Theory of Machines

Regenerative Braking System

Syed Mohammad Hamza Wasti (2015439)

Muneeb Aslam (2015345)
Mohammad Wajahat Ali (2015334)
Navian Nadeem (2015360)
Abstract:
This report covers the effort of 4 students, who worked together to achieve a
great milestone in the shape of a Regenerative Braking System in a Bicycle. This
can be huge breakthrough in the field of mechanical engineering and if utilized
properly with improved efficiency, energy can be conserved and used in the
driving mechanism. The report consists the analysis of the design mechanism,
cost breakdown and improvements for increasing the efficiency of the design.
Introduction:
Conventional braking system consisted of applying brakes to the front wheel. The
wheel doesn’t always stop immediately, it rubs off the brakes and in the process,
creates friction and heat energy. So stepping on a cycle’s brakes leads to a
proportional energy loss. Physics tells us that energy cannot be destroyed. So,
when the cycle slows down, the kinetic energy that was propelling it forward has
to go somewhere. Most of it simply dissipates as heat and becomes useless. That
energy, which could have been used to do work, is essentially wasted.
Regenerative braking is an energy recovery mechanism which applies a braking
force on a vehicle or an object by converting its kinetic energy into a form which
can be either used immediately or stored until needed. In a nutshell, an elastic
belt is using the vehicle's momentum to recover energy that would be otherwise
lost to the wheels. This contrasts with conventional braking systems, where the
excess kinetic energy is converted to unwanted and wasted heat by friction in
the brakes, or with dynamic brakes, where energy is recovered by using electric
motors as generators but is immediately dissipated as heat in resistors. In
addition to improving the overall efficiency of the vehicle, regeneration can
greatly extend the life of the braking system as its parts do not wear as quickly.
Mostly the energy recovered by the regenerative braking systems is stored in a
capacitor and used as electrical energy, thus kinetic energy is converted into
electrical energy. This mechanism has been used in Hybrid cars, Electrical Bicycles
for a while now. But to store kinetic energy and use it to propel the tires in
forward direction is unheard of.
An elastic belt winded on the wheel and attached to a spindle is a simple solution
which is discussed in detail in the latter section of the report.
Parts used in the Process:
1. Bicycle Wheel:
A Bicycle wheel was used to demonstrate the effects of the regenerative brakes.
The wheel was held between two stationary links and was able to rotate freely.

2. Gears:
Two Gears having same number of teeth were used. They are meshed together
when the brake is applied. Gear 1 is attached to the shaft which is connected via
an elastic belt to the shaft on which wheel is rotating. Gear 2 is attached to the
spindle.

3. Spindle:
A spindle is a device used for winding or winding threads. It is used for the same
purpose here. An elastic belt is winded and fixed at one end at the spindle. The
other end goes to the freewheel attached to the wheel.

4. Retractable tape measure:

It is measuring device. But in our design, it’s mechanism of retracting was used.
Whenever the tape is pulled out and release, it goes rolling back into the device
(Spiral Spring Effect). The end of measuring tape is attached to the elastic belt
which goes from freewheel to the spindle.
 5. Freewheel (Inside a Sprocket):
The freewheel mechanism of the rear wheel comprises of two components- the
ratchet and the pawl. When pedaling, the pawls lock themselves to the dents in
the ratchet part thus forcing the inner mechanism to rotate. The pawls are held in
upward position by using tiny springs (can be seen under the pawls as leaf like
structures - leaf springs).

When pedaling backwards or when you stop pedaling the springs holding the
pawls upright, collapse and the pawls fall back in their collapsed positions. Thus,
making the freewheel to rotate on its axis freely.

This part was very crucial to our design.

Two freewheels on both sides of the wheel were attached. One as explained
above, used for pedaling. That is not shown in our design. The other freewheel on
the other end, is shown as the design revolves around it.
 6. Elastic Belt:

Two Elastic belts were used in this mechanism. One connects Gear 1 to the wheel
shaft. One as explained above was used to connect the spindle, freewheel and the
retractable tape. The energy that was stored is used through this belt. Gear 1
does not rotate until the brake is applied and the belt is stretched which reduces
the friction between the shaft connected to the gear and the belt and helps in
rotation.

7. Clutch Handle:

It is used for applying brakes and for pulling the Gear 1 to mesh it with Gear 2.

8. Braking cable:

Connected from clutch to the brakes and Gear 1.

Working:
*Note: The brake is not shown in the mechanism as we were using the rear wheel
in our mechanism and the brake will be applied to the front wheel.

- The Wheel is rotated in the forward direction with a great speed. At this point
only the wheel is rotating and not the shaft containing Gear 1, because the elastic
belt is not stretched so it just slips from the shaft. The second elastic belt, which
connects to the spindle, freewheel and tape measuring device, is fully un-winded
from the spindle.

- When the Clutch handle is pressed, it pulls the shaft connected to Gear 1 and
meshes it with Gear 2. In this process the elastic belt connecting Gear 1 and the
wheel, stretches and increases the coefficient of friction between belt and the
shaft. This in turn rotates the shaft and Gear 1 along with it.

- When Gear 1 is meshed with Gear 2. It rotates the second gears as well. In
meshing of the gears, when one gear is rotated, the other is also rotated but in
the opposite direction.

- The Gear 2 is connected to the spindle. When it rotates in the other direction, it
starts to wind the elastic belt around it. The tape is pulled from the retractable
tape measure device. The belt also forces the sprocket to rotate in the opposite
direction of the wheel but as it is in a free state while rotating backwards
(discussed in the freewheel mechanism), it does not rotate the wheel along with
it. Some of the belt connected to the tape measure winds on the spindle until the
wheel stops, at this point the handle is not released and both the gears are
meshed together thus stopping the elastic belt unwinding from the spindle. The
energy is stored in the retractable tape which is stretched and in a position to go
back in the device.

- When the handle is released, the Gears are released from the contact with each
other. The spindle begins to unwind the elastic belt as the retractable tape goes
back in the device. This in turn rotates the sprocket in the forward direction,
which rotates the wheel in the forward direction along with it.
Improvements:
*Note: This design works more efficiently if the brake is applied to a fast moving
bicycle because if the wheel stops immediately, there will be no winding and
unwinding in the spindle.

-To increase the efficiency, the recoil in the retractable tape mechanism can be
increased. In that manner, the belt unwinds quickly and the wheel rotates with
much greater speed.

-Using a better material than the elastic belt used in this experiment so the belt
does not slip and provides a better grip on the shaft.

-The contact surface in the slot between the gears can be made to of less friction
by lubrication.

-To improve the basics of the design, another braking system can be introduced at
the spindle’s shaft. This brake will not be operated by a clutch but by a lever
mechanism through which the brakes will be still applied after the lever is pulled
upwards. The function of these brakes is to stop the spindle from unwinding and
therefore storing the energy in the spiral spring inside the retractable tape for
later use. When the energy is to be used the lever can be pulled downwards.
Cost Breakdown:
Equipment or Process Price

Wheel Rs 400

Sprocket and Axle Rs 750

Fitting and Machining Rs 2500

Gears Rs 500

Clutch Rs 400

Miscellaneous Rs 1500

Total: Rs 6050