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REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 1
CHAPTER 1
INTRODUCTION
1.1 . INTRODUCTION
Brakes are employed to stop or retard the motion of any moving body. Thus,
inautomobiles the brakes are having the most important function to perform.
In conventional brakingsystem 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 conservation of energy state that ‘energy can neither be
destroyed itcan only be converted from one form to another’. It will be good if we could
store thisenergy somehow which is otherwise getting wasted out and reuse it next time
we startedto accelerate. That's the basic concept of regenerative ("regent") brakes,which
providebraking for the system when needed by converting the available energy to some
usableform. These are widely used in electric trains and the latest electric cars.
Regenerative brakeis 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 electricand hybrid electricvehicles,
the energy is stored in a batteryor bank of capacitorsfor later use. Energy may also be
stored by compressing airor in a rotating flywheel.
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
Vectrixelectric maxi-scooter, and the Chevrolet Volt.
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 2
1.2. 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 avehicle, and further
enhances the attractiveness of vehicles using regenerativebraking for city driving. At
higher speeds, too, regenerative braking has been shownto 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%.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 in energy conservation (regenerative breaking is a conservation of
energy).It reduces the emission of the vehicles. It improved the fuel consumption by
33%.
1.3. BASIC IDEA OF REGENERATIVE BRAKE
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
insteadof 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
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 3
fail).That's one reason why regenerative brakes don't save 100 percent of our braking
energy.
 THE MOTOR AS GENERATOR
Vehicles driven by electric motorse the motor as a generatorwhen 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
Fig 1.1 motor diagram
When the electric current passes through the coil in the magnetic field produced
by the permanent magnet, the magnetic force produces a torque which turns the DC
motor. The commutator reverses the current direction after each half revolution to keep
the coil turning. To use the DC motor as a generator ,we need to replace the battery with
a load and apply a torque to the shaft. As the rotor turns, a current is generated in the coil
by the magnetic field.
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 4
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.
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 5
CHAPTER 2
LITERATURE REVIEW
2.1. INTRODUCTION
The purpose of this chapter is to provide a literature survey of past research effort
such as journals or articles related to regenerative braking and to study the new
inventions related to this topic. Moreover, review of other relevant research studies is
made to provide more information in order to understand more on this research. Current
and previous research related to the regenerative braking will be discussed in the
literature review.
2.2. LITERATURE REVIEW BASED ON REGENERATIVE BREAKING
SYSTEM
Presently what the world needs is a method or a technology that saves energy
from getting wasted. Energy Conservation is the hour of need. In case of automobiles,
energy conservation can be done by using regenerative braking Systems (rbs). When
driving an automobile, a great amount of kinetic energy is wasted when brakes are
applied, which Then makes the start up fairly energy consuming. The main aim of this
project was to develop a product that stores the energy Which is normally lost during
braking, and reuses it. The use of regenerative braking system in automobiles provides us
the Means to balance the kinetic energy of the vehicle to some extent which is lost during
the process of braking. The authors of The paper have discussed and presented two
methods of using the kinetic energy which generally gets wasted by converting it into
either mechanical energy or into electrical energy. Flywheel is used for converting the
kinetic energy to mechanical Energy. Also, electric motor is used to convert kinetic
energy into electrical energy.
Soniya.k.malode,r.h.adware et al, did an experimental investigation regenerative
braking in electrical vehicle, Regenerative braking is an most excellent way for electric
vehicle to expand their driving capabilities. The regenerative braking plays an vital part
to maintain the vehicle’s strength and getting better energy. Electric vehicle’s use
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 6
mechanical brake to boost the roughness of wheel for the deceleration purpose. However
from the point of view of saving energy, mechanical brake increase out much energy
while the EV’s kinetic energy is renewed into the thermal one. The braking system for a
vehicle is based on hydraulic braking technology. Thus, this traditional braking
methodology causes a lot of wastage of energy since it produces unwanted heat during
braking. Thus, the creation of regenerative braking has rise above these disadvantages in
addition it helps in save energy and provide higher efficiency for a car. The main aim that
has been focus on having influence on brake energy regeneration that is usable is
discussed.
Santosh bawage, prashantranjan, omarchaudhari , sasmit rai et al,did study on
regenerative braking in automobile, World today is heading towards the brink of energy
crisis. So the need of hour is to save as much energy as possible. In automobiles a lot of
energy is lost due to braking in forms of heat due to friction between brake pad and the
disc. This paper talks about a regenerative circuit which slows down the vehicle while
braking but without energy being lost as heat between disc & pads as well as road &tyres.
Further this energy is reused later to power the vehicle in electrical or mechanical form.
Clegg, S.J et al, done a review based on regenerative braking system, When a
conventional vehicle applies its brakes, kinetic energy is converted to heat as friction
between he brake pads and wheels. This heat is carries away in the airstream and the
energy is effectively wasted The total amount of energy lost in this way depends on how
often, how hard and for how long the brakes are applied. Regenerative braking refers to a
process in which a portion of the kinetic energy of the vehicle is stored by a short
termstorage system. Energy normally dissipated in the brakes is directed by a power
transmission system to the energy store during deceleration. That energy is held until
required again by the vehicle, whereby it is converted back into kinetic energy and used
to accelerate the vehicle. The magnitude of the portion available for energy storage varies
according to the type of storage, drive train efficiency, drive cycle and inertia weight. A
lorry on the momway could travel 100 miles between stops. This represents little saving
even if the efficiency of the system is 100%. City centre driving involves many more
braking events representing a much higher energy loss with greater potential savings.
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 7
With buses, taxis, delivery vans and so on there is even more potential for economy.
Since regenerative braking results in an increase in energy output for a given energy input
to a vehicle, the efficiency is improved The amount ofwork done by the engine of the
vehicle is reduced, in turn reducing the amount of prime energy required to propel the
vehicle. In order for a regenerative braking system to be cost effective the prime energy
saved over a specified lifetime must offset the initial cost, size and weight penalties of the
system. The energy storage unit must be compact, durable and capable of handling high
power levels efficiently, and any auxiliary energy transfer or energy conversion
equipment must be efficient, compact and of reasonable cost.
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 8
CHAPTER 3
BASIC ELEMENT OF SYSTEM
There are four elements required which are necessary for the working of
regenerative braking system, these are follows
3.1. Energy Storage Unit (ESU):-
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:
I. High specific energy storage density
II. High energy transfer rate
III. Small space requirement
The energy recaptured by regenerative braking might be stored in one of three devices:
 An electrochemical battery
 A flywheel
 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
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 9
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 frictionbrakes are used.
 Fly wheel
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 notable 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.
3.2. 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.
3.3. 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. 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.
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 10
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 a hybrid or
electric car, the brake controller makes the entire regenerative braking process possible.
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 11
CHAPTER 4
DIFFERENT TYPE OF REGENERATIVE BRAKING
4.1. Electric Regenerative braking:-
In an electric system which is driven only by means of electric motor the system
consists of an electric motor which acts both as generator and motor. Initially when
thewhen the system is cruising the power is supplied by the motor and when the there is a
necessity for braking depending upon driver’s applied force on the brake pedal the
electronic unit controls the charge flowing through the motor and due to the resistance
offered motor rotates back to act as a generator and the energy is energy is stored in a
battery or bank of twin layer capacitors for later use.
Fig4.1 components of electric regenerative braking system
The main component of this system are
 Engine
 Motor/generator
 Battery
 Electronic control system
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 12
Fig 4.2 showing energy consumption from battery
Fig4.3 energy store to battery by regenerative braking
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 13
During acceleration, the Motor/generator unit acts as electric motor drawing
electrical energy from the batteries to provide extra driving force to move the car
as(Shown in fig 2). With this help from the motor, the car’s internal combustion engine
that is smaller and with lower peak power can achieve high efficiency. During braking
electric supply from the battery is cut off by the electronic system. As the car is still
moving forward, the Motor/ Generator unit is acts as electric generator converting ca’s
kinetic energy into electrical and store in the batteries for later use.
4.2. Hydraulic Regenerative Brakes:-
Components as well as hydraulics to improve vehicle fuel economy. An
alternative regenerative braking system is being developed by the Ford Motor Company
and the Eaton Corporation. It's called Hydraulic PowerAssistor HPA. With HPA, when
the driver steps on the brake, the vehicle's kinetic energy is used to power a reversible
pump, which sends hydraulic fluid from a low pressure accumulator (a kind of storage
tank) inside the vehicle into a high pressure accumulator. The pressure is created by
nitrogen gas in the accumulator, which is compressed as the fluid is pumped into the
space the gas formerly occupied. This slows the vehicle and helps bring it to a stop. The
fluid remains under pressure in the accumulator until the driver pushes the accelerator
again, at which point the pump is reversed and the pressurized fluid is used to accelerate
the vehicle, effectively translating the kinetic energy that the car had before braking into
the mechanical energy that helps get the vehicle back up to speed. It's predicted that a
system like this could store 80 percent of the momentum lost by a vehicle during
deceleration and use it to get the vehicle moving again.
Bosch Rexroth has a regenerative braking system that does not require a hybrid
vehicle. In fact, it does not involve electrical storage. The Hydrostatic Regenerative
Braking (HRB) system is intended for commercial vehicles and mobile equipment. The
company says that initial measurements show that the HRB system reduces the fuel
consumption in these vehicles by up to 25%.
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 14
In the HRB system, braking energy is converted to hydraulic pressure and stored
in a high-pressure hydraulic accumulator. When the vehicle accelerates, the stored
hydraulic energy is applied to the transmission reducing the energy that the combustion
engine has to provide. An electronic controller and a hydraulic valve manifold control the
process.
At present, these hydraulic regenerative brakes are noisy and prone to leaks;
however, once all of the details are ironed out, such systems will probably be most useful
in large trucks.
Fig4.4 hydraulic regenerative braking
4.3. Fly Wheels:-
Regenerative brakes may seem very hi-tech, but the idea of having "energy-
savingReservoirs" in machines is nothing new. Engines have been using energy-storing
devicescalled flywheels virtually since they were invented.
The basic idea is that the rotating part of the engine incorporates a wheel with a
veryheavy metal rim, and this drives whatever machine or device the engine is connected
to. Ittakes much more time to get a flywheel-engine turning but, once it's up to speed,
theflywheel stores a huge amount of rotational energy. A heavy spinning flywheel is a
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 15
bitlike a truck going at speed: it has huge momentum so it takes a great deal of stopping
andchanging its speed takes a lot of effort. That may sound like a drawback, but it's
actuallyvery useful. If an engine supplies power erratically, the flywheel compensates,
absorbingextra power and making up for temporary lulls, so the machine or equipment
it'sconnected to is driven more smoothly.It's easy to see how a flywheel could be used for
regenerative braking. In somethinglike a bus or a truck, you could have a heavy flywheel
that could be engaged ordisengaged from the transmission at different times. You could
engage the flywheel every time you want to brake so it soaked up some of your kinetic
energy and brought you to a halt. Next time you started off, you'd use the flywheel to
return the energy and get you moving again, before disengaging it during normal driving.
The main drawback of using flywheels in moving vehicles is, of course, their extra
weight. They save you energy by storing power you'd otherwise squander in brakes, but
they also cost you energy because you have to carry them around all the time.
The transfer of energy in both directions (captured from the driveline during
coasting and braking, and released to the driveline for boost) is managed through a CVT
(Continuously Variable Transmission) gear box. Packaged inside a single housing is a
shaft mounted flywheel that is connected via a chain/gear or belt/pulley drive to a series
of discs and rollers (the CVT). During braking and coasting, the flywheel spools-
up(accelerates as it spins) and absorbs a storehouse of otherwise wasted energy (heat
from friction brakes). During power delivery, as the vehicle begins to accelerate, the
pent-up energy in the flywheel is released and it turns the shaft. The rollers within the
CVT can change position across the discs and either retard or augment the torque of the
spinning flywheel shaft much like a conventional step-up or step-down gear box. This
“gearing” is necessary, because unlike aircraft, and to a certain extent watercraft, which
travel at a relatively constant load and speed, earth-bound vehicles travel at regularly and
greatly varying speeds and loads as they negotiate traffic and topography. It is this
variable output velocity that allows for smooth power transmission from the flywheel to
the driveline as the vehicle travels over the roadway.
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 16
Advanced transmissions that incorporate hi-tech flywheels are now being used as
regenerative systems in such things as formula-1 cars, where they're typically referred to
as Kinetic Energy Recovery Systems (KERS).
 PROPERTY OF FLYWHEEL SYSTEM
 Compact weight and size -- The entire system (the CVT, the flywheel and the
housing) is roughly half the weight and packaging of a battery hybrid system.
 Twice as efficient -- Battery-electric structures lose kinetic potential during the
conversion of energy from mechanical to electrical to chemical, and then back
again. It’s a fundamental of the Second Law of Thermodynamics: transforming
energy from one form to another introduces losses. Battery electrics are
approximately 34 percent efficient. Flywheel drives are all mechanical and
suffer no conversion losses. Most of the energy loss that does occur comes from
normal friction between moving parts. These systems are about 70 percent
efficient.
 Lower cost -- Smaller size and weight and reduced complexity make these
arrangements about one quarter the cost of a battery-electric system.
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 17
CHAPTER 5
APPLICATIONS
Some of vehicles using regenerative brake:-
-
Fig5.1- TOYOTA PRIUS
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 18
Fig5.2 -FORD FUSION
Fig5.3 -TESLA ROADSTER
Fig5.4 -VERTIX ELECTRIC SCOOTER
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 19
Fig5.5-KERS IN F1 CARS FROM 2009
Fig5.5 -Jaipur Metro uses the Regenerative Braking System& saves 35% of Electricity.
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 20
CHAPTER 6
COMPARISON
6.1. Advantages Of Regenerative Braking Over Conventional Braking:-
 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 there fore conserved rather than wasted as heat and light
which is what normally happens in the contemporary shoe/disc system.
 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.
 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
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 21
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.
6.2. Comparison of Dynamic brakes and Regenerative brakes:-
Dynamic brakes ("rheostatic brakes" in the UK), unlike regenerative brakes,
dissipate the electric energy as heat by passing the current through large banks of variable
resistors. Vehicles that use dynamic brakes include forklifts, Diesel-electric locomotives,
and streetcars. This heat can be used to warm the vehicle interior, or dissipated externally
by large radiator-like cowls to house the resistor banks. The main disadvantage of
regenerative brakes when compared with dynamic brakes is the need to closely match the
generated current with the supply characteristics and increased maintenance cost of the
lines. With DC supplies, this requires that the voltage be closely controlled. Only with the
development of power electronics has this been possible with AC supplies, where the
supply frequency must also be matched (this mainly applies to locomotives where an AC
supply is rectified for DC motors).A small number of mountain railways have used 3-
phase power supplies and 3-phase induction motors. This results in a near constant speed
for all trains as the motors rotate with the supply frequency both when motoring and
braking.
6.3 Why Regenerative Brakes are assisted with the Frictional Brake:-
 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
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 22
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 in corporate 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
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.
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 23
CHAPTER7
CONCLUSION
The beginning of the 21st century could very well mark the final period in
whichinternal combustion engines are commonly used in cars. Already automakers are
movingtoward alternative energy carriers, such as electric batteries, hydrogen fuel and
evencompressed air. Regenerative braking is a small, yet very important, step toward
oureventual 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
acombination of battery-electric and flywheel energy storage is probably the ideal
solutionfor hybrid vehicles.As designers and engineers perfect regenerative braking
systems, they will be come more and more common. All vehicles in motion can benefit
from utilizingregeneration to recapture energy that would otherwise be lost.
REGENERATIVE BRAKING SYSTEM
Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 24
8. REFERENCE
1. PULKIT GUPTA, 2ANCHAL KUMAR, 3SANDEEPAN DEB,
4SHAYAN1Department of Electronics and Communication Engineering,
Maharaja Agrasen Institute of Technology, New Delhi, Department of
Mechanical Engineering, SRM University, Chennai, regenerative braking
systems (rbs) (future of braking systems)
2. SONIYA.K.MALODE1, R.H.ADWARE2 1 M.Tech (P.E.D) Student,
G.H.R.C.E Department Of Electrical Engineering, Nagpur, India. 2 Assistant
Professor, G.H.R.C.E, Department of Electrical Engineering, Nagpur, India.,
regenerative braking system in electric vehicles
3. Santosh Bawage1, Prashant Ranjan2, Omar Chaudhari , Sasmit Rai4
Professor, Dept. Of Mechanical Engineering, DY Patil College OF Engineering,
Akurdi, Pune, India, regenerative braking system in automobiles
4. Clegg, S.J. (1996) A Review of Regenerative Braking Systems. Working Paper.
Institute of Transport Studies, University of Leeds , Leeds, UK.

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Regenerative breaking system

  • 1. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 1 CHAPTER 1 INTRODUCTION 1.1 . INTRODUCTION Brakes are employed to stop or retard the motion of any moving body. Thus, inautomobiles the brakes are having the most important function to perform. In conventional brakingsystem 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 conservation of energy state that ‘energy can neither be destroyed itcan only be converted from one form to another’. It will be good if we could store thisenergy somehow which is otherwise getting wasted out and reuse it next time we startedto accelerate. That's the basic concept of regenerative ("regent") brakes,which providebraking for the system when needed by converting the available energy to some usableform. These are widely used in electric trains and the latest electric cars. Regenerative brakeis 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 electricand hybrid electricvehicles, the energy is stored in a batteryor bank of capacitorsfor later use. Energy may also be stored by compressing airor in a rotating flywheel. 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 Vectrixelectric maxi-scooter, and the Chevrolet Volt.
  • 2. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 2 1.2. 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 avehicle, and further enhances the attractiveness of vehicles using regenerativebraking for city driving. At higher speeds, too, regenerative braking has been shownto 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%.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 in energy conservation (regenerative breaking is a conservation of energy).It reduces the emission of the vehicles. It improved the fuel consumption by 33%. 1.3. BASIC IDEA OF REGENERATIVE BRAKE 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 insteadof 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
  • 3. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 3 fail).That's one reason why regenerative brakes don't save 100 percent of our braking energy.  THE MOTOR AS GENERATOR Vehicles driven by electric motorse the motor as a generatorwhen 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 Fig 1.1 motor diagram When the electric current passes through the coil in the magnetic field produced by the permanent magnet, the magnetic force produces a torque which turns the DC motor. The commutator reverses the current direction after each half revolution to keep the coil turning. To use the DC motor as a generator ,we need to replace the battery with a load and apply a torque to the shaft. As the rotor turns, a current is generated in the coil by the magnetic field.
  • 4. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 4 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.
  • 5. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 5 CHAPTER 2 LITERATURE REVIEW 2.1. INTRODUCTION The purpose of this chapter is to provide a literature survey of past research effort such as journals or articles related to regenerative braking and to study the new inventions related to this topic. Moreover, review of other relevant research studies is made to provide more information in order to understand more on this research. Current and previous research related to the regenerative braking will be discussed in the literature review. 2.2. LITERATURE REVIEW BASED ON REGENERATIVE BREAKING SYSTEM Presently what the world needs is a method or a technology that saves energy from getting wasted. Energy Conservation is the hour of need. In case of automobiles, energy conservation can be done by using regenerative braking Systems (rbs). When driving an automobile, a great amount of kinetic energy is wasted when brakes are applied, which Then makes the start up fairly energy consuming. The main aim of this project was to develop a product that stores the energy Which is normally lost during braking, and reuses it. The use of regenerative braking system in automobiles provides us the Means to balance the kinetic energy of the vehicle to some extent which is lost during the process of braking. The authors of The paper have discussed and presented two methods of using the kinetic energy which generally gets wasted by converting it into either mechanical energy or into electrical energy. Flywheel is used for converting the kinetic energy to mechanical Energy. Also, electric motor is used to convert kinetic energy into electrical energy. Soniya.k.malode,r.h.adware et al, did an experimental investigation regenerative braking in electrical vehicle, Regenerative braking is an most excellent way for electric vehicle to expand their driving capabilities. The regenerative braking plays an vital part to maintain the vehicle’s strength and getting better energy. Electric vehicle’s use
  • 6. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 6 mechanical brake to boost the roughness of wheel for the deceleration purpose. However from the point of view of saving energy, mechanical brake increase out much energy while the EV’s kinetic energy is renewed into the thermal one. The braking system for a vehicle is based on hydraulic braking technology. Thus, this traditional braking methodology causes a lot of wastage of energy since it produces unwanted heat during braking. Thus, the creation of regenerative braking has rise above these disadvantages in addition it helps in save energy and provide higher efficiency for a car. The main aim that has been focus on having influence on brake energy regeneration that is usable is discussed. Santosh bawage, prashantranjan, omarchaudhari , sasmit rai et al,did study on regenerative braking in automobile, World today is heading towards the brink of energy crisis. So the need of hour is to save as much energy as possible. In automobiles a lot of energy is lost due to braking in forms of heat due to friction between brake pad and the disc. This paper talks about a regenerative circuit which slows down the vehicle while braking but without energy being lost as heat between disc & pads as well as road &tyres. Further this energy is reused later to power the vehicle in electrical or mechanical form. Clegg, S.J et al, done a review based on regenerative braking system, When a conventional vehicle applies its brakes, kinetic energy is converted to heat as friction between he brake pads and wheels. This heat is carries away in the airstream and the energy is effectively wasted The total amount of energy lost in this way depends on how often, how hard and for how long the brakes are applied. Regenerative braking refers to a process in which a portion of the kinetic energy of the vehicle is stored by a short termstorage system. Energy normally dissipated in the brakes is directed by a power transmission system to the energy store during deceleration. That energy is held until required again by the vehicle, whereby it is converted back into kinetic energy and used to accelerate the vehicle. The magnitude of the portion available for energy storage varies according to the type of storage, drive train efficiency, drive cycle and inertia weight. A lorry on the momway could travel 100 miles between stops. This represents little saving even if the efficiency of the system is 100%. City centre driving involves many more braking events representing a much higher energy loss with greater potential savings.
  • 7. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 7 With buses, taxis, delivery vans and so on there is even more potential for economy. Since regenerative braking results in an increase in energy output for a given energy input to a vehicle, the efficiency is improved The amount ofwork done by the engine of the vehicle is reduced, in turn reducing the amount of prime energy required to propel the vehicle. In order for a regenerative braking system to be cost effective the prime energy saved over a specified lifetime must offset the initial cost, size and weight penalties of the system. The energy storage unit must be compact, durable and capable of handling high power levels efficiently, and any auxiliary energy transfer or energy conversion equipment must be efficient, compact and of reasonable cost.
  • 8. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 8 CHAPTER 3 BASIC ELEMENT OF SYSTEM There are four elements required which are necessary for the working of regenerative braking system, these are follows 3.1. Energy Storage Unit (ESU):- 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: I. High specific energy storage density II. High energy transfer rate III. Small space requirement The energy recaptured by regenerative braking might be stored in one of three devices:  An electrochemical battery  A flywheel  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
  • 9. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 9 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 frictionbrakes are used.  Fly wheel 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 notable 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. 3.2. 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. 3.3. 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. 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.
  • 10. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 10 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 a hybrid or electric car, the brake controller makes the entire regenerative braking process possible.
  • 11. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 11 CHAPTER 4 DIFFERENT TYPE OF REGENERATIVE BRAKING 4.1. Electric Regenerative braking:- In an electric system which is driven only by means of electric motor the system consists of an electric motor which acts both as generator and motor. Initially when thewhen the system is cruising the power is supplied by the motor and when the there is a necessity for braking depending upon driver’s applied force on the brake pedal the electronic unit controls the charge flowing through the motor and due to the resistance offered motor rotates back to act as a generator and the energy is energy is stored in a battery or bank of twin layer capacitors for later use. Fig4.1 components of electric regenerative braking system The main component of this system are  Engine  Motor/generator  Battery  Electronic control system
  • 12. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 12 Fig 4.2 showing energy consumption from battery Fig4.3 energy store to battery by regenerative braking
  • 13. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 13 During acceleration, the Motor/generator unit acts as electric motor drawing electrical energy from the batteries to provide extra driving force to move the car as(Shown in fig 2). With this help from the motor, the car’s internal combustion engine that is smaller and with lower peak power can achieve high efficiency. During braking electric supply from the battery is cut off by the electronic system. As the car is still moving forward, the Motor/ Generator unit is acts as electric generator converting ca’s kinetic energy into electrical and store in the batteries for later use. 4.2. Hydraulic Regenerative Brakes:- Components as well as hydraulics to improve vehicle fuel economy. An alternative regenerative braking system is being developed by the Ford Motor Company and the Eaton Corporation. It's called Hydraulic PowerAssistor HPA. With HPA, when the driver steps on the brake, the vehicle's kinetic energy is used to power a reversible pump, which sends hydraulic fluid from a low pressure accumulator (a kind of storage tank) inside the vehicle into a high pressure accumulator. The pressure is created by nitrogen gas in the accumulator, which is compressed as the fluid is pumped into the space the gas formerly occupied. This slows the vehicle and helps bring it to a stop. The fluid remains under pressure in the accumulator until the driver pushes the accelerator again, at which point the pump is reversed and the pressurized fluid is used to accelerate the vehicle, effectively translating the kinetic energy that the car had before braking into the mechanical energy that helps get the vehicle back up to speed. It's predicted that a system like this could store 80 percent of the momentum lost by a vehicle during deceleration and use it to get the vehicle moving again. Bosch Rexroth has a regenerative braking system that does not require a hybrid vehicle. In fact, it does not involve electrical storage. The Hydrostatic Regenerative Braking (HRB) system is intended for commercial vehicles and mobile equipment. The company says that initial measurements show that the HRB system reduces the fuel consumption in these vehicles by up to 25%.
  • 14. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 14 In the HRB system, braking energy is converted to hydraulic pressure and stored in a high-pressure hydraulic accumulator. When the vehicle accelerates, the stored hydraulic energy is applied to the transmission reducing the energy that the combustion engine has to provide. An electronic controller and a hydraulic valve manifold control the process. At present, these hydraulic regenerative brakes are noisy and prone to leaks; however, once all of the details are ironed out, such systems will probably be most useful in large trucks. Fig4.4 hydraulic regenerative braking 4.3. Fly Wheels:- Regenerative brakes may seem very hi-tech, but the idea of having "energy- savingReservoirs" in machines is nothing new. Engines have been using energy-storing devicescalled flywheels virtually since they were invented. The basic idea is that the rotating part of the engine incorporates a wheel with a veryheavy metal rim, and this drives whatever machine or device the engine is connected to. Ittakes much more time to get a flywheel-engine turning but, once it's up to speed, theflywheel stores a huge amount of rotational energy. A heavy spinning flywheel is a
  • 15. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 15 bitlike a truck going at speed: it has huge momentum so it takes a great deal of stopping andchanging its speed takes a lot of effort. That may sound like a drawback, but it's actuallyvery useful. If an engine supplies power erratically, the flywheel compensates, absorbingextra power and making up for temporary lulls, so the machine or equipment it'sconnected to is driven more smoothly.It's easy to see how a flywheel could be used for regenerative braking. In somethinglike a bus or a truck, you could have a heavy flywheel that could be engaged ordisengaged from the transmission at different times. You could engage the flywheel every time you want to brake so it soaked up some of your kinetic energy and brought you to a halt. Next time you started off, you'd use the flywheel to return the energy and get you moving again, before disengaging it during normal driving. The main drawback of using flywheels in moving vehicles is, of course, their extra weight. They save you energy by storing power you'd otherwise squander in brakes, but they also cost you energy because you have to carry them around all the time. The transfer of energy in both directions (captured from the driveline during coasting and braking, and released to the driveline for boost) is managed through a CVT (Continuously Variable Transmission) gear box. Packaged inside a single housing is a shaft mounted flywheel that is connected via a chain/gear or belt/pulley drive to a series of discs and rollers (the CVT). During braking and coasting, the flywheel spools- up(accelerates as it spins) and absorbs a storehouse of otherwise wasted energy (heat from friction brakes). During power delivery, as the vehicle begins to accelerate, the pent-up energy in the flywheel is released and it turns the shaft. The rollers within the CVT can change position across the discs and either retard or augment the torque of the spinning flywheel shaft much like a conventional step-up or step-down gear box. This “gearing” is necessary, because unlike aircraft, and to a certain extent watercraft, which travel at a relatively constant load and speed, earth-bound vehicles travel at regularly and greatly varying speeds and loads as they negotiate traffic and topography. It is this variable output velocity that allows for smooth power transmission from the flywheel to the driveline as the vehicle travels over the roadway.
  • 16. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 16 Advanced transmissions that incorporate hi-tech flywheels are now being used as regenerative systems in such things as formula-1 cars, where they're typically referred to as Kinetic Energy Recovery Systems (KERS).  PROPERTY OF FLYWHEEL SYSTEM  Compact weight and size -- The entire system (the CVT, the flywheel and the housing) is roughly half the weight and packaging of a battery hybrid system.  Twice as efficient -- Battery-electric structures lose kinetic potential during the conversion of energy from mechanical to electrical to chemical, and then back again. It’s a fundamental of the Second Law of Thermodynamics: transforming energy from one form to another introduces losses. Battery electrics are approximately 34 percent efficient. Flywheel drives are all mechanical and suffer no conversion losses. Most of the energy loss that does occur comes from normal friction between moving parts. These systems are about 70 percent efficient.  Lower cost -- Smaller size and weight and reduced complexity make these arrangements about one quarter the cost of a battery-electric system.
  • 17. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 17 CHAPTER 5 APPLICATIONS Some of vehicles using regenerative brake:- - Fig5.1- TOYOTA PRIUS
  • 18. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 18 Fig5.2 -FORD FUSION Fig5.3 -TESLA ROADSTER Fig5.4 -VERTIX ELECTRIC SCOOTER
  • 19. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 19 Fig5.5-KERS IN F1 CARS FROM 2009 Fig5.5 -Jaipur Metro uses the Regenerative Braking System& saves 35% of Electricity.
  • 20. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 20 CHAPTER 6 COMPARISON 6.1. Advantages Of Regenerative Braking Over Conventional Braking:-  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 there fore conserved rather than wasted as heat and light which is what normally happens in the contemporary shoe/disc system.  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.  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
  • 21. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 21 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. 6.2. Comparison of Dynamic brakes and Regenerative brakes:- Dynamic brakes ("rheostatic brakes" in the UK), unlike regenerative brakes, dissipate the electric energy as heat by passing the current through large banks of variable resistors. Vehicles that use dynamic brakes include forklifts, Diesel-electric locomotives, and streetcars. This heat can be used to warm the vehicle interior, or dissipated externally by large radiator-like cowls to house the resistor banks. The main disadvantage of regenerative brakes when compared with dynamic brakes is the need to closely match the generated current with the supply characteristics and increased maintenance cost of the lines. With DC supplies, this requires that the voltage be closely controlled. Only with the development of power electronics has this been possible with AC supplies, where the supply frequency must also be matched (this mainly applies to locomotives where an AC supply is rectified for DC motors).A small number of mountain railways have used 3- phase power supplies and 3-phase induction motors. This results in a near constant speed for all trains as the motors rotate with the supply frequency both when motoring and braking. 6.3 Why Regenerative Brakes are assisted with the Frictional Brake:-  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
  • 22. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 22 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 in corporate 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 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.
  • 23. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 23 CHAPTER7 CONCLUSION The beginning of the 21st century could very well mark the final period in whichinternal combustion engines are commonly used in cars. Already automakers are movingtoward alternative energy carriers, such as electric batteries, hydrogen fuel and evencompressed air. Regenerative braking is a small, yet very important, step toward oureventual 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 acombination of battery-electric and flywheel energy storage is probably the ideal solutionfor hybrid vehicles.As designers and engineers perfect regenerative braking systems, they will be come more and more common. All vehicles in motion can benefit from utilizingregeneration to recapture energy that would otherwise be lost.
  • 24. REGENERATIVE BRAKING SYSTEM Dept. of Mechanical Engineering, VAST TC, Kilimanoor Page 24 8. REFERENCE 1. PULKIT GUPTA, 2ANCHAL KUMAR, 3SANDEEPAN DEB, 4SHAYAN1Department of Electronics and Communication Engineering, Maharaja Agrasen Institute of Technology, New Delhi, Department of Mechanical Engineering, SRM University, Chennai, regenerative braking systems (rbs) (future of braking systems) 2. SONIYA.K.MALODE1, R.H.ADWARE2 1 M.Tech (P.E.D) Student, G.H.R.C.E Department Of Electrical Engineering, Nagpur, India. 2 Assistant Professor, G.H.R.C.E, Department of Electrical Engineering, Nagpur, India., regenerative braking system in electric vehicles 3. Santosh Bawage1, Prashant Ranjan2, Omar Chaudhari , Sasmit Rai4 Professor, Dept. Of Mechanical Engineering, DY Patil College OF Engineering, Akurdi, Pune, India, regenerative braking system in automobiles 4. Clegg, S.J. (1996) A Review of Regenerative Braking Systems. Working Paper. Institute of Transport Studies, University of Leeds , Leeds, UK.