DEPARTMENT OF EEE

REGENERATIVE BRAKING SYSTEM

SEMINAR REPORT

ADITH P S
MET’S SCHOOL OF ENGINEERING MALA
DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
 A SEMINAR REPORT ON
“REGENERATIVE BREAKING SYSTEM”

Submitted in a partial fulfilment of the requirement for the award of

diploma in

ELECTRICAL AND ELECTRONICS ENGINEERING

Presented by

Adith P S
Reg No : 20033445

Department of Electrical and Electronics Engineering

MET’S SCHOOL OF ENGINEERING

KURUVILASSERY PO, MALA, THRISSUR-680732
(2021 - 2023)
 MET’S SCHOOL OF ENGINEERING
KURUVILASSERY PO, MALA, THRISSUR-680732
(2021 - 2023)

Certificate
This is to certify that the seminar paper titled
“REGENERATIVE BREAKING SYSTEM”
Has been presented by
ADITH P S
Of fifth semester diploma in Electrical & Electronics Engineering in
partial fulfilment of the requirement for the award of diploma in
Electrical and Electronics Engineering under the Directorate of
Technical Education, Government of Kerala during the year
(2021 – 2023)

Place – Mala
Date – 22/11/2022

PROF. ALIAS. K V PROF. ALIAS. K V

Seminar Guide HOD,EEE Department
 ACKNOWLEDGEMENT

I would like to thank respected Prof. ALIAS. K V for giving me such a wonderful
opportunity to expand my knowledge for my own branch and giving me guidelines
to present aseminar report. It helped me a lot to realize of what we study for.

Secondly, I would like to thank my parents who patiently helped me as i went through
my workand helped to modify and eliminate some of the irrelevant or un-necessary
stuffs.

Thirdly, I would like to thank my friends who helped me to make my work more
organized andwell-stacked till the end.

Next, I would thank Microsoft for developing such a wonderful tool like MS Word.
It helped mywork a lot to remain error-free.

Last but clearly not the least, I would thank The Almighty for giving me strength to
complete myreport on time.
 ABSTRACT

Regenerative braking is a technology that utilizes the energy generated by a

moving vehicle and converts it into electrical energy. The purpose of regenerative
braking is to slow down the vehicle while also capturing energy that would
otherwise be lost as heat during friction-based braking. This results in several key
benefits, including increased fuel efficiency, extended battery life, and improved
performance in electric and hybrid vehicles.

In summary, regenerative braking is a key technology that offers several

advantages in terms of fuel efficiency, battery life, and overall performance in electric
and hybrid vehicles. By capturing energy that would otherwise be lost, regenerative
braking helps to reduce the environmental impact of transportation while also
providing a more efficient driving experience.
 TABLE OF CONTENTS
INTRODUCTION 1

CHAPTER – 1 2

NEED OF REGENERATIVE BRAKING 3

HISTORY OF REGENERATIVE BRAKING 4

CHAPTER – 2 5

BASIC IDEA OF REGENERATIVE BRAKING 5

WORKING PRINCIPLE OF R.B.S 6
THE MOTOR AS A GENERATOR 7
BASIC ELEMENTS OF THE SYSTEM 7
ENERGY STORAGE UNIT 7
BATTERIES 8
FLYWHEEL 8
CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 8
CONTROLLER 9
REGENERATIVE BRAKE CONTROLLERS 9
APPLICATION OF R.B.S 9
ADVANTAGES OF R.B.S 9
DISADVANTAGES OF R.B.S 10
FUTURE SCOPE 10

CHAPTER – 3 11

DIFFERENT TYPES OF REGENERATIVE BRAKING 11

ELECTROMAGNETIC 11
FLYWHEEL 11
ELECTROMAGNETIC FLYWHEEL 11
SPRING 12
HYDRAULIC 12

CHAPTER – 4 13

KINETIC ENERGY RECOVERY SYSTEM (K.E.R.S) 13

WORKING OF K.E.R.S 13
HISTORY OF KERS 14
DIFFERENT TYPE OF KERS: 16
MECHANICAL KERS: 16
ELECTRICAL KERS: 16
HYDRAULIC KERS: 17
HYDRO-ELECTRIC KERS: 17
APPLICATIONS OF K.E.R.S 17

CHAPTER – 5 18

COMPARISIONS 18
ADVANTAGES OF REGENERATIVE BRAKING OVER CONVENTIONAL BRAKING 18
ENERGY CONSERVATION: 18
WEAR REDUCTION: 18
FUEL CONSUMPTION: 18
BRAKING IS NOT TOTAL LOSS: 19
WHY REGENERATIVE BRAKES ARE ASSISTED WITH THE FRICTIONAL BRAKE ? 19
CARS AND BIKES WHICH USE REGENERATIVE BRAKING. 21

CONCLUSION 23

REFERENCES 24
 LIST OF FIGURES
Fig No Name of figures Page No
1.1 Circuit diagram of EV 10
1.2 Graphical representation of two different vehicle 11
1.3 Concept of EV with regenerative breaking by AMC 12
1.4 basic idea of regenerative braking 13
1.5 Energy flow diagram of regenerative breaking 14
1.6 Normal forward driving condition 14
1.7 Regenerative action during braking 14
1.8 Gear set-up of the KERS system 21
1.9 F1 Model racing car 23
1.10 Tesla model M 29
1.11 TATA Nexon EV 29
1.12 Ather 450x 30
1.13 eDumper (World’s largest EV) 30
1.14 Mahindra mini picup 30
Regenerative braking system Department of
EEE

INTRODUCTION
Brakes are employed to stop or retard the motion of any moving body. Thus, in
automobiles the brakes are having the most important function to perform.

In conventional braking system the motion is retarded or stopped by absorbing

kinetic energy by friction, by making the contact of the moving body with frictional rubber
pad (called brake liner) which causes the absorption of kinetic energy, and this is wasted in
form of heat in surroundings. Each time we brake, the momentum of vehicle is absorbed
that it has gained by it and to re-accelerate the vehicle we have to start from the scratch to
redevelop that momentum by using the more power from an engine. Thus, it will
ultimately result in huge waste of energy. As the basic law of Physics says ‘energy can
neither be created nor be destroyed it can only be converted from one form to another’. It
will be good if we could store this energy somehow which is otherwise getting wasted out
and reuse it next time we started to accelerate. That's the basic concept of regenerative
("regent") brakes, which provide braking for the system when needed by converting the
available energy to some usable form. These are widely used in electric trains and the
latest electric cars. Regenerative brake is an energy recovery mechanism which slows a
vehicle by converting its kinetic energy into another form, which can be either used
immediately or stored until needed. Thus, the generated electricity during the braking is
fed back into the supply system (in case of electric trains), whereas in battery electric
and hybrid electric vehicles, the energy is stored in a battery or bank of capacitors for
later use. Energy may also be stored by compressing air or in a rotating flywheel.

An Energy Regeneration Brake was developed in 1967 for the AMC Amitron. This
was a completely battery powered urban concept car whose batteries were recharged by
regenerative braking, thus increasing the range of the automobile.

Many modern hybrid and electric vehicles use this technique to extend the range of the
battery pack. Examples include the Toyota Prius, Honda Insight, the Vectrix electric maxi-
scooter, and the Chevrolet Volt.

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1. CHAPTER – 1
1.1. REGENERATIVE BRAKING SYSTEM IN EV
Regenerative braking is an energy recovery mechanism that slows down a moving
vehicle or object by converting its kinetic energy into a form that can be either used
immediately or stored until needed. In this mechanism, the electric traction motor uses the
vehicle's momentum to recover energy that would otherwise be lost to the brake discs as
heat. This method contrasts with conventional braking systems. In those systems, the
excess kinetic energy is converted to unwanted and wasted heat due to friction in the
brakes, or with rheostatic brakes, where the 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 significantly extend the life of the
braking system as the mechanical parts will not wear out quickly.

The most common form of regenerative brake involves an electric motor

functioning as an electric generator. In electric railways, the electricity generated is fed
back into the traction power supply. In battery electric and hybrid electric vehicles, the
energy is stored chemically in a battery, electrically in a bank of capacitors, or
mechanically in a rotating flywheel. Hydraulic hybrid vehicles use hydraulic motors to
store energy in the form of compressed air. In a hydrogen fuel cell powered vehicle, the
electrical energy generated by the motor is stored chemically in a battery, similar to
battery- and hybrid electric vehicles.

Fig: 1.1 Circuit diagram of EV

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1.2. NEED OF REGENERATIVE BRAKING

The regenerative braking system delivers a number of significant advantages over a
car that only has friction brakes. In low-speed, stop- and-go traffic where little deceleration
is required; the regenerative braking system can provide the majority of the total braking
force. This vastly improves fuel economy with a vehicle, and further enhances the
attractiveness of vehicles using regenerative braking for city driving. At higher speeds, too,
regenerative braking has been shown to contribute to improved fuel economy – by as much
as 20%.

Consider a heavy loaded truck having very few stops on the road. It is operated
near maximum engine efficiency. The 80% of the energy produced is utilized to overcome
the rolling and aerodynamic road forces. The energy wasted in applying brake is about 2%.
Also its brake specific fuel consumption is 5%.

Now consider a vehicle, which is operated in the main city where traffic is a major
problem here one has to apply brake frequently. For such vehicles the wastage of energy
by application of brake is about 60% to 65%.

Fig : 1.2 Graphical representation of two different vehicle

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Regenerative braking system Department of
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1.3. HISTORY OF REGENERATIVE BRAKING

The idea of a brake that could take the kinetic energy it absorbs and turn it into
potential energy for later use has been around since the late 1800s. Some of the early
attempts of this technology were to install spring type RBS on front wheel drive bicycles
or horse-drawn cabs.

The Baku-Tbilisi-Batumi railway started applying RBS in the early 1930s. This is
one example of early using of this technology in railway system.

In the 1950s, Swiss company Oerlikon developed the gyro-bus, which utilized
flywheel as its energy storage method. The effects of gyroscopic motion on the bus soon
resulted in it being discontinued.

In 1967, the American Motor Car Company (AMC) created an electrical energy
regeneration brake for their concept electric car, the AMC Amitron. Toyota was the first
car manufacturer to commercialize RBS technology in their Prius series hybrid cars.

Since then, RBSs have evolved to be used in almost all electric and hybrid cars, as
well as some gas-powered vehicles.

Fig: 1.3 Concept of EV with regenerative breaking by AMC

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Regenerative braking system Department of
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2. CHAPTER – 2
3.1 BASIC IDEA OF REGENERATIVE BRAKING
Concept of this regenerative brake is better understood from bicycle fitted with
dynamo. If our bicycle has a dynamo (a small electricity generator) on it for powering the
lights, we'll know it's harder to peddle when the dynamo is engaged than when it's
switched off. That's because some of our peddling energy is being "stolen" by the dynamo
and turned into electrical energy in the lights. If we're going along at speed and we
suddenly stop peddling and turn on the dynamo, it'll bring us to a stop more quickly than
we would normally, for the same reason: it's stealing our kinetic energy. Now imagine a
bicycle with a dynamo that's 100 times bigger and more powerful. In theory, it could bring
our bike to a halt relatively quickly by converting our kinetic energy into electricity, which
we could store in a battery and use again later. And that's the basic idea behind
regenerative brakes!

Electric trains, cars, and other electric vehicles are powered by electric motors
connected to batteries. When we're driving along, energy flows from the batteries to the
motors, turning the wheels and providing us with the kinetic energy we need to move.
When we stop and hit the brakes, the whole process goes into reverse: electronic circuits
cut the power to the motors. Now, our kinetic energy and momentum makes the wheels
turn the motors, so the motors work like generators and start producing electricity instead
of consuming it. Power flows back from these motor-generators to the batteries, charging
them up. So a good proportion of the energy we
lose by braking is returned to the
batteries and can be reused when we start
off again. In practice, regenerative
brakes take time to slow things down, so
most vehicles that use them also have
ordinary (friction) brakes working
alongside (that's also a good idea in case
the regenerative brakes fail). That's one
reason why regenerative brakes don't
save 100 percent of our braking energy.

Fig : 1.4 basic idea of regenerative braking

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Regenerative braking system Department of
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3.2. WORKING PRINCIPLE OF R.B.S

Fig:1.5 Energy flow diagram of regenerative breaking

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.

Fig 1.6: Normal forward driving condition Fig 1.7: Regenerative action during braking
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
recharge the batteries as shown in figure (1.3). Meanwhile in figure (1.4) 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

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lowering emissions. These types of brakes work effectively in driving environment such as
stop-and-go driving situations especially in urban city.

3.3. THE MOTOR AS A GENERATOR

Vehicles driven by electric motors use the motor as a generator when using
regenerative braking, it is operated as a generator during braking and its output is
supplied to an electrical load; the transfer of energy to the load provides the braking
effect.

Regenerative braking is used on hybrid gas/electric automobiles to recoup

some of the energy lost during stopping. This energy is saved in a storage battery
and used later to power the motor whenever the car is in electric mode.

3.4. BASIC ELEMENTS OF THE SYSTEM

There are four elements required which are necessary for the working of
regenerative braking system, these are:

3.4.1 Energy storage unit

 The ESU performs two primary functions
1. To recover & store braking energy
2. To absorb excess engine energy during light load operation

 The selection criteria for effective energy storage include:

1. High specific energy storage density
2. High energy transfer rate
3. Small space requirement

 The energy recaptured by regenerative braking might be stored in one of three devices:
1. An electrochemical battery
2. A flywheel
3. Compressed air

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3.4.2 Batteries
With this system as we know, the electric motor of a car becomes a generator when
the brake pedal is applied. The kinetic energy of the car is used to generate electricity that
is then used to recharge the batteries. With this system, traditional friction brakes must also
be used to ensure that the car slows down as much as necessary. Thus, not all of the kinetic
energy of the car can be harnessed for the batteries because some of it is "lost" to waste
heat. Some energy is also lost to resistance as the energy travels from the wheel and axle,
through the drive train and electric motor, and into the battery.

When the brake pedal is depressed, the battery receives a higher charge, which
slows the vehicle down faster. The further the brake pedal is depressed, the more the
conventional friction brakes are employed.

The motor/generator produces AC, which is converted into DC, which is then used
to charge the Battery Module. So, the regenerative systems must have an electric controller
that regulates how much charge the battery receives and how much the friction brakes are
used.

3.4.3 Flywheel
In this system, the translational energy of the vehicle is transferred into rotational
energy in the flywheel, which stores the energy until it is needed to accelerate the vehicle.
The benefit of using flywheel technology is that more of the forward inertial energy of the
car can be captured than in batteries, because the flywheel can be engaged even during
relatively short intervals of braking and acceleration. In the case of batteries, they are not
able to accept charge at these rapid intervals, and thus more energy is lost to friction.
Another advantage of flywheel technology is that the additional power supplied by the
flywheel during acceleration substantially supplements the power output of the small
engine that hybrid vehicles are equipped with.

3.4.4 Continuously Variable Transmission (CVT)

The energy storage unit requires a transmission that can handle torque and speed demands
in a steeples manner and smoothly control energy flow to and from the vehicle wheels.

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3.4.5 Controller
An “ON-OFF” engine control system is used. That means that the engine is “ON”
until the energy storage unit has been reached the desired charge capacity and then is
decoupled and stopped until the energy storage unit charge fall below its minimum
requirement.

3.4.6 Regenerative Brake Controllers

Brake controllers are electronic devices that can control brakes remotely, deciding
when braking begins ends, and how quickly the brakes need to be applied.

During the braking operation, the brake controller directs the electricity produced
by the motor into the batteries or capacitors. It makes sure that an optimal amount of
power is received by the batteries, but also ensures that the inflow of electricity isn't more
than the batteries can handle.

The most important function of the brake controller, however, may be deciding
whether the motor is currently capable of handling the force necessary for stopping the car.
If it isn't, the brake controller turns the job over to the friction brakes. In vehicles that use
these types of brakes, as much as any other piece of electronics on board ahybrid or
electric car, the brake controller makes the entire regenerative braking process possible.
3.5 APPLICATION OF R.B.S
 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.

3.6 ADVANTAGES OF R.B.S

 Better Performance.
 Cuts 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.

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 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

3.7 DISADVANTAGES OF R.B.S

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
why 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.
 A Regenerative braking safety is limited when the batteries storing the recovered
energy are 100 % charged. The excessive charge would cause the voltage of the
battery to rise above a safe level.
 Added maintenance – Dependent on the complexity of the design.

3.8 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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Regenerative braking system Department of
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4. CHAPTER – 3
4.1 DIFFERENT TYPES OF REGENERATIVE BRAKING
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

4.1.1 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 vehicles,
the 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 cars.

4.1.2 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

4.1.3 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

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the electromagnetic system; however, the energy is stored in a flywheel rather than in
batteries. 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.

4.1.4 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.

4.1.5 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. 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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5. CHAPTER – 4
5.1 KINETIC ENERGY RECOVERY SYSTEM (K.E.R.S)
Working of K.E.R.S

Fig: 1.8 Gear set-up of the KERS system

The flywheel has been used since prehistoric times. It utilizes the moment of inertia
to store energy by rotating. When this cylinder disc rotates, the energy it stores can be
utilized by connecting it to a medium we want to provide energy to. Commonly, flywheels
are connected to engines to provide energy to drive a machine or vehicle. They can also be
used in bicycles to recover the kinetic energy during breaking, it stores the kinetic energy
as potential energy, which can be converted back when needed. Their high efficiency can
lead to replacement of electrochemical cells for storage of kinetic energy generated during
motion or rotational energy. In our project, we are planning to apply the knowledge we
have into designing a flywheel that will be integrated into a bicycle.

The most plausible feature of the flywheel is its high-power density and storage
capacity. The development of material such as carbon fiber and light anodized aluminum
alloys has increased the power densities of the flywheels and at the same time reducing
their

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weight and amount of force required initially to overcome their stationary inertia. The use
of such materials makes it even easier to apply it to a bicycle.

Flywheels as kinetic energy recovery systems has first taken root in the formula
one industry. In 2009, the rules were changed allowing vehicles to be fitted with such
systems. This came as a relief as the manufacturers know the benefits of using flywheels in
engines and other propulsion systems. It provides continuous energy supply during
intermittent cycles in the piston firing system in the engine. Hybrid vehicles are also
rolling out the use of flywheels in the engine. This is used to complement the engine and
fuel propelled system with an extra source of energy. Since it has already been established
that the flywheel is more efficient and cheaper, the electrochemical system will be
supplemented by one or a series of flywheels.

5.2 History of KERS

The first of these systems to be revealed was the Flybrid. This system weighs 24 kg
(53 lbs) and has an energy capacity of 400 kJ after allowing for internal losses. A
maximum power boost of 60 kW (81.6 PS, 80.4 HP) for 6.67 seconds is available. The 240
mm (9.4") diameter flywheel weighs 5.0 kg (11 lbs) and revolves at up to 64,500 rpm. The
maximum torque generated at the flywheel is 18 Nm (13.3 ft-lbs), and the torque at the
gearbox connection is correspondingly higher for the change in speed. The system
occupies 13 litres of volume.
Two small accidents were reported during testing of various KERS systems in the
year 2008. The first incident happened with Red Bull Racing when the team tested their
KERS battery for the first time in July, the battery malfunctioned and accidentally caused a
fire, to avoid any causality evacuated the building. The second incident happened within a
week. A BMW Sauber mechanic got an electric shock when he touched Christian Klien's
KERS-equipped car during a test at the Jerez circuit.

Formula one has stated that they support environment friendly technology and thy
have allowed use of KERS in 2009 F1 championship. Due to the previous accidents with
KERS system many teams did not use it in their cars. Only four teams opted for KERS in
2009 session that to in few races only. Ferrari, BMW, Renault and McLaren were the fore
teams using the KERS in their cars. Due to some malfunctioning BMW and Renault
stopped using this system during the season. Vodafone McLaren Mercedes was the first
team to win a F1 GP using a KERS equipped car on July 26, 2009 at the Hungarian Grand
Prix. Lewis

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Hamilton was driving that car to become the first driver to win a pole position with a car
equipped with KERS. In that race only their car which was also equipped with KERS
finished fifth. Kimi Räikkönen won Belgian Grand Prix with KERS equipped Ferrari on
30th August 2009. This time the KERS contributed directly to race victory. Giancarlo
Fisichella who came out second in that race claimed that he was faster than Kimi
Räikkönen and Kimi only beat him because of KERS equipped car. KERS helped Kimi
win the race substantially and get the lead.

Fig: 1.9 F1 Model racing car

In 2011, though KERS was legal no team used it on a united assertion. In 2011 F1
changed the rules and increased the minimum driver and car weight limit by 20Kg and the
total weight to 4 640kg. This time FOTAteams agreed to use the
KERS devices and KERS is back in race. This time also the KERS system was options but
all the teams except three used KERS devices on their cars.

WilliamsF1 was the first to develop their own flywheel-based KERS system.
Unfortunately they could not use it in their F1 cars because of packaging issues. Thus they
developed an electrical KERS system of their own. They even set up Williams Hybrid
Power to sell their developments in the field of KERS. In the year 2012 Audi announced to
use Williams Hybrid Power in its Le Mans R18 hybrid car. By the year 2014, the power
accumulation capacity of KERS systems has increased from 80bhp to 160bhp. F1 started
using 1.6 litre V6 engines with an integration with KERS devices instead of 2.4 litre V8
engines.

In the field of motor racing Bosch Motorsport Service is a pioneer and it is

developing a KERS that can be used in motorbikes. In the year 2009 KTM racing boss
Harald Bartol announced that during the 2008 season-ending the factory raced with a
KERS

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secretly fitted to Tommy Koyama's motorcycle in 125cc Valencian Grand Prix. This use of
KERS was illegal, hence the team was banned from using that equipment in future.

5.3 Different type of KERS:

 Mechanical KERS
 Electrical KERS
 Hydraulic KERS
 Hydro-electric KERS

5.3.1 Mechanical KERS:

The mechanical KERS utilises a flywheel as a flywheel as the energy storage
device and a variable drive transmission to control and transfer the energy to and from the
driveline. 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 .

5.3.2 Electrical KERS:

Electrical kinetic energy recovery system converts the kinetic energy into
chemical energy for storage and an electric motor generator system is used as the energy
transfer and control media. The common components used in battery storage type kinetic
energy recovery system are Electric Propulsion Motor /Generator, Power Electronics –
Inverter, and the Quad Flywheel Storage. Capacitors are fundamental electrical circuit
elements that store electrical energy in the order of microfarads and helps in filtering. The
main function of a capacitor is to get charged and discharged electricity. A super-capacitor
is an upgraded version of a capacitor having special features such as long life, rapid
charging, low internal resistance, high power density, and simple charging method as
compared to capacitors and batteries.

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5.3.3 Hydraulic KERS:

Regenerative braking in vehicles using a variable displacement hydraulic
pump/motor together with a hydro pneumatic accumulator has attracted considerable
interest during the last 20–25 years. Such a system is particularly suitable for application in
city. Despite the significant gains in the efficient use of energy that the use of this system
has not attained great popularity. The added cost, which may represent 10–15% of the total
for the vehicle, is one of the major drawbacks of this system.

5.3.4 Hydro-electric KERS:

A hydraulic electric synergy system (HESS) is a hydraulic accumulator and battery
hybrid energy system. This system follows hybrid energy structure to integrate a high
specific energy battery with a high power hydraulic accumulator to get required output.
Hence it overcomes the drawbacks of a single energy storage source type KERS.

5.3.5 Applications Of K.E.R.S

 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.

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6. CHAPTER – 5
6.1 COMPARISIONS
Advantages of regenerative braking over conventional braking

6.1.1 Energy Conservation:

The flywheel absorbs energy when braking via a clutch system slowing the car
down and speeding up the wheel. To accelerate, another clutch system connects the
flywheel to the drive train, speeding up the car and slowing down the flywheel. Energy is
therefore conserved rather than wasted as heat and light which is what normally happens in
the contemporary shoe/disc system.

6.1.2 Wear Reduction:

An electric drive train also allows for regenerative breaking which increases
Efficiency and reduces wear on the vehicle brakes. In regenerative braking, when the
motor is not receiving power from the battery pack, it resists the turning of the wheels,
capturing some of the energy of motion as if it were a generator and returning that energy
to the battery pack. In mechanical brakes; lessening wear and extending brake life is not
possible. This reduces the use of use the brake.

6.1.3 Fuel Consumption:

The fuel consumption of the conventional vehicles and regenerative braking system
vehicles was evaluated over a course of various fixed urban driving schedules. The results
are compared as shown in figure. Representing the significant cost saying to its owner, it
has been proved the regenerative braking is very fuel-efficient. The Delhi Metro saved
around 90,000 tons of carbon dioxide (CO2) from being released into the atmosphere by
regenerating 112,500 megawatt hours of electricity through the use of regenerative braking
systems between 2004 and 2007. It is expected that the Delhi Metro will save over 100,000
tons of CO2 from being emitted per year once its phase II is complete through the use of
regenerative braking. 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 is that it may be able to capture as much as
half of that wasted energy and put it back to work. This could reduce fuel consumption by
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25 percent. Hydraulic regenerative braking systems could provide even more impressive
gains, potentially reducing fuel use by 25 to 45 percent.

6.1.4 Braking is not total loss:

Conventional brakes apply friction to convert a vehicle’s kinetic energy into heat. In
energy terms, therefore, braking is a total loss: once heat is generated, it is very difficult to
reuse. The regenerative braking system, however, slows a vehicle down in a different way.
6.2 Why Regenerative Brakes are assisted with the Frictional Brake.
Traditional friction-based braking is used in conjunction with mechanical regenerative
braking for the following reasons:

 The regenerative braking effect drops off at lower speeds; therefore the friction brake
is still required in order to bring the vehicle to a complete halt. Physical locking of
the rotor is also required to prevent vehicles from rolling down hills.
 The friction brake is a necessary back-up in the event of failure of the regenerative
brake.
 Most road vehicles with regenerative braking only have power on some wheels (as in
a two-wheel drive car) and regenerative braking power only applies to such wheels,
so in order to provide controlled braking under difficult conditions (such as in wet
roads) friction based braking is necessary on the other wheels.
 The amount of electrical energy capable of dissipation is limited by either the
capacity of the supply system to absorb this energy or on the state of charge of the
battery or capacitors. No regenerative braking effect can occur if another electrical
component on the same supply system is not currently drawing power and if the
battery or capacitors are already charged. For this reason, it is normal to also
incorporate dynamic braking to absorb the excess energy.
 Under emergency braking it is desirable that the braking force exerted be the
maximum allowed by the friction between the wheels and the surface without
slipping, over the entire speed range from the vehicle's maximum speed down to zero.
The maximum force available for acceleration is typically much less than this except
in the case of extreme high-performance vehicles. Therefore, the power required to be
dissipated by the braking system under emergency braking
conditions may be many times the maximum power which is delivered under acceleration.
Traction motors sized to handle the drive power may not be able to

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cope with the extra load and the battery may not be able to accept charge at a sufficiently
high rate. Friction braking is required to absorb the surplus energy in
order to allow an acceptable emergency braking performance.

For these reasons there is typically the need to control the regenerative braking and
match the friction and regenerative braking to produce the desired total braking output.

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6.3 Cars and bikes which use regenerative braking.

Fig: 1.10 Tesla model M

Fig: 1.11 TATA NEXON EV

Fig: 1.12 Ather 450x

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Fig: 1.13 Edumper (world’s largest EV)

Fig: 1.14 Mahindra mini picup

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7. CONCLUSION
The beginning of the 21st century could very well mark the final period in which
internal combustion engines are commonly used in cars. Already automakers are moving
toward alternative energy carriers, such as electric batteries, hydrogen fuel and even
compressed air. Regenerative braking is a small, yet very important, step toward our
eventual independence from fossil fuels. These kinds of brakes allow batteries to be used
for longer periods of time without the need to be plugged into an external charger. These
types of brakes also extend the driving range of fully electric vehicles. In fact, this
technology has already helped bring us cars like the Tesla Roadster, which runs entirely on
battery power. Sure, these cars may use fossil fuels at the recharging stage -- that is, if the
source of the electricity comes from a fossil fuel such as coal -- but when they're out there
on the road, they can operate with no use of fossil fuels at all, and that's a big step
forward. When you think about the energy losses incurred by battery electric hybrid
systems, it seems plausible to reason that efficient flywheel hybrids would soon become
the norm. But of course it’s not quite so black and white, and further analysis shows that a
combination of battery-electric and flywheel energy storage is probably the ideal solution
for hybrid vehicles.

As designers and engineers perfect regenerative braking systems, they will become
more and more common. All vehicles in motion can benefit from utilizing regeneration to
recapture energy that would otherwise be lost.

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8. REFERENCES

 Wikepidia.org
 Scrib.com
 wwwHowstuffswork.com
 www.seminarsonly.com
 studymafia.org
 www.123seminarsonly.com