VISVESVARAYA TECHNOLOGICAL UNIVERSITY

Jnana Sangama Belgaum -590018,Karnataka

A Project Phase - 1 Report

On

Regenerative Braking for 4 wheel System

Bachelor of Engineering
in
Mechanical Engineering
by

SAMARTH M V 1DB18ME052
RITHWIK RANJAN SHETTY 1DB18ME048
VISHNU RAJ B Y 1DB18ME071
LEO RUBAN 1DB19ME010

Under the Guidance of

Dr. SHIVANNA.
Head of Department

Department of Mechanical Engineering

Don Bosco Institute of Technology

Department of Mechanical Engineering

Don Bosco Institute of Technology
Kumbalagodu, Mysore Road, Bangalore-560 074
2022-2023
 DON BOSCO INSTITUTE OF TECHNOLOGY
Kumbalagodu, Mysore Road, Bangalore-560 074

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

Certified that the work Project Phase - 1 report entitled Regenerative Braking for 4

wheel System carried out by Samarth M V(1DB18ME052),Rithwik Ranjan Shetty

(1DB1ME048), Vishnu Raj BY(1DB18ME71),Leo Ruban (1DB19ME010) are bonafide
students of Don Bosco Institute of Technology, in partial fulfilment for the award Bachelor
of Engineering in Mechanical Engineering of Visvesvaraya Technological University,
Belgavi,during academic year 2021-2023. It is certified that all corrections/suggestions
indicated for Internal Assessment have been incorporated in the report deposited in the
departmental library. The project report has been approved as it satisfies the academic
requirements in respect of project work prescribed for the said degree.

Dr. Shivanna Dr. Shivanna Dr. Nagabhushana B S

Project Guide Head of Department Principal

External Viva

Name of the Examiners and Signatures with date

1.

2.
 DECLARATION

We the undersigned solemnly declare that the Project Phase - 1 report is based on our
work carried out during the course of our study under the supervision of Dr.Shivanna
We assert the statements made and conclusions drawn are an outcome of our research
work. We further certify that, the work contained in the report is original and has been done
by us under the general supervision of our supervisor.
The work has not been submitted to any other Institution for any other
degree/diploma/certificate in this university or any other University of India or abroad.
We have followed the guidelines provided by the university in writing the report.
Whenever we have used materials (data, theoretical analysis, and text) from other sources, we
have given due credit to them in the text of the report and giving their details in the
references.

Sl.N
USN NAME SIGNATURE
o
1DB18ME052 SAMARTH M V
1

1DB18ME048 RITHWIK RANJAN SHETTY

2

1DB18ME071 VISHNU RAJ B Y

3

1DB19ME010 LEO RUBAN

4
 AKNOWLEDGEMENT

It is my duty and privilege to acknowledge the support I received from several people in
preparation of this report. It would not have been possible to prepare this report without their
valuable help and guidance.

First and foremost, I thank Management and our beloved Principal, Prof. Nagabushan B S
Don Bosco Institute of Technology, Bangalore for his constant support and encouragement.
My sincere thanks to DR. SHIVANNA, Head of the department of Mechanical Engineering,
DBIT, for his valuable support and guidance.

I express my sincere gratitude to my guide Dr. Shivanna, Department of Mechanical

Engineering, DBIT, Bangalore for guiding me and numerous discussions with him were very
helpful. We thank him for the guidance, encouragement and inspiration received from him.

Last but not least, I wish to thank my parents for financing my studies in this college and
constantly encouraging me to learn. Their personal sacrifice in providing the opportunity to
learn is greatly acknowledged.

Place: Bengaluru
 ABSTRACT

As in today’s world, where there are energy crises and therefore the resources are
depleting at a better rate, there's a requirement of specific technology that recovers the
energy, which usually gets wasted. So, just in case of automobiles one among these useful
technologies is the regenerative braking system. Regenerative braking is an energy
recovery mechanism that slows a vehicle or object by converting its Kinetic Energy (K.E)
into a form which will be either used immediately or stored until needed. Using
regenerative braking systems in automobiles enables us to recover the K.E. of the vehicle
to some extent that's lost during the braking process. The converted K.E. is stored for
future use or is fed back to the facility system of the vehicle. This energy is often stored
during a battery or bank of capacitors for later use. Energy also can be stored with the
assistance of a rotating flywheel which is one among the foremost inexpensive and
effective methods of storing and regenerating power. The present invention provides an
energy-storing regenerative braking system by transmitting the flywheel force as a torque
tending to oppose the forward rotation of a wheel on applying the brakes.
A brake-pad assembly, mounted concentrically with the hub of a ground-engaging wheel,
is actuated upon braking to supply frictional engagement between the hub and clutch
mechanism, while applying a decelerating torque to the wheel. The special braking
mechanism is selectively held in position by a rider-controlled clutch mechanism, to
accumulate energy over several braking events. Vehicles driven by electric motors use the
motor as a generator when using regenerative braking and its output is supplied to an
electrical load. The transfer of energy to the load provides the braking effect and
regenerates power.
 CONTENTS
Chapter Topic Name Page
No. No.
1 Introduction 7

2 Objective 8

3 Literature Review 9-11

4 Methodology 12-14

5 Scope of project 15

6 Cost Estimation 16

7 Present Status 17
1. Introduction

● In recent years, there has been a lack of reliable alternative energy sources. Increasing
efficiency and reducing exhaust gas emissions has become one of the key areas of
focus in modern automotive research.
● 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.
● Energy recovery technology can significantly bring down the energy consumption of
electrified vehicles particularly in urban operated routes.
● Regenerative braking recovers some of the kinetic energy that would otherwise turn
into heat and instead converts it into electricity. In this system, the motor drives the
wheels during acceleration or cruising, but the wheels drive the motor while
decelerating
2. Objective

• Demonstrate the use and general working principle of regenerative braking system
using a 4-wheel system.
• To control the speed of the vehicle as well as to stop it quickly and efficiently without
sticking.
• To show how regenerative braking behaves at different speeds and show how it is
more efficient at high-speed conditions.
• To demonstrate the various advantages of regenerative braking like less wear on brake
components, increased fuel economy, efficiency, environment friendly nature and its
use outside the automotive industry.
 3. Literature Review

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, 1881-84.

In this paper [17] a test bench for testing of regenerative braking capability of a

Brushless DC Motor is design 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.

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), 736-39.

In this paper [18] the advantages of regenerative braking system over

conventional braking system have 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 movies at high speeds builds up lots of kinetic
 energy, so they conserve energy more efficiently. It has broad scope for further

advancements and the energy conservation.

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). 2229-5518

In this paper [19] 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 increase performance, using super capacitor also improves the

conversion rate of energy in regenerative braking system, making the automobile

compact also tends to increase the efficiency of the system.

4.Jagadeesh Vikram, D. Mohan Kumar, Dr. P. Naveen Chandra,

‘Fabrication of Regenerative Braking System’, International Journal of Pure and

Applied Mathematics Volume 119, (2018).

In this paper [20] the Fabrication process on the Regenerative Braking System had

been implemented as per the prescribed measures has been taken and the future

enhancements should be processed on basis of the need of the study. The

Implementation of the regenerative braking system be quite essential in automotive

transportation with maximized performance in braking.

5.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).
2395-4396,
In this paper [21] 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

high temperature range and are efficient as compared to conventional braking

system. 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 braking process. The use of more efficient

systems could lead to huge savings in the economy of any country.

4. Methodology
Block Diagram
● In ‘Fig a’ we can see drive condition. Here the battery (energy sink) is powering the
Motor which drives the vehicle. Energy is moving in forward direction.

• In ‘Fig b’ we can see regenerative braking system in action. Here the kinetic energy
produced under braking is converted to electric energy and fed back to the battery for
future use. Here the motor is working in reverse condition making it a generator.
Energy is moving in reverse direction.

Fig a

Fig b
Components
Name Function/Specification
Main Frame We are using L angle Mild steel bars for the main frame.
Main frame will support all the other components and act as
chassis.

Shaft We are using 16mm Mild Steel bar as shaft which will act as
the driving axle.

Wheel We will be using 14-inch wheels.

Motor/Generator We will be using 12v DC motor which will be used to drive

the vehicle in forward direction and generate energy in
reverse direction

Power Supply We will be using 12v, 4.5 AH battery to match the power
requirements of the motor. Battery will be used as the energy
sink. It will power the vehicle in forward direction and store
energy in reverse direction.

Braking Mechanism We will be using pedal brakes to perform the braking action

Rectifier We will be using a bridge wave rectifier to convert AC

current produced by the generator into DC current. It is a
part of the control electronics.

Diode We will be using a IN4007 3-amp diode. It is also a part of

the control electronics. Function diode is to make sure
current flows in one direction.
5. Scope of the Project
● Successfully demonstrate the working of regenerative braking system using 4-wheel system.
● Successfully demonstrate how regenerative braking improves efficiency and saves
energy.
● Explain the various uses of regenerative braking in automotive industry and outside it.

Future Scope of the project

● Make a more efficient system that can save more wasted kinetic energy.
● Make a regenerative braking system that can function independently without friction
braking.
● Use ultracapacitors and complex flywheels as energy sink for much higher efficiency.
6. Cost Estimation

Name Price in ₹

Main Frame, Shaft, Brakes and Wheels 6000

Battery and Motor 3500-4000

Control Electronics and Wiring 1500

Labour (welding and cutting) and 2000

travelling

Miscellaneous and Safety Budgeting 2000-2500

Total 15000-16000
7. Present Status
● We are currently finalizing the design.

● We have acquired most of the necessary parts which are design independent.

● We have found a few prospective places for cutting and welding processes to make
the mainframe.