Maharashtra State Board of Technical Education

Mumbai
Government Polytechnic Osmanabad
Micro Project Title:

Submitted By
Sr.No Name Roll No
1 Nalwade Shivratna Prabhakar 15
2 Panchal Chandrashekhar Satish 16
3 Nimbalkar Omraje Amol 38
4 Rathod Omkar Ganpat 39

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 Maharashtra State Board Of Technical Education,
Mumbai
GOVERNMENT POLYTECHNIC OSMANABAD
CERTIFICATE
This is certified that the, micro project entitled." Regenerative
braking System "
Submitted By Mr. Rathod Omkar Ganpat.
Roll no 39 of fifth semester of Diploma In Mechanical engineering has
completed project work satisfactory in the course Elements Of
Machine Design the academic year 2021-2022 as prescribed in the
curriculum
Place-Osmanabad.

Enrollment no-1901180088 Exam seat no:-

Subject Teacher Head of the Department Principal

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 ➢ ACKNOWLEDGMENTS
would like to express my special thanks of
gratitude to my teacher Prof.U.B.Rathod Who
gave me the golden opportunity to do this
wonderful project on the topic. Regenerative
Braking System Which also helped me in doing a
lot of Research and I came to know about so many
new things I am really thankful to them. Secondly I
would also like to thank my friends who helped me
a lot in finishing this project within the limited
time. THANKS AGAIN TO ALL WHO HELPED ME

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 INDEX
No Sub Topics Page
no
1 Introduction 5
2 Working Principle 7
3 Types 9
4 Problem Statement 13
5 Use of Regenerative 14
braking System
6 Advantages and 15
disadvantages
7 Efficiency and limitations 17
8 Future Scope 20
9 Reference 21

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 ➢ Introduction
In recent years, there is the lack of reliable alternative energy sources,
increasing efficiency and reducing exhaust gas emissions has become the
focus of the modern automotive research. Commercial vehicles such as
refuse trucks and delivery vehicles lose a tremendous amount of kinetic
energy during frequent braking and constant drive at low speeds on
designated city routes, which results in higher fuel consumption and Green
House Emission Gas (GHG) emission than other on-road vehicles. Numerous
attempts have been made to improve type of vehicles. The technological
combination of Exhaust Gas Recirculation (EGR) and Diesel Particulate Filter
(DPF) after treatment is one of the effective ways to solve the vehicle
emission, especially for NOx and soot. However, this method is not able to
reduce the GHG emission since the low temperature combustion of this
technology results in increasing the fuel penalty. Sacrificing engine efficiency
in exchange for reduced pollutants cannot fundamentally solve the energy
crisis. In order to achieve overall GHG reduction targets, a strong reduction is
needed particularly for commercial vehicles.
Regenerative energy technology is one of the key features of electrified
vehicles. It allows the vehicle to capture a tremendous amount of the kinetic
energy lost during braking or decelerating for reuse. That is saying, energy
recovery technology can significantly bring down the energy consumption of
electrified vehicle, particularly in urban operated route. Generally, there are
two regenerative energy approaches which have been applied to commercial
vehicles: Regenerative Braking System and Boost Recuperation System. The
former is usually applied in series hybrid Architecture; the latter in the
parallel architecture. The regenerative braking system is equipped in
The driven axle to recuperate the braking energy loss. The boost
recuperation system is parallel Coupled with the mechanical propulsion

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system to recuperate kinetic energy during the Deceleration process. Both
technologies allow commercial vehicles to have a significant Improvement of
reducing fuel consumption as well as emissions. However, few researchers
have Addressed the regenerative energy rate of hybrid commercial vehicles.
The more energy the Regenerative braking recuperates; the less fuel is
consumed. Typical hybrid commercial vehicles Are generally designed as rear
drive and the regenerative braking system is equipped in rear Driven axle(as)
to recuperate the braking energy loss. Due to the change of the center
gravity in The vehicle under different load conditions, braking energy loss
may vary in both front and rear Axles.

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 ➢ Working Principle

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 principle as an alternator. IN
regenerative braking mode, it uses the motor to slow down the car when the
driver applies

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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 recharge the
batteries as shown in
figure (1.2.2). Meanwhile in figure (1.2.1) shows the car in normal running
condition whereas
the motor turning forward and taken 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 environment such as stop-and-go driving
situations
especially in urban

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Types of Regenerative Braking System
There are multiple methods of energy conversion in Regenerative Braking
System including spring, flywheel, electromagnetic and hydraulic. More
recently, an electromagnetic-flywheel hybrid Regenerative Braking System
has emerged as well. Each type of Regenerative Braking System utilizes a
different energy conversion or storage method, giving varying efficiency and
applications for each type.The Types are as follows:
• Electromagnetic
• Flywheel
• Electromagnetic flywheel
• Spring
• Hydraulic

➢ ELECTROMAGNETIC
In Electromagnetic system, the drive shaft of the vehicles is connected to an
electric generator,
which uses magnetic fields to restrict the rotation of the drive shaft, slowing

the vehicle and generating electricity. In the case of electric and hybrid

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vehicles, electricity generated is sent to the batteries, giving them a recharge.
In gas powered vehicles, the electricity can be used to power the cars
electronics or sent to a battery where it can later use to give the vehicle an
extra boost of power. This technique is currently used in some Le Mans
Prototype racing car

➢ Flywheel
In Flywheel Regenerative Braking System, the system collects the kinetic
energy of the vehicle
to spin a flywheel that is connected to the drive shaft through a transmission
and gear box. The
spinning flywheel can then provide torque to the drive shaft, giving the
vehicle a power boost.

➢Electromagnetic flywheel
Electro flywheel regenerative brake is a hybrid model of electromagnetic and
flywheel Regenerative Braking System. It shares the basic power generation

methods with the electromagnetic system; however, the energy is stored in a

flywheel rather than in batteries.

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In this sense, the flywheel serves as a mechanical battery, where electrical
energy can be stored and recovered. Due to the long life of flywheel
batteries compared to lithium-ion batteries, electric flywheel Regenerative
Braking System is the more cost-effective electricity storage method.

➢ Spring
The spring-loaded regenerative braking system is typically used on human
powered vehicles, such as bicycles or wheelchairs. In spring Regenerative
Braking System, a coil or spring is winded around a cone during braking to
store energy in the form of elastic potential. The potential can then be
returned to assist the driver while going uphill or over rough terrain.

➢ Hydraulic
The Hydraulic Regenerative Braking System slows the vehicle by generating
electricity which is then used to compress a fluid. Nitrogen gas is often
chosen as the working fluid.

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Hydraulic Regenerative Braking Systems have the longest energy storage
capability of any system, as compressed fluid does not dissipate energy over
time. However, compressing gas with a pump is a slow process and severely
limits the power of the hydraulic Regenerative Braking System.

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 ➢ Problem statement
At this century, automotive industry has posted a great challenge in order to
reduce the vehicle fuel consumption and emission, these 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 brake. The
invention of 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.

➢ Applications
❖ Kinetic energy recovery mechanism.
❖ Regenerative braking systems are used in electric elevators and crane
lifting motors.
❖ Also used in electric and hybrid cars, electric railway vehicles, electric
bicycles, etc.
❖ Could be used in an industry that uses a conveyor system to move
material from one workstation to another and halts at a certain
distance after a prescribed interval.
❖ Recovering Kinetic energy of vehicle lost during braking process.

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 ➢ Use Of Regenerative Braking

• Bicycles

Regenerative braking is also possible on a non-electric bicycle. The United

States Environmental Protection Agency, working with students from the
University of Michigan, developed the hydraulic Regenerative Brake Launch
Assist (RBLA It is available on electric bicycles with direct-drive hub motors.

• Cars
Many electric vehicles employ regenerative braking in conjunction with
friction braking first used in the US by the 1967 AMC Ambition electric
concept car Regenerative braking systems are not able to fully emulate
conventional brake function for drivers, but there are continuing
advancements The calibrations used to determine when energy will be
regenerated and when friction braking is used to slow down the vehicle
affects the way the driver feels the braking action.
• Examples of cars include:
• Audi e-Tron
• Chevy Bolt
• Ford Fusion Hybrid
• Hyundai Kona Electric
• Nissan Leaf
• Tesla Model 3
• Toyota Prius
• Mitsubishi Outlander PHEV

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➢ Advantages
• Better Performance
• down on pollution related to supply generation.
• Efficient Fuel Economy–The fuel consumption is reduced, dependent on
the machine
• cycles, vehicle design, automation control plan, and the individual
component’s efficiency.
• Reduced wear and tear of Engines.
• Reduced Brake Wear– Cutting down the replacement brake linings cost,
the cost of labor
• for installation, and machine downtime.
• Reduced emissions–Cuts down on pollution related to power
generation, engine decoupling
• reduces the total number of revolutions and thus engine emissions.
• Smaller accessories – reducing fuel tank size and thus the weight of the
vehicle.
• Savings of around 30% in energy consumption. Increased battery
autonomy. Zero consumption even with the vehicle stopped but turned
on.
• Maximum efficiency as the electric motor has Maximum torque at zero
rpm.

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➢ Disadvantages
• In practice, the regenerative brakes take the time to slowdown a
vehicle, hence most of the
• vehicles that use them, also have friction brakes working alongside. This
is one reason regenerative brakes don't save 100 percent of braking
energy.
High cost of components, engineering, and installation.
• As compared to dynamic brakes, regenerative brakes are needed to
match the power produced by the input supply (D.C. and A.C. supplies),
and it is achieved only with the help of development of power
electronics.

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 ➢ REGENERATIVE BRAKING EFFICIENCY
The energy efficiency of a conventional car is only about 20 percent,
with the remaining 80 percent of its energy being converted to heat through
friction. The miraculous thing about regenerative braking systems could
provide even more impressive gains, potentially reducing fuel use by 25 to 45
percent. In a century that may see the end of the vast fossil fuel reserves that
have provided us with energy for automotive and other technologies for
many years, and in which fears aboutcarbonemissions are coming to a peak,
this added efficiency is becoming increasingly important. The added
efficiency of regenerative braking also means less pain at the pump, since
hybrids with electric motors and regenerative brakes can travel considerably
farther on a gallon of gas, some achieving more than 50 miles per gallon at
this point. And that’s something that most drivers can really
No machine can be 100% efficient (without breaking the laws
of physics), as any transfer of energy will inevitably incur some loss as
heat, light, noise, etc. Efficiency of the regenerative braking process
varies across many vehicles, motors, batteries and controllers, but is
often somewhere in the neighborhood of 60-70% efficient. Regen
usually loses around 10-20% of the energy being captured, and then
the car loses another 10-20% or so when converting that energy back
into acceleration, according to Tesla. This is fairly standard across
most electric vehicles including cars, trucks, electric bicycles, electric
scooters, etc.
Keep in mind that this 70% does not mean that regenerative
braking will give an 70% range increase. This isn’t going to bump your
range from 100 miles to 170 miles. This simply means that 70% of the
kinetic energy lost during the act of braking can be turned back into
acceleration later.

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 This is why only reporting the efficiency of the system doesn’t
really mean much. Someone could be very efficient when they work,
but if they only work an hour a day, they probably aren’t accomplishing
a lot. What should interest us more is the effectiveness of regenerative
braking.

➢Regenerative braking System limitations

Regenerative braking is a huge benefit to drivers, allowing them to
save on energy costs as they brake safely. However, there are
limitations to this technology that should be considered for all EV and
hybrid owners.The biggest drawback drivers experience with
regenerative braking is the impracticality of repurposing all of the
energy conducted at high speeds and high deceleration rates,
according to an article by Stanford University student Juan Leis-
Presto. Not that the high-speed braking power is completely lost;
rather, more energy must be used to slow the vehicle down rather
than reutilize it for battery power.Leis-Pretto also finds that outside
forces will affect how much energy is able to be saved such as:

▪ Weight transfer
▪ Wind
▪ Vehicle age
▪ Rolling resistance
▪ Terrain
▪ Temperature changes
▪ Motor torque variations
Motor torque variations are the biggest deciding factor on this list
because how a driver applies the brakes as they slow down will force
the regenerative technology to reconfigure how much energy it can

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use towards the battery. Typically, a driver will apply more force to
the brake as they get closer to their stop which creates an inconsistent
variable for the regenerative braking technology.

Vehicle torque, when applied to EVs with two-wheel drive, can create
a more serious situation for the driver. Regenerative braking is
applied to the drive wheels with negative torque; however, when the
vehicle is

braking, the negative torque is applied to the wheels with brakes

causing the vehicle to potentially fishtail or skid. This event is most
common in extreme braking conditions.
Regenerative braking benefits
Knowing these limitations can help drivers adjust the way they handle
a vehicle with regenerative braking. In this case, knowledge is power
— to navigate through a changing vehicle efficiency landscape.

Regenerative braking systems help drivers save on not only the cost of
energy but, as we've learned, on replacing brake pads as well. Without
the need to apply force to your brake pad as often as with traditional
braking systems, an EV's brake pads will deteriorate less quickly.

➢ CONVERSION OF KINETIC ENERGY TO

ELECTRICAL ENERGY USING MOTOR
The most common form of regenerative brake Involves using an
electric motor as an electric Generator. The working of the
regenerative braking System depends upon the working principle of
an Electric motor, which is the important component of The system.
Electric motor gets activated when some Electric current is passed

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through it. But, when some External force is applied to activate the
motor (during The braking), then it behaves as a generator and
Generates electricity. This means that whenever motor Runs in one
direction, the electric energy gets Converted into mechanical energy,
which is then used To accelerate the vehicle and whenever the motor
runs In opposite direction, it performs functions of a Generator,
which then converts mechanical energy into Electrical energy, which
makes it possible to Utilize the Rotational force of the driving axle to
turn the electric Motors, which results in regenerating electric energy
For storage in the battery and simultaneously reducing The speed of
the car with the regenerative resistance of The electric motors. This
electricity is then used for Recharging the battery.

➢ 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.
Regenerative braking systems require further research To develop a better
system that captures more energy And stops faster. As the time passes,
designers and Engineers will perfect regenerative braking systems, So these
systems will become more and more Common. All vehicles in motion can
benefit from These systems by recapturing energy that would have Been lost
during braking process.
Future technologies in regenerative brakes will Include new types of
motors which will be more Efficient as generators, new drive train design
which Will be built with regenerative braking in mind, and Electric systems
which will be less prone to energy Losses.

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 ➢ Reference

1.Books Of Elements Of Machine Design

2. INTERNET ( various websites )
3. WWW.YOUTUB.COM
4. 3.WWW.WIKIPEDIYA.COM

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