Machine Design

Table of Contents
Abstract:.................................................................................................................................................. 2
Introduction:............................................................................................................................................ 3
KERS: ................................................................................................................................................. 3
Electrical KERS:................................................................................................................................. 3
Mechanical KERS:.............................................................................................................................. 3
Components of Kers: .............................................................................................................................. 3
Assumptions:........................................................................................................................................... 4
Calculation for energy stored in flywheel:.............................................................................................. 5
Rolling Resistance: .............................................................................................................................. 6
Aerodynamic drag............................................................................................................................... 6
Factor Of Safety: ..................................................................................................................................... 7
References: ............................................................................................................................................. 8

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Machine Design

Abstract:
This report is prepared to use flywheel as an energy storing device. The transfer of vehicle
kinetic energy to flywheel kinetic energy can be seen as a momentum exchange. Energy is
transferred from the vehicle to the flywheel. In doing this the speed of the vehicle decreases
and that of the flywheel increases which we can effectively call as a braking. At the start of
braking process the vehicle has a higher speed than the flywheel, giving a certain speed ratio
between them whereas at the end of braking the vehicle has a lower speed than the flywheel
so the ratio of speeds has changed. Examination of the energy transfer shows that the ratio
between vehicle speed and flywheel speed necessarily changes continuously during the
energy transfer event.

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Introduction:
KERS:
A kinetic energy recovery system (KERS) is an automotive system which recovers the kinetic
energy of a moving vehicle under braking. The energy recovered is stored in the terms of
potential energy which is later used for acceleration.
There are basically two types of KERS.

i. Electrical
ii. Mechanical

Electrical KERS:
This system is less efficient but it can store power for a longer duration and gives us the
ability to manipulate the torque and rpm output as per our requirement.

Mechanical KERS:
On the other hand, the mechanical system has a better efficiency (nearly twice as that of the
prior one) but it cannot be stored for longer period and need to be used within a short period
of time. In the real world we can find many situations where we need to use the recovered
Kinetic energy with in very short span of time of its recovery and we don’t even need a wide
range of torque and rpm output as a particular range of torque & rpm combinations satisfy
our requirements completely. A bicycle is a perfect example of this kind.
We have selected this system for our design.

Components of Kers:
Front Sprocket Clutch Drive Rear Sprocket

Central Shaft Chain

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Machine Design

Front view of Kers

Top view of Kers

Assumptions:

 Flywheel material  Flywheel are of various materials like steels, Pb alloys,

Beryllium
 Although cast iron is cheap, we have chosen High Strength
Steel because they are less likely to break under high rpm.
 https://fidanza.com/aluminium-vs-steel/

 Flywheel Type  Circular disk

 Bicycle mass  Normally 10-15kg (Avon Boom Bicycles)
 We have selected 12kg.
 Flywheel outer Dia  25cm≅0.25m (assumed)
 Flywheel inner Dia  2cm≅0.02m (assumed)
 Flywheel Mass  5kg
 Mass of Person  65kg
 Total mass  82kg

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Machine Design

Calculation for energy stored in flywheel:

Let us assume that the flywheel stores enough energy to take the whole system from rest to
10km/hr in 5sec.

 v = 10km/hr = 2.78m/s Distance for this speed is

 u = 0km/hr = 0m/sec v×t=d
d=2.78×5
Time = 5sec
d=13.9m
 a = (V - U)/ Time = 0.556m/sec2

Energy of the system when it reaches

10km/hr = E
0

E = ½mv2 = 316.8 joules
(This means that 316.8 joules is required
for covering 13.9m,but
Note: We want to find it for 1m)

So, let us calculate the rpm or speed of the wheel

DR = Diameter of the bicycle wheel
= 29inch ≅ 736.6mm ≅ 0.7366m
RR=0.3683m
Number of revolution made by the wheel at 10kmph per sec

V= r×ω (ω=2πNt)

=
π r

= 1.2rps×60
= 72.07rpm

Force required in taking the bicycle from rest to 10kmph in 5 sec

Fa= ma = 45.592N

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Machine Design

Rolling Resistance:
There will be rolling resistance to tires thus we have to calculate value for rolling friction
which is calculated from formula:
Fr = c×m×9.81

Where,
C =Friction co-efficient 0.03
M =Mass of system 82
Fr =24.13N
The value of c is taken from:
https://www.google.com/amp/s/www.engineeringtoolbox.com/amp/rolling-friction-
resistance-d_1303.html

Aerodynamic drag = FA
FA= CdρAv2
Where
Cd = coefficient of drag = 0.75
= density of air = 1.202 kg/m at 25°C
A = projected area = 1m2 (let us assume)
V = velocity of bicycle = 2.78m/sec3
FA =7.24N
These assumed values are taken from:
http://www.cartech.com/subjects/auto_eng/Road_loads.htm

Total force required to overcome above forces is

F= FA+Fr+ Fa
F=76.96N

Now, Torque required at the centre of wheel to get this required force

T=F×r
T = 76.96 × 0.3683
T = 28.34Nm

When our system reaches 10kmph our flywheel should have a speed directly in proportional
with the wheel speed (rpm)(provided that no. of teeth on both gears i.e flywheel & wheel
must be equal)
So, flywheel rpm =1.2rps = 72.07rpm

Now, Energy released by flywheel can be given as,

Efl = I (ω12- ω22)
ω1=2πNt
ω1=452.89
&
ω2=0 because initially angular velocity is zero.

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Thus,
Efl = Im (452.89)2..........(1)

Im = (ro2-ri2)
By putting values we get,
Im=0.15525Kgm2
& (1) becomes
Efl = (0.15525) (452.89)2

Efl=15921.6J

(Since Energy stored in flywheel is greater than energy required for system thus our
calculations are right )
Also,

For riding:

F=Wsin30+f
F=(82sin30)+ μN
F=487.355

E=Fd
E=487.355J

Since again the value of energy is greater than

system’s energy, this means that designed
flywheel is satisfactory.

Factor Of Safety:

Suppose Safety factor is 3

Yield Strength δ 250MPa

Weight density ɣ 7800kg/m3
76491.87N/m3
Poisson ratio ν 0.25-0.33
We have selected 0.3

Ny =

(Robert L.Norton-Machine Design_An integrated approach(2010,Prentice Hall)

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Machine Design

ɣ ν
σ = ω2 ( ) [(ri2+ro2) + ( )– r2]

By putting values

= (0.53789×109)[0.0629+0.250897-0.08198]

= (0.53789×109)[0.231997]

=0.124789×109

Thus,

×
Ny= . ×

Ny=2

This means our design is safe.

References:
 https://fidanza.com/aluminium-vs-steel/
 https://www.google.com/amp/s/www.engineeringtoolbox.com/amp/rolling-friction-
resistance-d_1303.html
 http://www.cartech.com/subjects/auto_eng/Road_loads.htm
 (Robert L.Norton-Machine Design_An integrated approach(2010,Prentice Hall)
Article 10.1
 www.bikepanthi.com/
 www.autosport.com/news

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