Regenerative Braking
SEMINAR REPORT
Submitted by
MUHAMMED NAFRIN
REG NO. 2201021385
In partial fulfillment of the reqirement for the award of
DIPLOMA IN TECHNOLOGY
in
MECHANICAL ENGINEERING
ILAHIA POLYTECHNIC COLLEGE
PEZHAKKAPPILLY P.O.,MUVATUPUZHA -686673
2024
ILAHIA POLYTECHNIC COLLEGE
PEZHAKKAPPILLY P.O., MUVATTUPUZHA -686673
DEPARTMENT OF MECHANICAL ENGINEERING
CERTIFICATE
This is to certify that the report entitled is an authentic report of the“THE REGENRATIVE
BRAKING SYSTEM” seminar done by MUHAMMED NAFRIN (Reg No
:2201021385) discipline of MECHANICAL ENGINEERING in ILAHIA POLYTECHNIC
COLLEGE,Pezhakkappilly P.O. Muvattupuzha in partial fulfilment the requirement for the
award of Diploma in MECHANICAL ENGINEERING under the board of technical education
during the year 2021-2024.
Mr. AJIMSHA K SHAJI Mr.FAROOQUE S
Guide and Lucture Head of section
Mechanical Engineering Mechanical Engineering
INTERNAL EXAMINAR EXTERNAL EXAMINAR
ACKNOWLEDGEMENT
I wish to express my sincere gratitude to the management of ILAHIA POLYTECHNIC
COLLEGE, for providing immense facilities in our institution.
I am very proudly rendering my thanks to our Principal Mr. Suresh Kumar CT, for the
facilities and the encouragement given by him to the progress and completion of my
seminar.
I proudly render my immense gratitude to Mr. Farooque S, the Head of the Mechanical
Engineering Department, for his effective leadership, encouragement and guidance in the
seminar and extending all the facilities and his valuable help in finishing this seminar.
I would like to express our indebtedness to my guide Mr. Ajimsha k shaji, Lecturer in
Department Of Mechanical Engineering, for his valuable guidance in bringing out this
seminar.
I wish to extend our sincere thanks to all faculty members of Mechanical Engineering
Department for their valuable suggestions, kind co-operation and constant encouragement
for successful completion for this seminar.
I wish to acknowledge the help received from various departments and various individuals
during the preparation and editing stages of the manuscript.
MUHAMMED NAFRIN
ABSTACT
This seminar presents a vision-based approach for automatic gear tooth alignment aimed at
enhancing preventive maintenance processes. The method utilizes image processing techniques
to detect and analyze gear tooth positions, facilitating early identification of misalignments or
wear. By integrating computer vision with mechanical diagnostics, the proposed system offers
real-time monitoring and precise alignment adjustments, thereby improving equipment reliability
and reducing downtime. Experimental results demonstrate the effectiveness of the approach in
accurately detecting and correcting gear misalignments, highlighting its potential for enhancing
maintenance practices in industrial settings.
Table of Content_______________________
CERTIFICATE _______________________________________________________________ i
ACKNOWLEDGEMENT _______________________________________________________ ii
Introduction ________________________________________________________________ 1
History of regenerative braking system ______________________________________________________ 7
Energy Consumed in Braking ____________________________________________________________ 12
Braking Power and Energy on Rear & Front Wheels ____________________________________
10 _______________________________________________________________________________ 14
Importance of Regenerative Braking _______________________________________________________ 14
“Regenerative Braking” ________________________________________________________________ 15
Energy recovered from Regenerative Braking? ________________________________________ 17
Woking Principal of Regen ______________________________________________________ 19
When does Regen Work? _______________________________________________________ 22
• “Safety” ______________________________________________________________ 22
• Performance ___________________________________________________________ 23
• Limitations ____________________________________________________________ 23
Energy balance surrounding Regen ________________________________________________ 24
“Regen Ratio” ___________________________________________
Disadvantages of “Regenerative Braking System.” _____________________________________ 25
Fine-Tuning Commercial Regenerative Braing ________________________________________ 28
“Regenerative Braking”
Introduction
The electronic motors available in Electric and Hybrid Electric Vehicles can be
used to work as generators to alter the kinetic or potential energy of the automobile
directly into electrical energy which can be deposited in the cells of the battery and
reclaimed.
“Electric model of a Regen System”
An effectively fabricated braking agreement for an automobile should constantly
try and perform two discrete requests:
1. When emergency brakes are used; the automobile must be brought to a
complete standstill as fast as safely possible.
“Regenerative Braking”
2. The driver must have control over the automobile’s direction when using
brakes, which necessitates the stopping force to be dispersed homogenously
on all the four wheels.
History of regenerative braking system
This Technology of regenerative braking and energy conservation sounds
unbelievably pioneering for automobiles & locomotives to come up with
regenerative braking system, however a small percentage of investigation proves
otherwise.
“Regenerative Braking”
First United States patent for a regenerative electrical locomotive is believed to be,
“US
Patent 714,196: Regenerative system” developed by “Martin Kubierschky” of
“Berlin, Germany”, and it was approved in “1902”, and expected to conserve a
rather enthusiastic 45% of the traditional energy expenditure.
Versions and Patents of regenerative braking system available prior to this were not
very practical and had no real-world application: this system appears to be mostly
developed and researched around the late 1980s and 1990s.
“Regenerative Braking”
The very first regenerative braking system present on an automobile is credited to
be developed by a French man “M.A. Darracq” and showcased at the “Salon du
Cycle Show” in “Paris in 1897”.
Just like a contemporary regenerative braking system it recycled decelerating
energy back into the cells of the battery to stretch out the automobile’s driving limit
which was believed to be about “48km or 30 miles”, but it allegedly claimed a
rather astonishing 35% energy recovery which is about 3x as compared to a
contemporary equivalent like “Tesla Model 3” or “Toyota Prius.”
“Regenerative Braking”
Concept of a braking system that could seize the kinematic energy it captivates &
convert it to probable energy with minimal losses for future usage has been in the
works since late 1850s. A few preliminary endeavours of this tech was to mount
coil type regenerative braking system next to FWD (front wheel drive) cycles and
stallion-drawn carts. “Baku-Tbilisi-Batumi railway” began using “Regenerative
Braking System” in the year 1931. This is amongst the many instances of this
technology being used in an early locomotive system.
In late “1950s”, Switzerland based brand “Oerlikon” industrialized the “gyro bus”,
that used “flywheel” as an energy storing technique. The influence of ‘gyroscopic’
movement on that bus cause motion sickness which resulted in the bus being
decommissioned.
In late 1960’s the “American Motor Car Company” (AMC) produced a
“regenerative braking system” for their conceptual all-electric automobile, “the
AMC Amitron.”
“Regenerative Braking”
“Toyota” is the first global car producer to use “RBS” tech in their “Prius” line of
“hybrid cars”.
“Regenerative Braking”
“Toyota Prius”
Now, Regenerative Braking Systems have advanced enough to be employed in
virtually all hybrid and electric vehicles, and some locomotives and Elevators.
Energy Consumed in Braking
A substantial quantity of kinetic energy is spent by using brakes. Stopping a 3000
kg body from 200 kmph to absolute standstill expends around 0.32 kWh of energy
in a few meters.
This quantity of energy is used in freewheeling by overwhelming the drag from
friction due to air and road, without braking, the vehicle will travel about 2km.
“Regenerative Braking”
Graph showing all energy loses in a car moving in 3 different scenarios
When cars are moving in a urban zone with a stop and go pattern, a substantial
quantity of kinetic energy is expended from using recurrent braking, which leads to
very fast depletion of battery.
The total stopping energy of a vehicle in a standard urban zone can reach beyond
30 percent of the whole traction energy of vehicle. In big cities, like Delhi, it can
potentially reach equal to 70 percent.
It’s settled that actual “regenerative braking system” can considerably enhance the
battery consumption and fuel depletion of electric & hybrid automobiles.
“Regenerative Braking”
Braking Power and Energy on Rear & Front
Wheels
Stopping power & braking energy expended via the rear & front tyres remain
closely related to the stopping forces on the rear & front wheels. For complete
perception of the stopping power, braking energy, and stopping force expended by
both sets of wheels in a standard drive cycle proves to be very helpful in Research
and Development of regenerative braking systems.
Graph showing relationship between Braking force and Deceleration rate in various
configurations
Importance of Regenerative Braking
“Regenerative Braking”
The range of Electric automobiles and Hybrid automobiles, primarily battery
powered electric vehicle is limited by the energy left in the battery.
The most significant characteristics of any Electric Vehicle is always its capability
to recuperate the stopping/braking energy, when vehicle is deaccelerating.
The electric motor is then operated to produce the appropriate amount of braking
force for recuperating braking energy as much as possible, which can then be
stored in the battery and then re-claimed to increase the driving range and energy
efficiency of the vehicle.
“HUD of Toyota Prius”
“Regenerative Braking”
In any battery-operated EMV, the “regenerative braking system” (“Regen”) is the
alteration of the automobile’s “kinetic energy into potential energy” which is then
“Regenerative Braking”
stored in the cells of battery as chemical energy, and can be later used to power the
vehicle.
“Regen” is called a “braking system” since it additionally aids to reduce the speed
of vehicle when the driver lets go of the accelerator pedal.
The system is called “regenerative” since the energy is recollected in the cells of
the battery which can be utilized later to drive the vehicle. This results in a direct
increase in driving range and fuel efficiency of the electric vehicle.
“Regenerative Braking”
The KE present in a moving vehicle is governed by the mass and velocity of the
vehicle and can be found out using the equation;
“E = ½ mv².”
“Everything else being constant, if a car is thrice as heavy it has three times the
kinetic energy; besides if it is moving 4x as fast, it has 8x times the kinetic energy.”
Whenever a body with some mass decelerates, the KE present in the body must go
someplace.
“Regenerative Braking”
“Regenerative Braking”
If we calculate this energy goes, we’ll find that there is constantly some KE spent
from the resistance due to rolling friction, mechanical friction inside the engine,
and aerodynamic resistance due to wind and shape of your car.
These bits add up together and are the cause of energy to expire into the asphalt, the
nearby surroundings, and other moving components in a vehicle. But a large chunk
of the KE is converted into thermal energy by the braking pads whenever the driver
hits the brakes.
In EMV’s and HMV’s, “Regenerative braking System” recuperates some of the
energy that otherwise would have gone wasted in braking.
“Regenerative Braking”
Energy recovered from Regenerative Braking?
“Regenerative Braking”
The amount of energy that can be recovered depends in what way & where the person
is driving. In a power-train POV, the total energy recovered looks very promising.
Energy alteration efficacies from chemical to electrical energy in battery, Direct
current to Alternating current, electrical to motorized work, are altogether fairly high
& operate just as proficiently recurring energy back to the battery.
Larger complication here are “aerodynamic losses” at high velocity & friction due
to rotating wheels. These two works together to deaccelerate the vehicle, but these
are non-recoverable.
“Regenerative Braking”
Also, the energy conversion efficiency of Transmission is pretty good (about 80% or
so) in the conversion of battery energy to wheel energy, & the energy composes a
complete cycle returning back into the battery. So, the energy gets transformed two
times for a net efficacy of 80%.
Woking Principal of Regen
Because of the straightforwardness of the Alternating current induction motor’s
unique uni-rotating part, electrics and hybrid vehicles do not generally encounter
the compression braking of a regular IC locomotive. In its place, cutting-edge
processes in the control of motor offers comprehensive control over torque for
riding and RBS.
“Regenerative Braking”
“Torque command” is a derivative of the “throttle control.” The controller
translates “torque command” into the suitable 3 phase V and I wave-forms to
harvest the ordered torque inside motor as efficiently as possible.
“The torque command can be positive or negative.”
As soon as the torque decelerates the automobile, the energy is reimbursed to the
cells of the battery and thus we have regenerative braking.
“Regenerative Braking”
“Deconstructed Braking system”
“I must also note that the motor and controller can distribute the torque command
at any operational speed, including 0 kph. This means that we can regen the car to
a complete standstill. But as a real-world matter, the KE of a leisurely moving car
is low enough that very small amount of energy is put back into the battery as the
vehicle comes to a halt.
In fact, the last tiny bit of decelerating the vehicle down produces such a small
quantity of energy that it does not even cover the fixed losses in the motor and
inverter.”
“Regenerative Braking”
When does Regen Work?
A number of restrictions & goals are present when operating Regen. Companies are
still polishing and fine tuning the “Regen torque profile” in order to accomplish the
goals inside the limitations.
“Regen System”
• “Safety”: “Negative torque applied to the rear wheels can cause a car to
become unstable. Since regen braking is a source of negative torque, the
“Regenerative Braking”
Tesla Roadster uses the traction control system to limit regen if the rear
wheels start to slip.” Developed and verified safety feature by Tesla Motors
on a frozen lake in Sweden.
• Performance: “Regenerative braking can drastically improve the driving
experience in ways not accessible with a traditional internal combustion
engine. Driving with regen gives driver the instant positive and negative
torque command right at their toes that make the driver feel in control.”
• Limitations: “Regenerative braking is essentially inadequate once the
batteries are at 100% charge as the extra energy from regen could trigger the
voltage to climb over a safe threshold, In the particular instance the
controller will limit the amount of regen torque.
Energy balance surrounding Regen
Inside the limits of contemporary R&D, the query of assessment of regenerative
energy through electric vehicle braking and hybrid vehicle braking are of primary
importance.
“Regenerative Braking”
“Ratio between Brake pedal and Braking Torque”
Approximation of recuperated energy is rather imperative at the planning phase as
it also aids to discover what effectiveness of each arrangement in different types of
vehicles.
A pointer of efficiency of Regen for numerous “Regenerative Braking” approaches
are assessed using this method
“Regen Ratio”
“Regenerative Braking”
“In the braking process on a flat road, the vehicle’s kinetic energy and regenerative
electrical energy are calculated by the following.,”
“With,”
“Where,”
“Ek is the battery voltage, I(t) is the battery current, R(t) is the charging resistance,
V1 is the initial velocity, V2 is the final velocity.”
“Regenerative Braking”
“MATLAB model of regenerative braking system”
Disadvantages of “Regenerative Braking System.”
• Added Weight-Extra machineries can increase weight and lower the overall
engine efficiency.
• Complexity on regulator required for using the regen system.
• Upfront and maintenance cost of machineries, machining, development, and
installation is somewhat high.
“Regenerative Braking”
• Regular friction brakes are required as RBS cannot stop the vehicle in an
emergency situation.
• Needs assisted Friction Braking at high speeds and does not operate at very
low speeds.
• Safety concern with any energy storing unit of high energy density.
• Steep learning curve from using traditional braking.
Fine-Tuning Commercial Regenerative Braking
Brands have to make a couple of subjective decision as to how their regen works
and how the torque is delivered to the wheels. Some individuals prefer regenerative
braking to operate all the way to zero km/h, which brings the vehicle to a standstill
whereas some people prefer to cruise the last 5 to 8 km/h.
Virtually everybody prefers their vehicle to use regenerative braking when they
remove their foot from the throttle and on the contrary other individuals would
rather have their vehicle to cruise when they let go of the throttle. Those people
want RBS to be linked with the use of the brake pedal which makes the system a
lot less efficient.
“Most prefer the likes of more aggressive regen offered to the driver, but a few are
more comfortable with a traditional ICE like compression braking system and coast
down profile.”
“Regenerative Braking”
One day everybody will be driving battery-powered cars and RBS will prove to be
a huge chunk of what will render these cars enjoyable to use, safe, & efficient.
The renewed R&D to assimilate the power-train and braking system in order to
deliver improved grip control that can be made easier only by using electrically
powered vehicles.
Additional incorporation of “antilock braking systems” (ABS) with the torque
supervisor will permit the motor to capitalise on more braking capability of these
vehicles.
“Tesla P100D- Fastest Commercial all Electric Vehicle”
“Regenerative Braking”
References
Tesla.com
https://www.explainthatstuff.com/how-regenerative-brakes-work.html https://ct-
stem.northwestern.edu/curriculum/preview/29/1/
https://www.coursehero.com/file/36557050/HYBRID-CARS-AP-PHYSICS-pdf/
https://www.thecarpicks.com/best-brake-fluid-reviews/
https://www.tesla.com/en_AU/blog/magic-tesla-roadster-regenerative-braking
https://www.tesla.com/de_DE/blog/magic-tesla-roadster-regenerative-braking
https://www.electronicdesign.com/technologies/analog/article/21789949/motorcont
rol-more-than-just-switching-mosfets
“Regenerative Braking”
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