performed b us, showing that
at typical cycling speeds of 20 km/h, 6-14 % of the cyclist's physical power output (6-14 W) is used to power headlamps and
flashers.Furthermore, even when disengaged, the flow of eddy currents in the armatures of hub-integrated generators dissipates 1-6 W.
This suggests that this additional "generator drag" isa key drawback, which deters man potential users. Thus, a system capable of similar
functionality without requiring additional exertion from the cyclist might be an interesting alternative.
3.OBJECTIVE OF INVENTION
► To design a efficient, cost effective and safe hybrid Braking System for E Bicycles
► To hybridise the braking system effectively
4.SUMMARY OF INVENTION
This product contains compact electronic parts (electronic circuitry, motor) and durably and innovatively
designed friction braking equipments (brake callipers).This work develops a method for capturing some of the
kinetic energy lost during braking on bicycles to power LED safety flashers. The system is designed to eliminate:
(a)battery changing in popular LED flashers, and (b) the "generator drag" associated with battery less human-powered
bicycle lights and flashers. System sizing, mechanical design considerations, potential end-user factors. and a model
for braking frequencies in urban settings are discussed. With the urban commuter cyclist in mind as a potential user of
the regenerative braking system, custom direct-pull brake calipers (or "V-Brakes") were designed and manufactured
to include both conventional friction pads in addition to a DC motor to be used as a generator for kinetic energy
capture. The energy captured b the DC motor during braking is passed through a full wave bridge to a bank of
Nickel-Cadmium batteries at an efficiency of 79%.
5.DRAWINGS(if any)

Hybrid
Braking
System
Design

Circuit design for Regen

Braking
Innovative Calliper Design
6.Detailed description
This work develops a method for capturing some of the kinetic energy lost during braking on bicycles to
power LED safety flashers. The system is designed to eliminate: (a)battery changing in popular LED
flashers, and (b) the "generator drag" associated with battery less human-powered bicycle lights and flashers.
System sizing, mechanical design considerations, potential end-user factors. and a model for braking
frequencies in urban settings are discussed. With the urban commuter cyclist in mind as a potential user of
the regenerative braking system, custom direct-pull brake calipers (or "V-Brakes") were designed and
manufactured to include both conventional friction pads in addition to a DC motor to be used as a generator
for kinetic energy capture. The energy captured b the DC motor during braking is passed through a full wave
bridge to a bank of Nickel-Cadmium batteries at an efficiency of 79%.The output of the full wave bridge and
the batteries areconnected in parallel with a step-down switching voltage regulator, which insulates the LED
safety flasher from voltage spikes due to braking at high cycling speeds. The performance of the final
prototype was evaluated at cycling speeds ranging from 8 to 19 mph and braking frequencies ranging from 2
to 8 operations/stops per mile of ravel. From the mean power flow (charging) into the batteries per unit
distance of travel and the power required by LED safety flashers, the effectiveness of the system at each
speed and stopping frequency is examined. For cyclists traveling at average speeds of 10 mph or higher, the
LED safety flashers can be powered continuously for stopping frequencies of 8 times per mile and
semi-continuously (> 50% of the time) for stopping frequencies of at least 4 times per mile. As such, the
system is determined to be potentially useful to urban commuter cyclists, who frequently perform braking
operations at regularly spaced intersections and traffic signals,and who regularly travel by bicycle in
low-light conditions (dawn or dusk), though usually less than 50% of the time.
7.Citation
1) S.J.Clegg,“A Review of Regenerative Braking System”, Institute of Transport Studies,
University of Leeds, Working paper of 471, 1996.

2) Ranjan Kumar ,Department of Mechanical Engineering, Indian School Of Mines, Dhanbad,

“Regenerative Brake: To Harness the Kinetic Energy of Braking” JETIR (ISSN-2349-5162)
January 2015, Volume 2, Issue 1
8. CLAIMS
We claim:
1. The system developed by us is a new one to fulfill the need , i.e., effectively implementing hybrid
braking.
2. The system as claim in 1 is also highly effective and low maintenance.
Rudra Prasad Patra
Of National Institute of Technology
Rourkela 769008
Dated this ______15/4/2022______
Title of invent
Hybrid braking system for E- Bicycles
Abstract
This Work develops a method for capturing some of the kinetic energy lost during,braking on bicycles
to power LED safety flashers. The system is designed to eliminate: (a)battery changing in popular LED
flashers, and (b) the "generator drag" associated with battery less human-powered bicycle lights and
flashers. System sizing, mechanical design considerations, potential end-user factors. and a model for
braking frequencies in urban settings are discussed. With the urban commuter cyclist in mind as a
potential user of the regenerative braking system, custom direct-pull brake calipers (or "V-Brakes") were
designed and manufactured to include both conventional friction pads in addition to a DC motor to be
used as a generator for kinetic energy capture.
To
The Controller of Patents,
The Patent Office,
Kolkata
 STARTUP STRATEGY
1.Market Analysis:
Target Group:
Socio-economic: Population using E Bicycle for transportation

Geographical area - Metro Cities Sl. No. Part Material Make/ Quantity Cost(Rs)
Name Buy
2.Break Even Analysis Basic Aluminium
1 structure
Buy 1 10000
, Rubber
COST TABLE of E bicycle etc

Additional Diode,Recti
2 electronic fier,regulato
Buy As 1000
component rs etc. required
s

Brake Rubber
3 Callipers Make 2 1000

Motor
4 Buy 1 3000
TOTAL
15000
Fixed Costs:
Land Rent:
100000/acre/month for 20 acres per annum = 24000000 per annum
R & D = 5000000 per annum
Marketing costs = 1000000 per annum
Total fixed cost per annum = 30000000 per annum
Variable cost (per piece):
Direct Labour, fuel/electricity
Revenue-related cost such as commission
Packaging cost:500
Type Of Production/Manufacturing System:
Batch Production.A mass network system is developed for the procurement of the parts. After R&D the
complete model is finalized. An assembly line is assigned for the assembly of the procured parts. A
team is assigned to test various parts for their proper functionality. There is a continuous and
longrunning supply to meet large requirements in minimum time

Organizational Or Management Structure:

Location Of Firm:
This start-up is to be based in Bengaluru, India. This location is chosen for the
following reasons:
► Ample availability of skilled workforce and technicians
► Ample supply of electronic components
► Easy target market reach due to traffic issues
► Availibility of 3d printing technologies
Arrangement Of Raw Materials:
► Personal contribution
► Angel investors
► Venture capitalists
► Sponsorship and partnership
Vision And Mission:
Vision Statement- To reduce energy loss during braking in E-Bicycles
Mission Statement-Effective solution for hybrid braking in E bicycles
Business Roadmap:

OPERATIONS:
PRODUCT:
● Price and tariff-cap negotiations
● Technology Demonstarator
● Functional Needs
● Full scale prototype
● Inventory Maintenance

Finance
SALES:
● Capital Borrowing
● Urban population in metro cities to
● Gov. Schemes such as Make in
be targeted
India
● Online sales
● Angel Investors