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
BHARATHA H S 1MV20ME008
MAYUR PRAKASH 1MV20ME025
SHOAIB AFFAN M 1MV20ME036

Under the Guidance of

Mr. K Ejaz Ahmed
Associate Professor
Department of Mechanical Engineering
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 – 18
6. Results 6. 19
7. Conclusion 7. 20
 INTRODUCTION
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 S Y S T E M S

 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 S Y S T E M S
 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 V A N TA G E S , D I S A D V A N TA G E 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 DISADVANTAGES

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
 Sayed Nashit et al, studied ‘Design, Fabrication and Testing of Regenerative Braking Test Rig for BLDC Motor’,
2016, pg 1881-84.

 Khushboo Rahim and Mohd. Tanveer, studied ‘Regenerative Braking System: Review Paper’, International
Journal on Recent and Innovation Trends in Computing and Communication, 5.5 (2018), pg 736-39.

 Tushar L. Patil, et al, studied ‘Performance Improvement of Regenerative braking system’, International Journal
of Scientific & Engineering Research Volume 9, Issue 5, (2018). Pg 2229-5518.

 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.

 Anchal Kumar, et al, studied (Regenerative Braking system (RBS) future Braking system) (May 2014) Vol.2, Issue
5: Regenerative braking systems (RBS).
L I T E R AT U R E S U R V E Y
 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.

 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.

 Tako Nama, et al, studied, ‘Design, Modelling and Hardware Implementation of Regenerative Braking for
Electric Two-Wheelers for Hilly Roads’ (December 2022).

 Y. Luo, D. Huang and X. Gao’s "Research on energy recovery for electric vehicle based on motor-generator
integration system,"

 Sanket Rajendra Sathe, et al, studied. “Regenerative Braking System: A Review” Volume 10, Issue 5, May 2022.
P R O B L E M S T AT 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.
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
energy due to its motion.
2.Braking Initiation: When the brakes are applied, the
regenerative braking system activates.
3. Kinetic energy conversion: Kinetic energy is
transferred from the wheels to the flywheel.
4. Energy storage: The flywheel stores the converted
kinetic energy as rotational energy.
5. Brake release: Upon acceleration, the stored energy is
released from the flywheel.
6. Power supplementation: The released energy
supplements power from the engine or electric motor.
7. Repeated cycling: The process of regenerative braking
and energy storage can be repeated multiple times
during a drive.
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

 E N E R G Y E Q U AT I O N S
1.Rotational kinetic energy (E): 2.Change in rotational kinetic energy (ΔE):
E = (1/2) * I * ω² ΔE = (1/2) * I * (ωf² - ωi²)
Where: Where:
E is the rotational kinetic energy in joules (J) ΔE is the change in rotational kinetic energy in joules (J)
I is the moment of inertia of the flywheel in kilograms per I is the moment of inertia of the flywheel in kilograms per
square meter (kg·m²) square meter (kg·m²)
ω is the angular velocity of the flywheel in radians per second ωf is the final angular velocity of the flywheel in radians per
(rad/s) second (rad/s)
ωi is the initial angular velocity of the flywheel in radians per
second (rad/s)
E N E R G Y E Q U AT I O N S
3.Energy conversion efficiency (η):

η = (ΔE / Ebrake) * 100

Where:

η is the energy conversion efficiency in percentage (%)

ΔE is the change in rotational kinetic energy in joules (J)

Ebrake is the energy consumed during braking in joules (J)

 Sl. RPM after brake pedal Voltage
RPM before brake pedal pressed
No pressed output
R E S U LT S 1 50 48 9.34
It can be seen from the result tables 2 90 87 10.88
that the efficiency of the regenerative
3 130 126 11.81
braking systems using D.C Motors
4 170 165 12.91
increases as the angular velocity of the
motor increases and hence the 5 210 204 13.49

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.
THANK YOU