Design Analysis & Fabrication of

Regenerative Braking System For

Two Wheelers

Group Members Project Guide

Mohit Singh - 14303 Dr. Sunand Kumar
Gourav Mittal - 14352 Professor
Arvind Rathore -14309 Mechanical Engineering
Shambhu - 14379 Department
NIT Hamirpur
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 CONTENTS 2

Introduction

Construction and Design

Working of RBS

Working Equations and Animation

Front ,side ,top and isometric view

Components of RBS

Project schedule

Theoretical and practical results

Graphs between peak current ,voltage with RPM

Graphs between braking distance and peak power with RPM

Working sequence

Actual fabricated model

Ansys static analysis

Actual results

Conclusions
 Why Regenerative Braking?
What is Regenerative Braking System ?
Regenerative braking means recapturing
the kinetic energy of the vehicle motion and
turning into another energy during braking.

Purpose
Commonly, kinetic energy is converted into
electric energy. This energy is stored in
storage battery and used later to power the
vehicle or Auxilaries.

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 Why Do we need RBS

Regenerative braking have the potential to improve the

fuel economy of vehicles.
The price increase of petroleum based fuel also given rise
to various research and development efforts in energy
conservation.
It reduces the emission of the vehicles.
 It may improve the fuel consumption upto 33%.
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Construction & Design
Components
1. Rotating wheel

2. Brake drums

3. paddle and
levers
4. Auxilary LEDs

5. Frame

6. Wires

7. Bearings

8. Motors

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 WORKING OF RBS
• Rotating wheel is fixed on the shaft which
is mounted on the frame Brake Rotor is
connected with wheel by means of shaft.
Brakes drums are mounted on levers in
such a manner that when brakes are
applied brake drums come in contact with
brake rotor and start rotating. These brake
rotors are contacted to motor which
convert mechanical energy into electrical
energy using the principle of faraday’s law.
Energy generated is stored in energy
storage unit generally a battery.
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WORKING ANIMATION

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Front view

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Side View

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Top view

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Isometric View

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 ANSYS STATIC ANALYSIS

Component for analysis Mesh for shaft assembly

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Shaft without deflection Total Deformation Under Normal Loading
Conditions (Scale 45:1)
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Total Stress Under Normal Loading Equivalent Elastic Strain (Scale 45:1)
Conditions ( Scale 45:1)
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Shear Stress ( Scale 45:1) Total Deformation (Scale 1:1)

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 COMPONENTS
Bicycle Wheel Friction Wheel
• Diameter = 26 inches Diameter =90 mm
• Materials = Rubber Tyre Material = mild steel
and Steel Rim

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 COMPONENTS

DC Motor Brake rotor

Diameter = 232 mm
• RPM = 100 Material = Mild Steel
• Torque= 25 N-cm

• Voltage = 12 V

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 COMPONENTS
Braking Arm Bearing No – 6203
• Material = Mild Steel Diameter OD= 42

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 ACTUAL
FABRICATED MODEL

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Brake Arm Wheel

Brake Spring
Brake
Wheel
Frame
Shaft
Bearing

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WORKING SEQUENCE
Brake Applied

Power Cut off

Motor Engages to
Brake Rotor

Mechanical Energy
to Electrical Energy

Electrical Energy
Stored

Electrical Energy
used for Auxilaries

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OBSERVATIONS

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 WORKING EQUATIONS
• Voltage V= 12V
• Torque of motor = T=25N-cm
• Tension in brake wire =T1
• Friction force = µN = µT1
• Angular Deceleration a = (µN*r+T)/Irotor
𝝎
• Stopping Time t =
a
• Energy Gained VIt =0.5*Irotor ω2
• Current I = (0.5*Irotor ω2 )/Vt
• Coefficeint Of Friction between Wheel and Rotor = 0.67

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 RESULTS

S.No RPM Peak Peak Volts Stopping Speed Braking Power

Current (v) Time Km/h Distance (Watt)
(mA) (sec) (m)

1. 50 207 30 0.8 6.12 0.8 6.21

6. 70 300 32 1 8.57 1.5 9.6

3. 80 320 35 1.2 9.8 2.0 11.2

4. 100 350 48 1.4 12.25 2.5 16.8

5. 120 388 50 2 14.70 4.1 16.9

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 Practical Results

S.No RPM Peak Peak Volts Stopping Speed Braking Power

Current (v) Time Km/h Distance (Watt)
(mA) (sec) (m)

1. 50 157 14 1 6.12 .85 2.198

2. 70 179 22 1.2 8.57 1.43 3.938

3. 80 195 23 1.5 9.8 2.04 4.485

4. 100 186 26 1.8 12.25 3.05 4.836

5. 120 200 32 2.1 14.70 4.29 6.4

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450 Peak Current vs RPM

400

350

300

250

200

150

100

50

0
50 70 80 100 120
Peak Current Ideal Peak Current Actual
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Peak Voltage vs RPM
60

50

40

30

20

10

0
50 70 80 100 120
Peak Voltage Ideal Peak voltage Actual
 Braking Distance vs RPM 28
5

4.5

3.5

2.5

1.5

0.5

0
50 70 80 100 120
Braking Distance Ideal Braking Distance Actual
 Peak Power Vs RPM 29
18

16

14

12

10

0
50 70 80 100 120
Peak Power Ideal Peak Power Actual
 7TH SEMESTER
PROJECT
Milestone 1 Milestone 3
SCHEDULE Milestone 4
Milestone 2

2017 Aug Sep Oct Nov Dec

Task 1 (Literature Review)

Task 2 (Design of Prototype)
Task 3 (Analysis of Design)
Task 4 (Fabrication)
Task 5
(Practical Obersvations)

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 CONCLUSIONS
• After fabrication of final design we performed several experiments with the project to justify
the integrity of design. After noting down the experimental results and analysing we can say
that the fabricated model is in high accordance with the designed model.
• By using regenerative braking in two wheelers we would be able to save a lot of energy and
friction wear of brake parts.
• Regenerative brake can save a good amount of energy efficiently in stop & go traffic
condition which is more common in metropolitan traffic.
• As fuel price is increasing day by day, in such situation use of regenerative brake
encourages the development of electric vehicles because it works more efficiently in such
vehicle.
• We got maximum 6.4 watt power per brake. So for an average ride of 10 Km, if we brake at a
normal rate of 5 times per km, we can get 320 Watt per ride. Which is quite beneficial for a
two wheeler.

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