D.

Y PATIL COLLEGE OF ENGINEERING

Presents
Team Predators Racing Recruitment 2022

REGENERATIVE BRAKING SYSTEM

By Group no. 7

Group Members

AJAY GIRHE (F.E ROBOTICS & AUTOMATION)

MANDAR KATOLKAR (F.E MECHANICAL)
YASH BEDAGKAR (F.E A.I.D.S)
SANCHET GULWADE (F.E ENTC)
 Table of Contents

Sr. No. Content Page No.

1 ➔ BRAKES 3
◆ Law of brakes
◆ Newton first law
◆ Pascal law
● Plugging
● Dynamic
● Regenerative

2 ➔ REGENERATIVE 4
◆ Principle
◆ Need of regenerative brakes
3 ➔ Generator 6
◆ Principle
◆ Working
4 ➔ Motor 7
◆ principle
◆ Working

5 ➔ Types of motor in regenerative

◆ Induction motor 8
● Regenerative braking of induction
motor
◆ PMSM
● PMSM in regenerative braking
◆ TRACTION MOTOR
● Traction in regenerative braking
◆ Brushless DC Motor
● BLDC motor in regenerative
braking

6 ➔ Regenerative braking efficiency 9

◆ Properties
◆ Applications
7 ➔ Conclusions 12
 Introduction

Brakes

A brake is a mechanical device that inhibits motion by absorbing energy from a moving
system. It is used for slowing or stopping a moving vehicle, wheel, axle, or to prevent its
motion, most often accomplished by means of friction.

Laws of Brakes

Newton's First Law

● Newton's first law states that if a body is at rest or moving at a constant

speed in a straight line, it will remain at rest or keep moving in a straight line
at constant speed unless it is acted upon by a force.

➔ Pascal law

● Pascal law states that a pressure change at any point in a confined

incompressible fluid is transmitted throughout the fluid such that the same
change occurs everywhere.

(i) Plugging Brakes- When the brake pedal is pressed in the electric vehicle equipped with
plugging braking, the polarity of the motors changes which in turn reverses the direction of
the motor and causes the braking.

(ii) Dynamic or Rheostat Braking- It is the type of electrical braking in which resistance
provided by the rheostat causes the actual braking, in this type a rheostat is attached to the
 circuit that provides the resistance to the motor which is responsible for deceleration or
stopping of the vehicle.

REGENERATIVE -

It is the type of electrical braking in which at the time of braking the motor which is the
main power source of the vehicle becomes the generator i.e. when brakes are applied, the
power supply to the motor cuts off due to which the mechanical energy from the wheels
becomes the rotating force for the motor which in turn converts this mechanical energy into
the electric energy which is further stored in the battery.

Regenerative braking is a unique technique that is used in EVs to capture energy that the
vehicle has due to its motion or, in other words, its kinetic energy that would have been
wasted when the vehicle decelerates or comes to a standstill while braking.

● Regenerative braking saves energy and is widely used in today’s electric vehicles.
● Tesla Model-S provides the most effective regenerative braking.
● At present, these kinds of brakes are primarily found in hybrid vehicles like the Toyota
Prius, and in fully electric cars, like the Tesla Roadster

Principle

Regenerative braking is based on the principle of physics that states that energy cannot be
destroyed; it can only be transformed from one form to another. In a traditional braking
system, pressing on the brake pedal causes a pair of brake pads in each wheel to come into
contact with the surface of a brake rotor.

Need for Regenerative Brakes

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%.

The mechanical braking system powers the hand brake or emergency brake. It is the type of
braking system in which the brake force applied on the brake pedal is carried to the final
brake drum or disc rotor by the various mechanical linkages like cylindrical rods, fulcrums,
springs etc. In order to stop the vehicle.
Generator

Principle: Electromagnetic Induction (EMI)

Faraday's Principle of Electromagnetic Induction states that the emf induced in a loop due by
a changing magnetic flux is equal to the rate of change of the magnetic flux threading the
loop.

Working

A conductor coil (a copper coil tightly wound onto a metal core) is rotated rapidly between
the poles of a horseshoe type magnet. The conductor coil along with its core is known as an
armature. The armature is connected to a shaft of a mechanical energy source such as a
motor and rotated.

Motor

Principle: Magnetic Effect of Current

When a current carrying conductor is placed in an external magnetic field it experiences a

force.

Working

The simple motor built in class uses a coil that is a temporary electromagnet. This coil gets
the force to help create torque from the electrical current supplied by the battery. The donut
magnet used in the motor is a permanent magnet, which means it has a north and a south
pole that are permanently in place.
Types of Motor in Regenerative Braking

1) Induction Motor

The motor which works on the principle of electromagnetic induction is known as

the induction motor. Electromagnetic induction is the phenomenon in which the
electromotive force induces across the electrical conductor when it is placed in a
rotating magnetic field.

Regenerative Braking of Induction Motor

When the speed of the motor is more than the synchronous speed, relative speed between
the motor conductors and air gap rotating field reverses, as a result the phase angle
becomes greater than 90o and the power flow reverses and thus regenerative braking takes
place.
2) Permanent magnet synchronous motors (PMSM)

The working of PMSM depends on the rotating magnetic field of the stator and the
constant magnetic field of the rotor. The permanent magnets are used as the rotor to
create constant magnetic flux, operate and lock at synchronous speed. These types
of motors are similar to brushless DC motors.

When the 3-phase AC supply is given to the stator, it creates a rotating magnetic field
and the constant magnetic field is induced due to the permanent magnet of the
rotor. This rotor operates in synchronism with the synchronous speed.

By using the configuration with permanent magnet, PMSM can also be used as
alternator in the cars.Due to this property Permanent Magnet Synchronous Motor is
very effective in regenerative braking.

Permanent-magnet synchronous motor is widely adopted in many fields with the

advantage of a high efficiency and a high torque density. Regenerative Braking
Systems (RBS) provide an efficient method to assist PMSM systems achieve better
fuel economy and lower exhaust emissions.

PMSM IN REGENERATIVE BRAKING

Permanent-magnet synchronous motor is widely adopted in many fields with

the advantage of a high efficiency and a high torque density. Regenerative
Braking Systems (RBS) provide an efficient method to assist PMSM system
achieve better fuel economy and lowering exhaust emissions
The simulation analysis indicates that a smooth control could be realized and
the highest efficiency and the smallest current ripple could be achieved by
Regenerative Braking Systems.
 3) Traction motors

Traction motors are powered by electricity and generate the power to rotate the wheels of
the train. The turning force produced by traction motors is transmitted to the wheels via the
driving gear unit and axle. Traction motors are typically mounted in the trucks where the
wheels are housed.

Traction in regenerative braking

In a regenerative braking system the kinetic energy is converted to electric energy by

the same traction motor which acts as a generator while braking. A part of this
regenerated energy is used by other trains which are in the power mode .

4) Brushless DC Motor

A brushless DC motor (BLDC motor) is a synchronous motor using a direct current (DC)
electric power supply. In this, the armature is fix and the magnets rotate. It uses an
electronic controller to switch DC currents to the motor windings producing magnetic fields
which effectively rotate in space and which the permanent magnet rotor follows. The
controller adjusts the phase and amplitude of the DC current pulses to control the speed
and torque of the motor.
BLDC motor in Regenerative Braking

After driving the BLDC motor and when a stopping command is given to the motor,
the motor will stop after a certain time with its own inertia. It will produce back EMF. A
regenerative braking will also be activated during this time. The regenerative braking system
will induce the back EMF. The advantages of a brushless motor over brushed motors are high
power-to-weight ratio, high speed, nearly instantaneous control of speed (rpm) and torque,
high efficiency, and low maintenance .Brushless DC motor is suitable to be implemented in
electric vehicles since it can provide high torque and is capable to do regenerative braking.
While the motor is running, back electromotive force is generated with its magnitude lower
than the DC-link voltage.

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 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 10 to 25 percent Hydraulic 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
about carbon emissions are coming to a peak, this added efficiency is becoming increasingly
important.
The main advantages of regenerative braking systems can be summarised as:

● Improved fuel economy - dependent on duty cycle, powertrain design, control

strategy and the efficiency of the individual components.
● Bmissions reduction - engine emissions reduced by engine decoupling, reducing total
engine revolutions and total time of engine operation (engine on - off strategy)
● Improved performance.
● Reduction in engine wear - engine on off strategy.
● Reduction in brake wear -reducing cost of replacement brake linings, cost of labour
to install them and vehicle down time.
● Smaller accessories - hybrid powertrain offers potential for eliminating (electric
starter) or downsizing (fuel tank) some accessories, thus partially offsetting the
increased vehicle weight and cost due to the hybrid hardware additions.
● Operating range is comparable with conventional vehicles - a problem not yet
overcome by electric vehicles.

The possible disadvantages of regenerative braking systems can be summarised as:

● Added weighthulk - extra components can increase weight, increasing fuel

consumption, offset by smaller engines operating at their best efficiency.
● Complexity - depends on control necessary for operation of regenerative braking
system.
● Cost - of components, engineering, manufacturing and installation. Mass production
would bring costs down to a more reasonable level.
● Noise - dependent on the system.
● Safety - Primary concern with any energy storage unit of high energy density. There
must be very little chance of dangerous failure during normal vehicle operation.
Passengers must be protected from risk that may be caused by the failure of the
hybrid system.
● Size and packaging constraints - most important for cars.
● Added maintenance requirement - dependent on complexity of design.
Conclusions

This study presents information about the principles and properties of regenerative
braking systems. Many automation, electromechanical, and constructive studies have been
carried out in this field in order to boost recovered energy efficiency and reduce
operating costs. Considering that most of the economic losses worldwide are caused by
mechanical wear, the importance of regenerative braking systems has become better
recognized. Safety, comfort, and economic aspects can be increased by developing these
brake systems. Regenerative braking systems, currently in limited use in electric vehicles,
can also be used in conventional braking or other motion control systems. When
They are widely used, economic input can be obtained by the reduction of mechanical
losses and energy savings can be achieved as a result of the recovered electrical energy.
In addition, vehicle emissions caused by conventional brake wear can be reduced, thus
contributing to the protection of the environment and human health. As a result, these
systems emphasise the recovery of energy, reduction of energy consumption, lowering of
costs, and provision of clean air. For this reason, more comprehensive studies in the field of
regenerative braking systems should be carried out and their findings presented to policy
makers and researchers.