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CHAPTER 1
INTRODUCTION
The objective of this the design and manufacture of an electric Bicycle with
regenerative braking. The intention behind this was to show that regenerative braking
is a cost effective way to increase the range of an electric Bicycle in an urban setting.
This developed a platform to demonstrate the range extension available through
regenerative braking. Although this platform has not yet yielded measurable results,
this test bed will serve as a starting point for future students to optimize regenerative
braking systems.
Global warming are becoming major problems in the current scenario.
Therefore people try to move towards clean energy. Transportation is one of the
source of pollution or global warming because bike or any type of vehicle work on
fuel (petrol, diesel)it burn and produce harmful gases in air due to that pollution is
increases and this source of energy is imitate therefore today’s need to move other
clean source of energy for transportation. That free from pollution and it easily
available. Electrical bike is one of the ways to reduce this type of problem. Electrical
bicycle called as e-bike. In the 1890s, electrical bicycles were documented within
U.S. Patents. On 31 December 1895, ogden bolton jr. was granted u. sparten
552,271foe battery power bicycle with “6-pole brush –and commutator direct current
(dc) hub motor mounted in the rear wheel”. There were no gears and the motor up to
100 amperes from a 10-volt battery. This type of e-bike is modified day by day but
this is also having some limitation just like it having charging by externally .if the
battery discharge in travelling it create problem that means it use for small distance
only. So some modification required in the design of e-bike. This modified design is
cheap for the common people in our country afforded to buy it.
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REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE
Fig. 1.1 Introduction of regenerative braking with self-power generating electrical bicycle
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CHAPTER 2
LITERATURE REVIEW
2.1 Literature review
C. Abagnalea, M. Cardoneb*, P. Iodicea, R. Marialtoc, S. Stranoa, M. Terzoa, G.
Vorraro aDepartment of Industrial Engineering, University of Naples Federico
II, [1] A new model of power-assisted bicycle has been designed, set up and tested.
The main innovative solutions for the pedelec prototype are described in the present
paper: the electric motor position; the new mechanical transmission; the low cost
measurement system of the driving torque; the special test rig. Differently from a
common approach, in which the electric motor is located on one of the three hubs of
the bicycle, the idea of the pedelec prototype consists of an electrical motor in the
central position that, by means of a bevel gear, transmits the torque on the central hub.
The other innovative solution is represented by the motion transmission from the
motor to the pedal shaft, achieved by two different gearboxes: the first one is a
planetary gearbox and the second one is a simple bevel gear. The pedelec prototype
contains also a new low cost measurement system of the driving torque based on a
strain gauge load cell located on one side of the rear wheel, between the hub and the
frame. Moreover, a commercial cycling simulator has been suitably modified in order
to properly install the different sensors for the measurement of the performance of the
pedelec. The test rig is able to reproduce an aforethought route or paths acquired
during road tests, to measure the performance of the e-bike in terms of instantaneous
power and speed. The experimental test rig can simulate the resistant torque of a
predetermined track and it aims to test and to optimize the control strategy available
on the electronic control unit. The authors have also conducted an environmental
analysis of the developed pedelec, in particular comparing the e-bike with a thermal
moped, in terms of environmental impact.
Ilyas Hussain1, AdithyaKumar2, Srirenga Venkatesh3, Satheesh Kumar4,
Pragatheeshwarar5 1Assistant Professor, 2,3,4,5B.E. Students,
1,2,3,4,5Department of Mechanical Engineering, Karpagam College of
Engineering, [2] The frequent news about the extinction of fossil fuels has increased
the importance of usage of electricity in the future. Electric bikes will be utilized to a
greater extent. Office going people and people who travel moderate distances will be
benefitted from the electric bike. The electric bike contains motor to help the vehicle
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move forward and various power sources are being used. The batteries provide power
to the motor and the motor drives the vehicle. When the battery is fully discharged the
battery is recharged again by using a battery charger. In this project, we have used a
DC motor/generator attached to the rear wheel of the bicycle. Two sets of batteries
are connected to the setup such as A and B. When one of the batteries gets discharged
another battery will provide the power required. During that time, the rotation of the
wheel rotates the shaft of the dc motor/generator which produces an output of voltage.
This voltage helps in the charging of the battery thus by increasing the mileage of the
electric bike.
Sachin Chouhan, Sanjiv Kumar, Krishna Veer Choudhary, Kuldeep Singh &
Mr.Vivek Sharma (Assiastant Professor) Department of Electrical Engineering,
SKIT, Jaipur[3] 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 auto mobile, a great amount of kinetic energy is wasted when
brake are applied, which then makes the startup fairly energy consuming. The main
aim of this project waste of develops a product that stores the energy which is
normally lost during braking, and reuses it. The use of regenerative braking system in
auto mobiles provides us the means to balance the kinetic energy of the vehicle to
some extent which is lost during the process so 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 use to convert Kinetic Energy into electrical energy.
Mr. Mragank Sharma1, Anshul Verma2, Gaurav Tiwari3, Sunny Singh4, Mohd
Nadeem5 Assistant Professor1, UG Scholar2, 3, 4, 5 Department of Mechanical
and Automation Engineering Amity University, Lucknow, India[4] The constant
global hunt to store the energy and convert it into other useful form since the need of
development of new technologies and system to explore in new way as in an electric
bike great amount of kinetic energy lost into the atmosphere during breaking in the
form of heat energy due to friction between brake shoe and the break drum .This
paper presents a way to design and fabrication of regenerative electric bike using
regenerative braking system. Regenerative braking refers to a process in which a
portion of the kinetic energy of the bike is stored for a short term by the storage
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REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE
system. To gain the power, we assemble the brushed dc motor, l-clamp iron bar and
frictional pulley clamp above the hub of front pulley. As we apply brake, system
actuated as the frictional pulley meshed with the centre hub of wheel which rotates
frictional pulley in opposite direction of the wheel due to which the armature of dc
motor rotates and convert mechanical work into useful electrical energy (charge)
which is stored in the battery. Additional energy increases the discharging time of
battery so that electric bike can move long distance. Hence efficiency of the bike is
improved. In present time, some elevator/lift systems use regenerative braking also.
Pierfrancesco Spagnol, Matteo Corno, Roberto Mura and Sergio M. Savaresi
Electrically Power Assisted Cycles (EPACs) have been gaining attention as an
efficient and clean means of transportation. In this work, the concept of full hybrid
bike presented in previous research is further developed by introducing a charge
sustaining strategy. The main idea is to consider the load-dependent efficiency of the
cyclist and let the electric motor assist the cyclist in low efficiency regions while
letting the cyclist recharge the battery in high efficiency regions. To this end a State-
of-Charge (SoC) controller is designed. Its tuning is analyzed and compared in terms
of efficiency and feeling against the acausal strategy available in the literature.
2.3 OBJECTIVES
The objective of the present work is to develop a new rollover carwash based
on an existing machine, and to build/test an operational prototype based on a new
structural design while keeping costs minimized. The redesign of the new rollover is
to accomplish a series of objectives for the respective company.
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REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE
CHAPTER 3
SYSTEM DESIGN
3.1 Method of Manufacturing Process
This chapter will cover the details explanation of methodology that is being
used to make this project complete and working well. Many methodology or findings
from this field mainly generated into journal for others to take advantages and
improve as upcoming studies. The method is use to achieve the objective of the
project that will accomplish a perfect result. In order to evaluate this project, the
methodology based on System Development Life Cycle (SDLC), generally three
major step, which is planning, implementing and analysis.
This final year project used three major steps to implement project starting
from planning, implementing and testing. All the methods used for finding and
analyzing data regarding the project related.
3.2 Planning
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REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE
Data collection is a stage in any area of study. At this stage I planned about the
projects resources and requirements, literature studies and schedule to get more
information in this study. All the materials are collected from journal, texts book and
research papers gathered from libraries and Internet.
Within the data collection period I have found the study about the Automatic
car parking in the Internet and do some research about the project related. Once I got
the project manual, I tried to find out the electronic component and other materials
and some of equipment to be used.
While planning, I have done the research about the project related, which
including with study about the mechanical & civil components such as Rack &
Pinion, Round pipe, DC gear motor, microcontroller kit etc. The study is not just for
the function of the component but the types of small circuit build by each component
related.
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REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE
1. Cutting.
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REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE
2. Drilling.
3. Grinding.
4. Tapping.
5. Welding.
6. Finishing.
7. Hammering.
Cutting operation is done for to cut the pipes for making an cylinder and
condenser is a required dimensions from it. The power hacksaw is used to cutting
purpose of pipe and also we required cutting operation through power hacksaw for
cutting of air receiver material so as to make receiver and condenser. The material of
air receiver and condenser is mild steel. So it does required additional stress for
cutting operation.
Fig.3.3.1 Cutting
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REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE
multipoint. The bit is passes against the work piece and rotated inside the work piece
so as to produce a drill on it. The most important type of drill is the twist droll.
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REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE
Welding
Arc welding is one of several fusion processes for joining metals. By applying
intense heat, metal at the joint between two parts is melted and caused to intermix -
directly, or more commonly, with an intermediate molten filler metal. Upon cooling
and solidification, a metallurgical bond is created. Since the joining is an intermixture
of metals, the final element potentially has the same strength properties as the metal
of the parts. This is in sharp contrast to non-fusion processes of joining (i.e. soldering,
brazing etc.) in which the mechanical and physical properties of the base materials
cannot be duplicated at the joint.
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REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE
Equipment
The equipment for the shielded metal arc welding process consists of a power
source, welding leads, electrode holder, and work clamp or attachment. A diagram of
the equipment is shown below.
The fixture assembly that brings all of the system together. These come in a
variety of configurations, vertical, horizontal, freestanding, or mobile cart.
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REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE
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REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE
refer to a range of human activity from handicraft high tech, but it most commonly
applied to the industrial production, in which the raw material are transformed into
finished goods on a large or small scale. Such finished goods may be used for
manufacturing other, more complex products, such as aircrafts, household appliances
or automobiles, or sold to wholesaler, who in turn sells them to retailers, who then sell
to end users (customers). The manufacturing sector is closely connected with
engineering and industrial design.
1. Cutting.
2. Drilling.
3. Grinding.
4. Tapping.
5. Welding.
6. Finishing.
7. Hammering.
Cutting operation is done for to cut the pipes for making an cylinder and
condenser is a required dimensions from it. The power hacksaw is used to cutting
purpose of pipe and also we required cutting operation through power hacksaw for
cutting of air receiver material so as to make receiver and condenser. The material of
air receiver and condenser is mild steel. So it does required additional stress for
cutting operation.
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REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE
Arc welding is one of several fusion processes for joining metals. By applying intense
heat, metal at the joint between two parts is melted and caused to intermix - directly,
or more commonly, with an intermediate molten filler metal. Upon cooling and
solidification, a metallurgical bond is created. Since the joining is an intermixture of
metals, the final element potentially has the same strength properties as the metal of
the parts. This is in sharp contrast to non-fusion processes of joining (i.e. soldering,
brazing etc.) in which the mechanical and physical properties of the base materials
cannot be duplicated at the joint.
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REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE
Fig.3.5.1 Welding
Equipment
The equipment for the shielded metal arc welding process consists of a power
source, welding leads, electrode holder, and work clamp or attachment. A diagram of
the equipment is shown below.
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CHAPTER 4
ASSEMBLY & WORKING PARAMETER
4.1 DESIGN AND DEVELOPMENT
The design and development process of the roll cage involves various factors;
namely material selection, frame design, cross-section determination and finite
element analysis. The details of each step are given below.
A. Material Selection
As per the constraint given in the rulebook, the roll cage material must have at
least 0.18% carbon content. After an exhaustive market survey, the following
materials which are commercially available and are currently being used for the roll
cage of an Bicycle are shortlisted. A comparative study of these shortlisted materials
is done on the basis of strength, availability and cost. The shortlisted materials are as
follows.
4.2.1 CHASSIS
1. Design
To begin the initial design of the frame, some design guidelines were
required to be set. They included intended transmission, their placement, mounting of
motor, design features and manufacturing methods.
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REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE
FABRICATION
From the results of the above tests it is concluded that the roll cage is safe under
severe conditions. After the static analysis of the roll cage, material procurement was
done. Total 7 tubes of 6m length each were procured at a cost of Rs.5000. The cost
per kg was Rs.70. The material was cut and machined to required dimensions. Rail
cutter available in the workshop was used to serve the purpose. After analysing the
material joining techniques available in the college workshop, metal arc welding was
selected. All the members of the roll cage can be joined by this technique. The
advantages of this welding technique are as follows:
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REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE
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REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE
Fig. 1. DC Motor
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Generator
Fig. 6. Regenerator
6V to 24V converter.
Description.
There are many instances where we require 24V DC from a 6V source. I also
once faced a situation like this when I decided to fit a small transistorized stereo
amplifier which operated from 24V DC in my car. I found this circuit to be well
enough for my application. This circuit can produce a steady 24C DC output and can
deliver up to 800mA of output current. The circuit is basically a dc converter built
around LM324 IC which is configured as an oscillator to produce the switching
frequency and a transistor as the semiconductor switching element.
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REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE
IC1 LM324 is the heart of this circuit. LM324 is a quad opamp and out of the four
operational amplifiers inside it, only two is used here. IC1a, resistors R1, R2, R3 and
C1 forms a oscillator which operates at around 500Hz. Resistor R2 and capacitor C1
is used to set the oscillator frequency. IC1b is wired as a comparator which compares
the output voltage with a reference and feeds back a voltage to the oscillator stage.
This is done for controlling the output voltage. Potential divider using preset R5 is
connected to the non-inverting pin of IC1. The output voltage is connected to the
inverting input pin through a 100K resistor. Output of this comparator stage is fed to
the non-inverting input pin of IC1a through another 100K resistor. Output of the
oscillator stage is connected to the base of transistor Q1 and resistor R7 is used for
limiting the base current of Q1.
When the output of the oscillator stage is high, transistor Q1 will be switched
ON and the current through the inductor L1 starts to increase. When the output of
oscillator goes low, transistor Q1 will be switched OFF and now the only path for the
inductor current is through diode D2, capacitor C3 and the load if any. The fly back
diode D2 will be forward biased and the energy stored in the inductor during the ON
state will be dumped into the capacitor. Diode D1 acts as a freewheeling diode.
An inductor will always try to oppose any variation in the current passing
through it and this property of the inductor is utilized here. When charged it stores
energy and when discharged it behaves like an energy source. The voltage it outputs
during the discharge phase is proportional to the rate of change of current through it.
As the switching frequency increases the induced emf (electro motive force) from the
inductor also increases.
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REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE
CHAPTER 5
PROCESS SHEET
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1
Search of topic 30 days
2
Selection of topic 10 days
3
Finalizing of topic 2 days
4
Literature review 15 days
5
Study of component 10 days
7
Calculations 5 days
9
Starting manufacturing 15 days
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Testing of model 2 days
12
Soft copy of report 5 days
13
Final report 7 days
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CHAPTER 6
COST ESTIMATION
1 Ms plate 0.430g 30 30
2 streep 0.300g 25 25
TOTAL 55/-
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Rs. 640/-
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REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE
Small Screw
6. Switch 1 20 20
7. Wire 1 30 30
Rs. 1790/-
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= 55+640+1790
=2885/-
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CONCLUSION
1. The regenerative braking system used in the vehicles satisfies the purpose of
saving a part of the energy lost during braking. Also it can be operated at high
temperature range and are efficient as compared to conventional braking
system. The results from some of the test conducted show that around 30% of
the energy delivered can be recovered by the system.
2. Regenerative braking system has a wide scope for further development and the
energy savings
3. The use of more efficient systems could lead to huge savings in the economy
of any country.
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REFERENCE
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REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE
PHOTO GALLERY
Arrangement of motor
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Regenerative braking
Switch
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REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE
Proposed model
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