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, when we apply the brake, this system slow down the vehicle and the speed of wheels are in form of rotational energy that is mechanical energy, which transfer to generator where the mechanical energy is converted into electrical energy and eventually which is stored in the battery.

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GUJARAT TECHNOLOGICAL UNIVERSITY
CHANDKHEDA, AHMEDABAD
L. J. INSTITUTE OF
ENGINEERING AND TECHNOLOGY
A REPORT ON
Design of regenerative braking system for conservation of
energy
Under the Subject of
DESIGN ENGINEERING–2B. (2160001)
B.E. III, SEMESTER – VI
(MECHANICAL ENGINEERING)
Submitted by
Patel Abhishek (170320119088)
Ms. Neha B Joshi
(Faculty Guide)
Ms. Prexa H. Parikh
(Head of Department)
Academic Year
2020

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L.J. INSTITUTE OF ENGINEERING AND TECHNOLOGY
Department of Mechanical Engineering
2020
CERTIFICATE
Date:
This is to certify that the Design Engineering – 2B. Work entitled “Design of
Regenerative Braking System for Conservation of Energy”,
carried out by the group of students mentioned below under my guidance is
approved for the Degree of Bachelor of Engineering in Mechanical
Engineering (Semester - VI) of Gujarat Technological University, Ahmedabad
during the academic year 2020.
List of Students:-
Patel Abhishek (170320119088)
Guide
Ms. Neha B Joshi
Mechanical Department
L.J.I.E.T.
Head of Department
Ms Prexa H Parikh
Mechanical Department
L.J.I.E.T.

3. 3
L.J. INSTITUTE OF ENGINEERING AND TECHNOLOGY
Department of Mechanical Engineering
2020
REPORT APPROVAL CERTIFICATE
Date:
This is to certify that the Design Engineering – 2B. Work entitled
“Design of Regenerative Braking System for Conservation of Energy”, carried
out by the group of students mentioned below is approved for the Degree of
Bachelor of Engineering in Mechanical Engineering (Semester - VI) of
Gujarat Technological University, Ahmedabad during the academic year 2020.
List of Students:-
Patel Abhishek (170320119088 )
Name and Sign
Internal Examiner
Name and Sign
External Examiner

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INDEX PAGE NO
CHAPTER 1. INTRODUCTION
1.1 Introduction about team members 12
1.2 Introduction to Faculty Guide 12
1.3 Understanding about Problem definition 12
1.4 Identification of component for Problem solving 13
CHAPTER 2. LITERATURE REASEARCH
2.1 Prior Art search 14
2.2 Understanding the SCAMPER tool 14
CHAPTER 3. EMPATHY MAPPING
3.1 AEIOU Sheet and its Summary 16
3.2 Snapshot of AEIOU Summary 17
3.3 Selected Users and its Stakeholders 19
3.4 Activities of Users and its Stakeholders 19
3.5 Story Telling 19
3.6 Snapshot of Empathy Mapping 21
CHAPTER 4. IDEATION CANVASS
4.1 Explanation of People and their Activities 22
4.2 Understanding about Situation/Context and Location 22
4.3Relevant and Irrelevant Props 22
4.4 Snapshot of Ideation Canvass 24

5. 5
CHAPTER 5. PRODUCT DEVELOPMENTCANVASS
5.1 Purpose 25
5.2 Discussion on Product Experience 25
5.3 Explanation of Product Functions 25
5.4 Explanation of Product features 25
5.5 Explanation of Product Components 25
5.6 Customer Revalidation 25
5.7 Discussion of Reject, Redesign and Retain 26
Parameters
5.8 Snapshot of Product Development Canvass 27
CHAPTER 6. LEARNING NEED MATRIX
6.1 Introduction to Learning need matrix 28
6.2 Description of learning need matrix 28
6.3 Snapshot of learning need matrix 29
CHAPTER 7. MIND MAPPING
7.1 SNAPSHOT OF MIND MAPPING 30
CHAPTER 8. PROTOTYPE DESIGN
8.1 Snapshot of Prototype 31
CHAPTER 9. DESIGN CALCULATIONS
9.1 Design of electric type and hybrid type system 32
9.2 Design Analysis and Calculations 33
9.3 Cost 34
CHAPTER 10 CAD MODEL

6. 6
10.1 Picture of CAD model 35
CHAPTER 11 REFERENCES
11.1 References 37

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Chapter -1-INTRODUCTION
1.1 Introduction about Team Members
Patel Abhishek (170320119088)
1.2 Introduction to faculty guide
• Neha B Joshi
❖ Assistant Professor at L.J.I.E.T.
❖ Assistant Professor of Design subjects
❖ Experience in Design subjects over 9 Years.
❖ She has very wide knowledge in mechanical based subjects.
1.3 Understanding about problem definition
❖ Regenerative Braking System is the way of slowing vehicle by using the motor as
brakes. Instead of the surplus energy of the vehicle being wasted as unwanted
heat, the motors act as generators and return some of it to the overhead wires as
electricity.
❖ The vehicle is primarily powered from the electrical energy generated from the
generator, which burns gasoline. This energy is stored in a large battery, and used
by an electric motor that provides motive force to the wheels. The regenerative
braking taking place on the vehicle is a way to obtain more efficiency, instead of
converting kinetic energy to thermal energy through frictional braking; the vehicle
can convert a good fraction of its kinetic energy back into charge in the battery,
using the same principle as an alternator.
❖ Therefore, if you drive long distance without braking, you’ll be powering the
vehicle entirely from gasoline. Regenerative Braking System comes into its own
when you’re driving in the city, and spending a good deal of your time braking.
You will still use more fuel in the city for each mile you drive than on the
highway, though. Thermodynamics tells us that all inefficiency comes from heat
generation. For instance, when you brake, the brake pedals heat up and a quantity
of heat, or energy, is lost to the outside world. Friction in the engine produces heat
in the same way.

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❖ In most electric and hybrid electric vehicles on the road today, this is
accomplished by operating the traction motor as a generator, providing braking
torque to the wheels and recharging the traction batteries. The energy provided by
regenerative braking can then be used for propulsion or to power vehicle
accessories.
1.4 Identification of component for problem solving
❖ Brake drum
❖ Friction lining
❖ Electric generator(DC Motor)
❖ Linking Mechanism
❖ Battery

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CHAPER 2 LITERATURE RESEARCH.
2.1 Prior art research.
Prior art research is all about the existing, it is an evidence that your invention is
already is known, somehow through any medium. An existing product is the most obvious
form of prior art.
Regenerative braking system:
• Regenerative braking is an energy recovery mechanism which slows a vehicle
or object by converting its kinetic energy into a form which can be either used
immediately or stored until needed. In this mechanism, the electric motor uses
the vehicle's momentum to recover energy that would be otherwise lost to the
brake discs as heat.
Past Uses of Regenerative braking system:
• In electric railways the electricity generated by motion of wheels.
Benefits of Regenerative braking system:
• It reduces the wear and tear on the braking system
• It improves the fuel economy of the vehicle
2.2 Understanding the SCAMPER tool:-
• Scamper tool is the concept linking with the reverse engineering, as we learn
the words that it holds, it gives us the brief idea of what to use and what not.
• Thus for our product, understanding the need of the product, we showdown
the tool as shown below.
➢ Substitute:-

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• Use ultra capacitor instead of battery
➢ Combine:-
• Combine friction brake with regenerative brake and make it more efficient
➢ Adopt:-
• Can be use in cars, railways, metros etc place which works on electric system
➢ Modify:-
• Motor
• battery
• Design
➢ Put to other use:-
• In railways, bicycle, trucks, two wheels etc
➢ Redesign:-
• Redesign the efficiency of battery

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Chapter-3-EMPATHY MAPPING
3.1 AEIOU sheet and Its Summary
❖ Environment
• Pollution
• Warm atmosphere
• Traffic Jam
• Noisy
• Dusty
• Foggy
❖ Activities
• Braking the car
• Talking in group
• Driving the vehicles
• Buying the car
• Parking the car
• Servicing the car
• Appling the brake while speed braker
❖ Interaction
• Student to student
• Car owner to mechanic
• Worker to driver
• Asking for car servicing
• Visitor to owner of garage
• Owner of car showroom to buyer
❖ Objects
• Engine
• Brake
• Transmission system

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• Battery
• Motor
• Flywheel
❖ Users
• employee
• Owner
• Worker
• Residential people
• Sales man
• Visitors
• Drivers
• Businessman
• Professor
• Teacher

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3.2 Snapshot of AEIOU mapping

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3. 3 selected users and its Stakeholders
Users:
❖ Student
❖ Drivers
❖ Visitor
❖ Businessman
❖ Teacher
❖ Engineers
Stakeholders:
❖ Investors
❖ Government
❖ Engineers
❖ Dealers
❖ Vehicle manufacturer
3.4 Activities:
❖ Driving Vehicles
❖ Brake the car
❖ Servicing the car
❖ Traffic jam
❖ accident
3.5 Story Telling
• HAPPY: Once I was travelling in the village and at that time my
power was almost going to finish and in village there was no electric
pump so I used my regenerative brakes over till I could find near electric
pump.
• HAPPY: My friend wants to buy a car and now a day the petrol and
diesel car rate is rapidly increase so I suggested him to buy a electric car,
because electric car required the electricity and its cost is less compare to
petrol and diesel and also the car use the regenerative braking system so
energy form again and again while Appling the brake and it use to charge
battery of car.

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• Sad: Once my friend was going to the college with little high speed and
suddenly dog come in front of the car as the car brakes were of
regenerative brake so it was not tight like the normal brakes, so accident
occurred and car was damaged and dog was badly injured.
• Sad: A month ago, I was going out of station for business work at that
time I noticed that my regenerative brake was not working and this mad
my trip risky. So I take my car to near workshop but this concept was new
so there were no skilled workers available easily. So, I had to keep the car
back and delayed my journey.

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3.6 Snapshot of Empathy Mapping

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Chapter-4 IDEATION CANVAS
4.1 Explanation of People and their Activities:
➢ Student:
o Student came to garage for servicing.
➢ Drivers:
o Drivers came to repairing the car.
➢ Businessman:
o Businessman buy to car
➢ Worker:
o Worker doing their job.
➢ Garage owner:
o Owner taking charge of car repairing, etc
➢ Car showroom manager:
o Show the car to the buyer
4.2 Understanding about Situation/Context and Location:
❖ hot whether
❖ crowdy
❖ noisy
❖ garages
❖ foggy
❖ traffic signal
❖ roadside
❖ Workshop
❖ Speed breaker
4.3 Relevant and Irrelevant Props:
❖ Use more efficient motor

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❖ Use ultra capacitor in car
❖ Use it in petrol and diesel
❖ Use the turbo charger for fast charging

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4.4Snapshot of ideation Canvass:

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Chapter-5 PRODUCT DEVELOPMENT CANVAS
5.1 Purposes:
❖ Convert mechanical energy to electric energy
❖ Reduce the pollution
5.2 Discussion on product experience:
❖ It is good, because to store energy and we will use it whenever it require
❖ Increase the effiency to store energy
5.3 Explanation of product function:
❖ To store the energy
❖ Converting mechanical energy to electrical energy
5.4 Explanation of product features:
❖ Pollution free transportation system
❖ Don’t let the heat loss
5.5 Explanation of components:
❖ Brake drum
❖ Electric generator
❖ Transmission system
❖ Shaft
❖ Ac motor
❖ battery
5.6 Customer revalidation:
❖ Elevator withstand more weight

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❖ Make it more efficient
5.7 Discussion of Reject, Redesign and Retain Parameters:
❖ Reject: Reject battery and use capacitor for more storage
❖ Redesign: Redesign the battery

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5.8 Snapshot of product Development Canvass:

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CHAPTER 6 LEARNING NEED MATRIX
6.1 Introduction to learning need matrix
• Learning Needs Matrix will help students to identify the learning requirements at an
early stage along with prioritization of specific learning along with defined time
duration/ time allocation for each.
• Identification will be focused with listing out Syllabus based and out of syllabus
learning & skill development.
• Students identify the need of learning.
• Students easily and early identify the prioritization of specific learning need.
• Students are to identify requirements in each four dimension.
6.2 Description of learning need matrix
• Priority learning shall be taken up in Sem V of BE III (At least one from any of the
four quadrants by each student).
• By the end of BE students will be developing working model .By that time ,most of
all quadrant shall be covered under learning.
• Supportive aspects (with least priority) shall be placed in BE V.
• Discretion lies with faculty guide and students group to identify prioritization and set
learning time lies targets.
• Once product components are identified, evaluated and checked for novelty, next
important task is to identify learning requirements well in advance.

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6.3 Snapshot of learning need matrix

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Chapter 7 MIND MAPPING:
7.1 Snapshot of mind map

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CHAPTER 8 PROTOTYPE DESIGN
8.1 Snapshot of prototype:

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CHAPTER 9 DESIGN CALCULATIONS
9.1 Design of electric type and hybrid type system:
• Component used in both system:
1. Internal combustion Engine
2. Transmission
3. Electric motor

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4. Fuel tank
5. Battery pack
6. Controller
7. Brake drum etc
9.2 Design Analysis and Calculations:
➢ Here we take the data from Tesla model X, which capacity of battery between 60 to
100kWh.
➢ For instance battery pack is 100kWh.
➢ Fully charged car drive up to 200miles which means around 320km.
320km required →100kWh battery pack
1km require how many?
ANS=0.3125kWh
➢ Consider the power P= 0.3125kWh = 0.3125×1000watt = 312.5watt
➢ For find rpm of the wheel, we know the formula
k=d×rpm×0.001885
Where k=speed in km per hour
D=diameter of wheel in cm
Rpm=rotation per minute
➢ If we consider the normal speed of the car 45 km per hour and diameter of wheel
42cm then rpm will be
45=42 × 𝑟𝑝𝑚 × 0.001885
Rpm = 568.39 ≅ 570
➢ For finding the torque we know the formula
𝑃 = 2𝜋𝑁𝑇 ÷ 60
𝑇 = 60𝑃 ÷ 2𝜋𝑁

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T= (60× 312.5) ÷ (2𝜋 × 570)
T=5.235Nm
9.3 COST:
➢ Cost requires driving the car:
❖ The cost of charging is totally depends on the size of the battery pack
that you have purchase with the car
❖ Let’s assume you have 100kWh battery, with full charging of battery
you can drive it up to 320km.
❖ And in USA average national electric pricing of 13 cents per kWh,
then full charge will cost 13$(1cent=0.01$).
❖ If we use the regenerative braking system then eventually it will save
around 30-40% energy, which will store in battery
➢ Cost of the parts use in system:
Components Cost
Battery pack Around $6000-8000
Motor Around $5000-7000
Transmission system $10000

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CHAPTER 10 CAD MODEL

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CHAPTER 11 REFERENCES
[1] A. Pina, P. Baptista, C. Silva, and P. Ferro, “Energy reduction potential
from the shift to electric vehicles: The Flores island case study,”
Energy Policy, vol. 67, no. 0, pp. 37 – 47, 2014.
[2] C. Ziogou, D. Ipsakis, P. Seferlis, S. Bezergianni, S. Papadopoulou,
And S. Voutetakis, “Optimal production of renewable hydrogen based
On an efficient energy management strategy,” Energy, vol. 55, no. 0,
pp. 58 – 67, 2013.
[3] Melody L. Baglione, “Development of system analysis methodologies
And tools for modelling and optimizing vehicle system efficiency,”
Ph.D. dissertation, University of Michigan, 2007.
[4] Ali Emadi, Energy - Efficient Electric Motors. New York: Marcel
Dekker, 2005.
[5] B. H. Kim, O. J. Kwon, J. S. Song, S. H. Cheon, and B. S. Oh,
“The characteristics of regenerative energy for pemfc hybrid system
With additional generator,” International Journal of Hydrogen Energy,
vol. 39, no. 19, pp. 10 208 – 10 215, 2014.