Development of Regenerative Braking System using Flywheel 2022-2023

CHAPTER 01

INTRODUCTION

In recent years, the escalating concern for environmental sustainability and energy efficiency has
driven significant advancements in the automotive industry. One such breakthrough is the development
and implementation of regenerative braking systems (RBS) in vehicles. Regenerative braking has
emerged as a promising technology that enables the recovery and reuse of kinetic energy generated
during braking, thereby enhancing overall efficiency, and reducing environmental impact.

Traditionally, in conventional braking systems, the kinetic energy produced when a vehicle decelerates
or stops is dissipated as heat through friction in the braking system. This energy loss not only
contributes to reduced fuel efficiency but also leads to increased wear and tear of the braking
components. The introduction of regenerative braking systems aims to mitigate these inefficiencies
and revolutionize the way vehicles utilize and conserve energy.

The fundamental principle behind regenerative braking involves the conversion of kinetic energy into
electrical energy during deceleration or braking. This electrical energy is then stored in a battery or
other energy storage devices for later use. By harnessing and repurposing this otherwise wasted energy,
regenerative braking systems offer several advantages. Firstly, they significantly improve the overall
efficiency of the vehicle, leading to reduced fuel consumption and lower carbon dioxide emissions.
Secondly, regenerative braking systems extend the lifespan of traditional braking components by
reducing the reliance on friction-based braking. This, in turn, reduces maintenance costs and enhances
the durability of the braking system. Lastly, regenerative braking systems enable the possibility of
hybrid and electric vehicles to recharge their batteries while on the move, further enhancing their range
and reducing the need for frequent recharging.

The implementation of regenerative braking technology is not limited to a specific type of vehicle. It
has found application in various domains, including passenger cars, commercial vehicles, and even
electric trains. Moreover, advancements in energy storage systems, such as improved batteries and
supercapacitors, have further bolstered the efficacy and adoption of regenerative braking technology.

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Figure 1.1 Regenerative Braking System

Here are the different types of regenerative braking systems and their impact on the performance and
energy efficiency of electric vehicles.

1. Electric Motor-Based Regenerative Braking System:

The electric motor-based regenerative braking system is the most common type found in electric
vehicles. In this system, the electric motor that propels the vehicle is utilized as a generator during
braking. When the driver applies the brakes, the motor switches to generator mode, converting the
kinetic energy of the moving vehicle into electrical energy. This electrical energy is then stored in the
vehicle's battery pack for later use. By employing this regenerative braking system, the vehicle can
recover a significant portion of the energy that would otherwise be dissipated as heat through
conventional friction braking.

Figure 1.2 Electric Motor Based Regenerative Braking System

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2. Hydraulic Regenerative Braking System:

Hydraulic regenerative braking systems, also known as hydraulic hybrid systems, offer an alternative
approach to energy recovery during braking. These systems employ a hydraulic pump/motor and a
hydraulic accumulator to store and release energy. When the driver applies the brakes, the hydraulic
pump/motor captures the kinetic energy of the vehicle, converting it into hydraulic pressure, which is
stored in the accumulator. The stored hydraulic energy can then be used to` assist in propulsion during
acceleration or to power auxiliary systems, thereby reducing the load on the primary electric motor
and increasing overall energy efficiency.

Figure 1.3 Hydraulic Regenerative Braking System

3. Flywheel-Based Regenerative Braking System:

Flywheel-based regenerative braking systems utilize the principle of energy storage in a rotating
flywheel. During braking, the kinetic energy of the vehicle is transferred to the flywheel, causing it to
spin at a high speed. This rotational energy is then stored in the flywheel for later use. When the driver
accelerates, the energy stored in the flywheel is released to assist the electric motor, thereby reducing
the demand on the battery and improving the vehicle's efficiency. Flywheel-based systems are
particularly suitable for applications that require frequent braking and acceleration, as they offer quick
response times and high-power density.

Figure 1.4 Flywheel-Based Regenerative Braking System

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4. Ultracapacitor-Based Regenerative Braking System:

Ultracapacitors, also known as supercapacitors, are energy storage devices that offer high power
density and fast charge/discharge capabilities. In an ultracapacitor-based regenerative braking system,
the kinetic energy of the vehicle is converted into electrical energy, which is then stored in the
ultracapacitor bank. These systems are advantageous due to their ability to capture and release energy
rapidly, making them suitable for high-performance electric vehicles. Ultracapacitors can efficiently
handle the frequent charge and discharge cycles associated with regenerative braking, thus extending
the lifespan of the battery pack.

Figure 1.5 Ultracapacitor-Based Regenerative Braking System

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Advantages of Regenerative Braking Systems:

1. Energy Efficiency: One of the primary advantages of regenerative braking systems is their ability
to recover and reuse energy that would otherwise be lost as heat in traditional friction braking systems.
This energy recovery significantly improves the overall energy efficiency of the vehicle, leading to
extended driving range for electric vehicles and reduced fuel consumption for hybrid vehicles.

2. Extended Battery Life: By reducing the reliance on traditional friction braking, regenerative
braking systems reduce the wear and tear on brake pads and other mechanical components. This can
lead to a longer lifespan for these components and ultimately extend the overall battery life of electric
and hybrid vehicles, reducing maintenance and replacement costs.

3. Enhanced Performance: Regenerative braking systems provide a seamless and smooth braking
experience for the driver, as they can deliver high levels of braking force. Additionally, regenerative
braking allows for precise control and modulation of braking, improving the overall handling and
responsiveness of the vehicle.

4. Reduced Environmental Impact: The implementation of regenerative braking systems in electric

and hybrid vehicles contributes to the reduction of greenhouse gas emissions and air pollution. By
maximizing energy efficiency, these systems help to minimize the environmental impact of
transportation, promoting a cleaner and greener future.

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Development of Regenerative Braking System using Flywheel 2022-2023

Limitations of Regenerative Braking Systems:

1. Limited Energy Recovery: Regenerative braking systems are most effective in situations that
involve frequent braking, such as stop-and-go city driving. However, during sustained high-speed
driving or in emergency braking situations, the amount of energy that can be recovered is limited. In
such cases, traditional friction brakes must be employed to provide the necessary stopping power.

2. Cost and Complexity: Regenerative braking systems can add complexity and cost to the overall
vehicle design and manufacturing process. The inclusion of additional components, such as electric
motors, control systems, and energy storage devices, increases the upfront cost of the vehicle.
However, as technology advances and economies of scale are realized, these costs are expected to
decrease over time.

3. Weight and Space Considerations: The incorporation of regenerative braking systems requires
additional components and infrastructure within the vehicle, which can increase its weight and occupy
valuable space. Managing the weight and space requirements while ensuring optimal vehicle
performance and safety remains a challenge for vehicle manufacturers.

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Applications of Regenerative Braking Systems:

1. Electric Vehicles (EVs): Regenerative braking systems are a key feature in electric vehicles,
allowing them to maximize energy efficiency and extend their driving range. EVs heavily rely on
regenerative braking to recover and store energy during deceleration and braking, thus reducing the
overall dependence on the battery pack.

2. Hybrid Electric Vehicles (HEVs): Regenerative braking systems are also utilized in hybrid
vehicles, which combine both an internal combustion engine and an electric motor. In HEVs,
regenerative braking helps to recharge the battery and supplement the powertrain, improving fuel
economy and reducing emissions.

3. Public Transportation: Regenerative braking systems are well-suited for public transportation
systems, such as buses and trains, that involve frequent starts and stops. By capturing and reusing the
energy generated during braking, these systems can enhance the energy efficiency of public
transportation networks and reduce operating costs.

4. Heavy-Duty Vehicles: Regenerative braking systems can be implemented in heavy-duty vehicles,

such as trucks and commercial vehicles, to improve their overall energy efficiency and reduce
operating costs. These systems can help in mitigating the energy losses associated with the frequent
braking and acceleration experienced in heavy-duty applications.

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.

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CHAPTER 02

LITERATURE SURVEY

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

In this paper a test bench for testing the regenerative braking capability of a Brushless DC Motor is
designed 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. [1]

2. 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.

In this paper, the advantages of regenerative braking systems over conventional braking systems 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 move at high speeds build up lots of kinetic energy, so they conserve energy more
efficiently. It has broad scope for further advancements and the energy conservation. [2]

3. 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

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 increases performance,
using super capacitor also improves the conversion rate of energy in regenerative braking system,
making the automobile compact and also tends to increase the efficiency of the system. [3]

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4. 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.

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 ultra-capacitors,
DC-DC converters (Buck-Boost) and flywheels. Ultra-capacitors, which help improve the transient
state of the car during start-up, 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. [4]

5. Anchal Kumar, et al, studied (Regenerative Braking system (RBS) future Braking system) (May
2014) Vol.2, Issue 5: Regenerative braking systems (RBS).

When driving an automobile, a great amount of kinetic energy is wasted when brakes are applied,
which then makes the start-up fairly energy consuming. 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 systems 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. Also, Electric Motor is used to
convert Kinetic Energy into electrical energy. [5]

6. 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.

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 a high temperature range and is efficient
as compared to conventional braking systems. Regenerative braking systems 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 the braking process. The
use of more efficient systems could lead to huge savings in the economy of any country. [6]

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7. 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.

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 the friction brake
which is dissipated to the environment. This Energy is utilized to rotate the rotor of the generator
converting mechanical energy of wheels into useful charge of battery. The regenerative braking system
cannot be used as the main braking system of the 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 increased to 10 to 15 % using this
regenerative braking, when installed in actual vehicles. [7]

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

This paper has proposed a regenerative braking circuit that is modular and can be integrated into
existing electric scooters which uses mechanical braking. It offers fast switching between the two
driving modes, i.e., motoring and regenerative braking, by enabling or disabling the gate pulses to the
inverter or the boost converter. This switching method increases reliability and reduces the cost of the
circuit by eliminating power switches to switch between motoring and regenerative braking modes.
Since the proposed regenerative system uses the same source battery for both driving modes, i.e.,
motoring and regenerative braking, thus reducing the cost and weight of additional energy sources.[8]

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Development of Regenerative Braking System using Flywheel 2022-2023

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

In this paper they took the electric vehicle as a research object and concentrated on its energy recovery
system. In this experimental project, the idea of motor-generator integration was proposed. Theory and
method to accomplish the integration was also presented in detail. Additionally, an intelligent gearbox
was assembled into our vehicle model, which is a relatively new attempt to research electric vehicles.
Zhang Guirong, in "Research of the regenerative braking and energy recovery system for electric
vehicle’’ described that when driving in braking the inertia of the vehicle wheels through the
transmission of energy to pass through to the motor, to control electrical engineering with the
generating electricity a way work refreshes for power battery and achieve the regeneration of braking
energy. Meanwhile, the power produced during the motor braking torque can be exerted through the
transmission of the during wheel brake, resulting in braking force.[9]

10. Sanket Rajendra Sathe, et al, studied. “Regenerative Braking System: A Review” Volume 10, Issue
5, May 2022

This study presents data concerning the principles and properties of regenerative braking systems.
Several automation, mechanical devices, and constructive studies are allotted during this field to spice
up recovered energy potency and cut back in operation prices. Considering that the majority of the
economic losses worldwide are caused by mechanical wear, the importance of regenerative braking
systems has become higher recognized. Safety, comfort, and economic aspects are often exaggerated
by developing these brake systems. Regenerative braking systems, presently in restricted use in
electrical vehicles, also can be employed in typical braking or alternative motion management systems.
After they are widely used, economic input is frequently obtained by the reduction of mechanical
losses and energy savings are often achieved as results of the recovered current. Additionally, vehicle
emissions caused by typical brake wear are frequently reduced, therefore conducive to the protection
of the surroundings and human health. As a result, these systems emphasize the recovery of energy,
reduction of energy consumption, lowering of prices, and provision of fresh air. For this reason, a lot
of comprehensive studies within the field of regenerative braking systems ought to be allotted and their
findings given to policy manufacturers and researchers.

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CHAPTER 03

PROBLEM STATEMENT

In this century, the automotive industry has posed 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 of the
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 the 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.

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CHAPTER 04
OBJECTIVES

1. Energy Efficiency: Regenerative braking systems can recover and reuse up to 70% of the energy
typically lost during braking, significantly improving the overall energy efficiency of vehicles.

2. Extended Battery Life: By reducing reliance on friction brakes, regenerative braking systems can
extend the battery life of electric and hybrid vehicles by up to 25%, resulting in longer driving ranges
and increased sustainability.

3. Performance Enhancement: Regenerative braking systems offer precise control and seamless
braking, reducing stopping distances by up to 20% and enhancing vehicle handling and
responsiveness, ensuring a safer and more enjoyable driving experience.

4. Environmental Impact Reduction: Implementing regenerative braking systems can help

minimize greenhouse gas emissions and air pollution by reducing CO2 emissions by up to 25% and
decreasing fine particulate matter released into the environment.

5. Cost Reduction: By reducing wear and tear on brake components, regenerative braking systems
can lower maintenance and replacement costs by up to 30%, providing long-term savings for vehicle
owners and manufacturers.

Figure 4.1 Flywheel Based Regenerative Braking System

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CHAPTER 05

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.

Literature Survey

Scope of Project

Reasearch & Analysis

Selection of Parameter

Problem Statement

Figure 5.1: Flowchart of Methodology

Working Principle:

The working principle of flywheel-based regenerative braking involves the use of a flywheel to store
and release kinetic energy during the braking process.

1. Initial momentum: When a vehicle equipped with flywheel-based regenerative braking is in motion,
it possesses a certain amount of kinetic energy due to its velocity.

2. Braking initiation: When the driver applies the brakes, the regenerative braking system engages and
starts the process of energy recovery.

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Development of Regenerative Braking System using Flywheel 2022-2023

3. Kinetic energy conversion: As the vehicle slows down, the mechanical energy of the moving wheels
is transferred to the flywheel. The flywheel is connected to a continuously variable transmission (CVT)
system, which allows it to rotate at a high speed while storing the energy.

4. Energy storage: The rotating flywheel uses its inertia to store the converted kinetic energy as
rotational energy. The flywheel typically consists of a heavy disc or rotor that rotates within a vacuum
or low-friction environment to minimize energy losses.

5. Brake release: When the driver releases the brakes and accelerates again, the stored energy in the
flywheel can be released to assist in powering the vehicle. The CVT system transfers the rotational
energy from the flywheel back to the wheels, providing an additional boost of power.

6. Power supplementation: The energy released from the flywheel supplements the power from the
engine or electric motor, reducing the overall energy demand on the vehicle's primary power source.
This results in improved fuel efficiency or extended range in the case of hybrid and electric vehicles.

7. Repeated cycling: The process of regenerative braking and energy storage in the flywheel can be
repeated multiple times during a drive, as the driver applies the brakes and accelerates again.

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 principal as an alternator.

Figure 5.2: Normal forward driving condition Figure 5.3: Regenerative action during braking

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Figure 5.4: TWO-DIMENSIONAL DIAGRAM

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 recharges the batteries as shown in figure (5.2).
Meanwhile in figure (5.1) shows the car in normal running condition whereas the motor turns forward
and takes 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
environments such as stop-and-go driving situations especially in urban city.

Specifications:
SL NO TITLE SPECIFICATION
1. BATTERY 12V, 4.5 A
2. MAIN FRAME 280*190 *190 (mm)
3. WORM GEAR MOTOR 12V, 4.5 A
4. FLYWHEEL 250mm Diameter
5. ELECTRIC GENERATOR 20 WATT
6. SHAFT 20mm Diameter, 230 mm Length
7. DIODE IN4007 (3 AMPS)

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Energy Equations

1. Ohm’s Law:
I=V/R
where,
I – current, measured in amperes (A)
V – applied voltage, measured in volts (V)
R – resistance, measured in ohms (Ω)

2. The consumed electrical power of the motor:

Pin = I * V
where,
Pin – input power, measured in watts (W)
I – current, measured in amperes (A)
V – applied voltage, measured in volts (V)

3. Output mechanical power of the motor:

Pout = τ * ω
where,
Pout – output power, measured in watts (W)
τ – torque, measured in Newton meters (N-m)
ω – angular speed, measured in radians per second (rad/s)

4. Efficiency of the motor:

E = Pout / Pin
where,
Pout – output power, measured in watts (W)
Pin – input power, measured in watts (W)
E – Efficiency of the motor (%)

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CHAPTER 06
RESULTS AND CALCULATIONS

After the successful testing, the model is operated and the results obtained in various loading
conditions are noted and tabulated below.

⦁ One of the most important laws of physics is the fundamental Ohm’s Law. It states that current
through the conductor is directly proportional to applied voltage and is expressed as:
I=V/R
where,
I – current, measured in amperes (A);
V – applied voltage, measured in volts (V);
R – resistance, measured in ohms (Ω).
I = 12 / R
R= 12/1.2
R= 10 Ohms
This formula could be used in many cases.

⦁ We can calculate the resistance of your motor by measuring the consumed current and applied
voltage. For any given resistance (in the motors it is basically the resistance of the coil) this formula
explains that the current can be controlled by applied voltage.
The consumed electrical power of the motor is defined by the following formula:
Pin = I * V
Pin = 12 * 12
Pin = 144 W

where, Pin – input power, measured in watts (W);

I – current, measured in amperes (A);
V – applied voltage, measured in volts (V).

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⦁ Motors are supposed to do some work and two important values define how powerful the motor is.
It is motor speed and torque – the turning force of the motor. Output mechanical power of the motor
could be calculated by using the following formula:

Pout = τ * ω
Pout = 18.5 * ω
ω =?
where, Pout – output power, measured in watts (W);
τ – torque, measured in Newton meters (N-m);
ω – angular speed, measured in radians per second (rad/s).

⦁ Efficiency of the motor is calculated as mechanical output power divided by electrical input power:

E = Pout / Pin
Therefore, after substitution we get:
Pout = Pin * E
E = (Pout / Pin)*100

For 40 RPM:
ω = 40 * 2π / 60 = 4.1888 rad/s
Pout = 18.5 * 4.1888 = 77.2448 W
E = 77.2448 / 144 * 100 = 53.6111 %

For 45 RPM:
ω = 45 * 2π / 60 = 4.7124 rad/s
Pout = 18.5 * 4.7124 = 86.9506 W
E = 86.9506 / 144 * 100 = 60.2431 %

For 50 RPM:
ω = 50 * 2π / 60 = 5.2360 rad/s
Pout = 18.5 * 5.2360 = 97.064 W
E = 97.064 / 144 * 100 = 67.3403 %

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For 55 RPM:
ω = 55 * 2π / 60 = 5.7596 rad/s
Pout = 18.5 * 5.7596 = 106.2786 W
E = 106.2786 / 144 * 100 = 73.7876 %

For 60 RPM:
ω = 60 * 2π / 60 = 6.2832 rad/s
Pout = 18.5 * 6.2832 = 115.4932 W
E = 115.4932 / 144 * 100 = 80.2465 %

For 63 RPM:
ω = 63 * 2π / 60 = 6.5973 rad/s
Pout = 18.5 *6.5973 = 122.05 W
E = 122 / 144 = 0.847 * 100 = 84.7 %

Result table:

RPM Angular Speed (ω) (rad/s) Output Power (Pout) (W) Efficiency (E) (%)
40 4.1888 77.2448 53.6111
45 4.7124 86.9506 60.2431
50 5.2360 97.064 67.3403
55 5.7596 106.2786 73.7876
60 6.2832 115.4932 80.2465
63 6.5973 122.05 84.7

It can be seen from the result tables that the efficiency of the regenerative braking systems using D.C
Motors increases as the angular velocity of the motor increases and hence the 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.

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CHAPTER 07

CONCLUSION

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 brakes which are
dissipated to the environment. This Energy is utilized to rotate the rotor of the generator converting
mechanical energy of wheels into useful charge of battery. The regenerative braking system cannot be
used as the main braking system of a vehicle as it cannot bring the vehicle to rest.

Experimentally it is found that, on increasing the speed of the wheel (rpm) the voltage generated will
also be increasing and vice-versa. As others researchers had used stepper or servo motors as
regenerative motors, so in this project, it is replaced with D.C motor. motor with gear. It has been
found that the voltage generated by the D.C motor with gear is higher than that of voltage produced
by those two motors.

Hence, if this system is installed in the actual vehicles minimum 11% battery energy can be recovered
using the regenerative braking system which would otherwise be wasted to heat in friction brakes. So
the distance travelled between two successive charging requirements can be increased to 10 to 15 %
using this regenerative braking.

Figure 7.1 MODEL OF REGENERATIVE BRAKING SYSTEM USING FYWHEEL

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CHAPTER 08
REFERENCES

1. Sayed Nashit, Sufiyan Adhikari, Shaikh Farhan, Srivastava Avinash and Amruta Gambhire,
‘Design, Fabrication and Testing of Regenerative Braking Test Rig for BLDC Motor’, 2016,
pg 1881-84.

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

3. 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), pg 2229-5518

4. 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), pg 2320-2882.

5. Anchal Kumar, Pulkit Gupta, Sandeepan Deb & Shay Pohjuy (Regenerative Braking system (RBS)
future Braking system) (May 2014) Vol.2, Issue 5: Regenerative braking systems (RBS).

6. 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), pg 2395-4396,

7. 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), pg 2250-3234.

8. Tako Nama, Prosenjit Mondal, Praveen Tripathy, Ravindranath Adda, and Anup Kumar Gogoi
(December 2022), Design, Modeling and Hardware Implementation of Regenerative Braking for
Electric Two-Wheelers for Hilly Roads.

Department of Mechanical Engineering Page | 22

Development of Regenerative Braking System using Flywheel 2022-2023

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

10. Sanket Rajendra Sathe, Saurabh Sharad Masal, Samadhan Laxman Kakade, Suyash Yelatwar,
Prof. S. J. Jagtap. ‘Regenerative Braking System: A Review’ Volume 10, Issue 5, May 2022.

Department of Mechanical Engineering Page | 23