MINI PROJECT

FINAL

REGENERATIVE BRAKING
Submitted in partial fulfilment of the requirements of the degree of
Bachelor of Engineering
in
Mechanical Engineering

Submitted by

ARNAV APTE 9650

KUSHAL PATIL 9674
TEJAS PIRWARE 9677
MANAN BHANSALI 9652

Under the Guidance

Dr. Ketaki Joshi

Department of Mechanical Engineering

Fr. Conceicao Rodrigues College of Engineering
Bandra, Mumbai – 400050
University of Mumbai
2022-2023
 CERTIFICATE

This is to certify that the Mini Project - 1A stage 1 report entitled

Regenerative braking is a bonafide work of Arnav Apte 9650, Kushal Patil 9674, Tejas Pirware 9677, Manan
Bhansali 9652 submitted to the University of Mumbai in partial fulfillment of the requirement for the award
of the degree of Bachelor of Engineering in Mechanical Engineering.

Dr. Ketaki Joshi

Guide

Dr. B T Patil Dr. S S Rathod

Head of Department Principal
 Approval Sheet

Mini Project - 1A Stage 1 Report Approval for B. E.

This mini project-1A stage 1 report entitled Project Title by Arnav Apte 9650,Kushal Patil 9674, Tejas Pirware
9677, Manan bhansali 9652 is approved for the partial fulfilment of award of Degree of Bachelor of
Mechanical Engineering.

Examiners

1.---------------------------------------------

2.---------------------------------------------

Date:

Place:
 Declaration

I declare that this written submission represents my ideas in my own words and where others'
ideas or words have been included, I have adequately cited and referenced the original sources. I also
declare that I have adhered to all principles of academic honesty and integrity and have not
misrepresented or fabricated or falsified any idea/data/fact/source in my submission. I understand
that any violation of the above will be cause for disciplinary action by the Institute and can also evoke
penal action from the sources which have thus not been properly cited or from whom proper

permission has not been taken when needed.

ARNAV APTE 9650

KUSHAL PATIL 9674
TEJAS PIRWARE 9677
MANAN BHANSALI 9652

____________________________

(Signature)

Date:
 Abstract
EVs are considered better than conventional gasoline vehicles in
energy usage but even in EVs, there is a constant strife to increase
energy efficiency. Energy crisis has gripped the world and the
available energy must be used efficiently if the civilization must
persist. The world consumed 23,900 terawatt-hours as of 2019 and
automobiles are a major part of it. In a world of automobiles fossil
fuels are being used drastically and thus the need for energy efficiency
in automobiles is at an all-time high, so automobile manufacturers are
constantly trying to improve energy efficiency in vehicles. Studies
have found that electric regenerative braking can help to improve fuel
efficiency by 20-50% depending on electric machine size [3]. The
energy efficiency of a convectional car is only 20% while the other
80% is wasted by being converted to heat during friction [2]. For this
purpose, regenerative system is mentioned as a energy recovery
mechanism which converts the kinetic energy of the vehicle to
electrical energy. So this project will study the comparison between
conventional and electric vehicles on different parameters
 CONTENTS

Sr. No. Topic Page No.

1. Introduction

2. Literature Review

3. Problem Definition

4. Methodology

5. Results and discussion

6. conclusion

References
 INTRODUCTION
Energy crisis has gripped the world; energy must be used efficiently if the civilization must persist. In a
world of automobiles fossil fuels are being used drastically and thus the need for energy efficiency in
automobiles is at an all time high.

The world is in an era which calls for an all time high energy requirements and to meet these massive
demands we need to get more efficient at using energy. We have created many machines to our
convenience and these machines demand energy to function. One of the machines majorly and
frequently used are automobiles. Greenhouse gas (GHG) emissions from transportation account for
about 27 percent of total U.S. greenhouse gas emissions

When brakes are applied friction is created between the brake pads and the wheel this fiction generates
heat. This heat gets dissipated and thus gets wasted. To counter this, the idea of regenerative braking
came into play the idea states that when brakes are applied simply put the heat energy is converted to
electrical energy and then transferred to the battery pack. This conversion must be done smoothly and
efficiently and cost effectiveness is also taken into consideration. In this project work we will be
comparing the regenerative braking system with conventional
 LITERATURE REVIEW

Adam Adamowicz and Piotr Grzes (2010) compared heat generated in regenerative braking ……….. [1].

Güney et al.(2020)From the given paper we received the calculation of the amount of kinetic energy
generated by vehicle of specific weight …[2]

PhaneendraBabuBobba and K. R. Rajagopal(2012) From the given paper we have understood the
problems faced by electric vehicles..[3]

Pratik Bhandari et al. (2017) From the given paper we received the values of efficiency of regenerative
brakes…[4]

J. K. Ahn et al. (2009) compared overall energy consumption of a vehicle with and without regenerative
braking in experiemental manner. They found that the average value of energy consumption in the vehicles
with and without regenerative braking was 145.26 Wh/km and 154.79 Wh/km, respectively……[5]

Wicks, F., & Donnelly, K. (1997) from this paper we received the value for braking force in regenerative
braking system …..[6]
 PROBLEM DEFINITION
With increasing concerns for environmental pollution and wastage of energy. The world
consumed 23,900 terawatt-hours as of 2019; automobile manufacturers are constantly trying to
improve energy efficiency in vehicles. Therefore, electric vehicles are in more popular than
normal combustion vehicles. That can be seen due to increased awareness of global warming
and also rise in petrol prices. Thus, due to increase in air pollution which is concern in
environment and increase in oil prices, the EVs are the ideal source of transportation. Even in
EVs, there is a constant strife to increase energy efficiency.

Some problems currently in EVs are

1. Battery is the only source of energy

2. Long recharge timings
3. Low recharging cycles
4. Poor driving range

Some of these problems are solved by the process of regenerative breaking .As we know that energy can
neither be created nor be destroyed but can only be converted from one form to another. In normal
braking systems when we brake, the kinetic energy of the vehicle is converted to heat energy in the disc
brakes Normally the highest amount of heat generated in the braking system in a time of 3 seconds is
recorded around 260°C..

.For this purpose, regenerative system is mentioned as a energy recovery mechanism which converts
the kinetic energy of the vehicle to electrical energy.

The energy efficiency of a convectional car is only 20% while the other 80% is wasted by being converted
to heat during friction [2]. Studies have found that electric regenerative braking can help to improve fuel
efficiency by 20-50% depending on electric machine size [3].

storage media, such as battery. The main benefit of this method is that it charges the battery which
sends this energy to propel the motor.
A regenerative system alone may not be enough to stop the vehicle at high speeds. Due to the critical
safety standards of the system

The main aim of this project is studying comparing regenerative braking with conventional disc braking
and answering the question “whether regenerative system is really the environmental bargain it is
framed as?”
 METHODOLOGY

We have compared the conventional braking system with the regenerative

braking system on the following parameters

 Heat dissipated in conventional braking and energy regenerated in

regenerative braking
 Use of both the braking systems in various vehicles
 Stopping distance of both braking systems
 Wear and tear of brake pads on both braking systems

1: HEAT DISSIPATED IN CONVENTIONAL BRAKING

A Brake Disc Temperature is often considered the maximum temperature.

BDTm = (0.527 * q * Sqrt (t)) / Sqrt(p*c*k) +

Tamb
Where ,

BDTm = brake disk temperature

q = heat flux (watts/m^2)

t = brake on time (s)

p = density of the brake disc (kg/m^3)

c = brake disc specific heat capacity (J/kg/K)

k = brake disc thermal conductivity (W/(m*K))

Tamb = ambient temperature (C)

2: ENERGY REGENERATED IN REGENERATIVE BRAKING
For testing, a toyota kijang super was used which has a curb weight of 1200 kilograms

After inserting 16 units oflead-acid batteries,electric motors, motor controllers,and chargers,

the weight becomes 1600 kilograms

The car was tested on a 12.4 kilometre road

Here the maximum speed was 60 km/hr and the loads put were 2 people weighing 50 and 45
kilograms

The vehicle was fully charged before testing

3: USE OF CONVENTIONAL BRAKING IN VARIOUS VEHICLES

Conventional braking has been used since the rise of automobiles which run on fossil fuels. Braking is an
integral part of a vehicle. Conventional braking systems are indeed very powerful. Conventional braking
systems have many types but the majorly used one is disc braking system. In this braking system the
major amount of heat is produced in brake pads and disc this heat is then dissipated into the
environment what this implies is that much of this energy could be used if it could be harnessed

Conventional braking in trains uses the same concept of using compressed air to push the pads onto to
the disc. As trains are larger and heavier vehicles the heat generated is also greater

In two wheeler vehicles too conventional braking is used and also is used

4: USE OF REGENERATIVE BRAKING IN VARIOUS VEHICLES

Regenerative braking is a more recent than the conventional braking system as it can be used
only in vehicles that have an existing and suitable battery storage system which is found in
electrical vehicles. Electric vehicles are at an all time high and thus have possibility for the use
of regenerative braking

For a 4 wheel electric vehicle regenerative braking is used it is generally paired with
conventional braking systems as an backup to regenerative braking .in a car the jerk that stops
the car in regenerative braking is transferred in the form of electrical energy back to the battery
pack

Regenerative braking is also used in trains. Trains work on electricity and have place to store
electricity. Regenerative braking is used in trains in a similar way to the 4 wheel vehicles but it is
on a much larger scale

Regenerative braking is also used in trams they use it on a scale bigger than 4 wheel cars but
not on the scale of trains

5: STOPPING DISTANCE IN CONVENTIONAL BRAKING

For a 10432 kg vehicle travelling at 56 km/h and assuming ideal conditions of a dry road with
perfect tires

TOTAL STOPPING DISTANCE = BRAKING DISTANCE +

REACTION distance
BRAKING DISTANCE = (v) ^2 * COEFFICIENT OF FRICTION
REACTION TIME IN 1 SEC (DISTANCE TRAVELLED BY
VEHICLE IN 1 SECOND) = 14.11 meters

6: STOPPING DISTANCE IN REGENERATIVE BRAKING

For a vehicle with weight 10432 kg travelling at 56km/h assuming ideal conditions. The vehicle
was analyzed for many daily cycles of rapid acceleration, short distance at constant speed, rapid
deceleration and short time in the stopped condition. We get a value of force to get distance

Braking Distance = coefficient of friction * weight of vehicle *

(speed)^2/ braking force
7: WEAR AND TEAR OF BRAKE PADS IN BOTH BRAKING SYSTEMS
In conventional braking systems the brake pads are constantly in contact with the brake discs
every time the bakes are applied as it cause heat in a disc it also cause the brake pad to heat up
to . A purely regenerative system is often paired with friction brakes but these brakes are only
used when the battery is full thus they are not used very often

RESULTS AND DISCUSSION

1: HEAT DISSIPATED IN CONVENTIONAL BRAKING

BDTm = (0.527 * q * Sqrt (t)) / Sqrt(p*c*k) +

Tamb
For a brake disc

q = 10,000 t=5 p = 7000 c = 500 k = 58 Tamb = 40

therefore,

BDTm = (0.527 * 10000 * Sqrt (5)) / Sqrt(7000*500*58) + 40

BDTm = 40.82 C

2: ENERGY REGENERATED IN REGENERATIVE BRAKING

The energy use in the vehicle with regenerative vehicle was 143.94 to 146.58 kW/hr

The average energy use in vehicle with regenerative braking is 145.26 kW/hr

3: USE OF CONVENTIONAL BRAKING IN VARIOUS VEHICLES

Conventional braking system is still the major braking system that too in the conventional
braking system disc braking system is the most used of all these systems. conventional is no
doubt the choice when in panic situations and for trains conventional braking is the only way to
go when a train is travelling downhill conventional braking is the only way
4: USE OF REGENERATIVE BRAKING IN VARIOUS VEHICLES

Regenerative braking has applications only where there is a possibility to store

electricity. Thus electric 4 wheel vehicles use regenerative braking and trains and
trams too use regenerative braking which is useful and increase their efficiency a
lot but regenerative braking is of no use when the battery pack is used. On smaller
vehicles regenerative braking is not the proper fit as there is a need for a certain
weight behind it.

5: STOPPING DISTANCE IN CONVENTIONAL BRAKING

TOTAL STOPPING DISTANCE = BRAKING DISTANCE +

REACTION distance
BRAKING DISTANCE = (v) ^2 * COEFFICIENT OF FRICTION
REACTION TIME IN 1 SEC (DISTANCE TRAVELLED BY
VEHICLE IN 1 SECOND) = 14.11 meters
= 12.54 m

6: STOPPING DISTANCE IN REGENERATIVE BRAKING

Braking Distance = coefficient of friction * weight of vehicle *

(speed)^2/ braking force
= 23.5 m
7: WEAR AND TEAR OF BRAKE PADS IN BOTH BRAKING SYSTEMS
In conventional braking system as brake pads are used every time the brakes wear out easily so
they need to be replace from time to time .but in regenerative braking friction brakes are not
used as frequently and are only used in panic situations or when the battery pack is full thus
cars with regenerative braking don’t require for the brake pads to be changed frequently
 CONCLUSION
We have done the comparison of regenerative braking with
conventional braking on many aspects, to conclude the
comparison we have understood that yes regenerative braking
regenerates energy that help us run electric vehicles for a
longer time but when the battery pack reaches maximum
capacity we must use conventional braking which does tend to
waste the energy put into braking by the vehicle. As we
compared the stopping distances we have understood that a
conventional braking system has more braking power in it than
regenerative braking system. We can also conclude
conventional braking needs more servicing than regenerative
braking . and to answer the question “is regenerative braking
the environmental bargain we hoped for?”the answer is quite
complicated, regenerative braking is a smaller initiative but a
valid one and also needs working on and if regenerative braking
can bring its stopping power on par with conventional braking
regenerative will be future of braking in electric vehicles and in
the future we will get electric vehicles that solely work on
regenerative braking
 REFERENCES
1]PhaneendraBabuBobba, K. R. Rajagopal, ‘’Modeling and Analysis of Hybrid Energy Storage Systems
Used in Electric Vehicles’’ 2012 IEEE International Conference on Power Electronics, Drives and Energy
Systems, December 16-19, 2012.

[2] Pratik Bhandari, Shubham Dubey, ScahinKandu, RupeshDeshbhratar, “Regenerative Braking

Systems(RBS)’’, IJSER February 2017.

3] J. K. Ahn, K. H. Jung, D. H. Kim, H. B. Jin, H. S. Kim and S. H. Hwang, "Analysis of a regenerativebraking

system for Hybrid Electric Vehicles using an Electro-Mechanical Brake," International Journal of
Automotive Technology, pp. 229-234, 2009.

4] Adam Adamowicz, Piotr Grzes. Analysis of disc brake temperature distribution during single braking
under non-axisymmetric load. Applied Thermal Engineering, Elsevier, 2011, 31 (6-7), pp.1003.
ff10.1016/j.applthermaleng.2010.12.016ff. ffhal-00723969

5] Güney, Bekir & Kılıç, Halil. (2020). Research on Regenerative Braking Systems: A Review. International
Journal of Science and Research (IJSR). 9. 160-166. 10.21275/SR20902143703.

6] https://www.iea.org/reports/electric-vehicles
7] https://www.epa.gov/transportation-air-pollution-and-climate-change/carbon-pollution-
transportation

8] https://calculator.academy/braking-force-calculator/

9] Huda, N., Kaleg, S., Hapid, A., Kurnia, M. R., & Budiman, A. C. (2020). The influence of the regenerative
braking on the overall energy consumption of a converted electric vehicle. SN Applied Sciences, 2(4), 1-8.

10] https://www.team-bhp.com/forum/road-safety/254541-formula-calculating-braking-distances.html

11] Wicks, F., & Donnelly, K. (1997, July). Modeling regenerative braking and storage for vehicles.
In IECEC-97 Proceedings of the Thirty-Second Intersociety Energy Conversion Engineering Conference
(Cat. No. 97CH6203) (Vol. 3, pp. 2030-2035). IEEE.