DOI 10.4010/2016.

1265
ISSN 2321 3361 © 2016 IJESC

Research Article Volume 6 Issue No. 5

Design and Fabrication of Regenerative Electric Bike

Mr. Mragank Sharma1, Anshul Verma2, Gaurav Tiwari3, Sunny Singh4, Mohd Nadeem5
Assistant Professor 1, UG Scholar2, 3, 4, 5
Department of Mechanical and Automation Engineering
Amity University, Lucknow, India

Abstract:
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 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.

1. INTRODUCTION
When a conventional vehicle applies its brakes, kinetic
energy is converted to heat energy as friction occurs
between the brake shoe and brake drum. This heat energy is
lost into the atmosphere. The total amount of energy lost in
this way depends on how often, how hard and for how long
the brakes are applied.
In regenerative braking system energy normally dissipated
during braking is converted into useful electrical energy.
Which by a power transmission system is stored in battery
during deceleration. That energy is stored until required
again by the vehicle, whereby it is used to accelerate the
vehicle which gains kinetic energy during motion. Since
regenerative braking results in an increase in energy output
for a given energy input to a vehicle, the efficiency is
improved.
Fig.1- Regeneration arrangement in front wheel
Fig.2- Regenerative Electric Bike
2. ELECTRIC BIKE
Electric bike use the electricity from the battery to run. But
electric bike is not feasible for long distances, as it can only
runs 60 to 70 km if charged fully. When we applies the
brake the kinetic energy of the vehicle is lost as a heat
energy in atmosphere due to friction between the brake shoe
and brake drum [1, 2]. The brushed DC motor is used in the
hub of the wheel which acts as a generator and generate the
electricity or electrical energy. Therefore the brushed DC
motor is used to charge the battery so that its efficiency is
increased to some extent [3]. This process is very less
efficient at low power because of the some fixed mechanical
losses, thus regeneration is up to the mark at low speeds, as
it acts as temporarily brakes.
Since 1945 the R&D is in process to improve the
performance of the battery [4, 5]. In 1994 the lead acid was
first commercially economical and viable battery technology
which tends to ideal [6]. Due to weight and volume of the
battery the electric vehicles have limited range and very
poor performance because of weight and volume of battery,
and energy transfer rate and lifetime limitations. To obtain

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the high regenerative voltage we have to apply the brakes 5. SPECIFICATIONS
gradually and if we applies the brakes very fast the braking
time is reduced hence reduced voltage is generated [7]. i) Brushed DC Motor
A block diagram of a regenerative braking system is shown
in Fig.3. DC supply 4-12V

RPM 45 at 12V

No load current 50mA at 12V

Load current 300mA(max) at

12V
Total length 46mm

Torque 5kg-cm at 12V

Motor diameter 36mm

Motor length 25mm

Fig.3-Block diagram of Regenerative Braking System
Brush type Precious metal
3. WORKING
Brushed dc motor attached to the iron L –clamp above the Gear head diameter 37mm
center hub of front wheel with the help of screw and nut.
And frictional wheel coupled with the brushed dc motor and
Gear head length 21mm
an iron bar. Rechargeable lead acid battery join to the
brushed dc motor which contains gear box in it, with the
help of wiring we connect to them. Battery is used to store Output shaft Centred
the generated energy which is produced with the help of
regenerative braking system while braking and produced Shaft diameter 6mm
energy is shown on digital display.
Shaft length 22mm
The advantages of regenerative braking system are –
 Increase of overall efficiency of a vehicle. Gear assembly Spur
 Increase vehicle range.
 Cuts down on pollution related to electricity
Motor weight 100gms
generation.
 Increase the lifespan friction braking system.
 Less use of traditional mechanical brakes leads to
less wear over time. ii) Friction Wheel

4. FABRICATION Inner diameter 58mm

Various methods and tools are used to fabricate the
regenerative electric bike.
Outer diameter 70mm
The methods include are.
 Cutting Shaft hole diameter 6mm
 Drilling
 Counter boring
 Brushed DC motor Width 20mm
 Friction wheel
 Printed circuit board(resistor, capacitor, voltage
Wheel material Plastic
regulator, other electrical components)
 LCD
 Multimeter Wheel material at Rubber
 Auxiliary battery periphery
 Wiring

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iii) Printed Circuit Board 5.2 Fluctuated Voltage vs Speed
Number of resistors used 2
Resistor Value E12 series Fluctuated Voltage vs
(within each decade)
Resistor type 4 band 50 Speed
Number of capacitor 1 45
used

FLUCTUATED VOLTAGE(VOLTS)
Capacitor type Monolithic 40
Voltage regulator 3-Terminal 1A 35
Positive
Voltage regulator KA78XX/KA78XXA 30
series 25
20
iv) LCD
LCD type 16x2 character 15
Dots with cursor 5x8 10
Power supply +5V 5
Duty cycle 1/16
0
0 5 10 15 20 25 30 35
5. TESTING & PERFORMANCE
5.1 Fluctuated Voltage vs Braking Time SPEED(IN KM/H)
at 100m distance at 200m distance

Fluctuated Voltage vs
Abrupt rise in fluctuation voltage is gained up to the speed
Braking Time of 25km/hr during braking, after this fluctuation voltage
increases gradually and tends to the saturation voltage.
50
5.3 Battery Discharge vs Distance Covered
45
Battery Discharge vs
40
Distance Covered
35
FLUCTUATED VOLTAGE(VOLTS)

48
BATTERY DISCHARGE(IN %)

44
40
30 36
32
28
25 24
20
16
12
20 8
4
0
15
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70
DISTANCE COVERED (IN KM)
10
Normal discharge Regenerative Discharge
5

0 Calculation
0 0.5 1 1.5 2 2.5 3 3.5
Efficiency:-
BREAKING TIME(IN SEC)
After full charging
- Distance covered by e-bike = 60km
At 100m distance At 200m Distane - Distance covered by regenerative
E-bike = 65km
Testing by using single motor: Extra distance covered by regenerative e-bike= 65- 60km =
Average fluctuation voltage obtained=37.5V 5km
Saturation voltage obtained experimentally = 45V

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Efficiency, Ƞ =
×100 [7] G.Hoolboom, B.Szabados. IEEE Transactions on
Veh'iular Technology, 1994, 43(4), 1136-114

= ×100 = 8.33%

6. CONCLUSION
The regenerative braking system used in the electric bike
satisfies the purpose of storing some part of energy lost
during braking. It also increased the discharging time of
battery and hence efficiency is improved 8.33% of the
vehicle.
Regenerative braking system has a wide scope for further
development and the energy saving. The use of more
efficient systems could lead to huge savings in the economy
of any country.

7. FUTURE SCOPE
 As the global warming is increasing day by day
and the reservoir of fossil fuel tends to end, the e-
bikes, solar bikes etc. will be better options.
 As compared to the fuel driven vehicles, the
electricity driven vehicles are better when we talk
about the pollution.
 In future, by using suitable arrangements in e-bikes
for regeneration like motor, solar panel etc., we
will increase the discharging time and therefore
increase efficiency.
 As the pollution is increasing a lot and the fossil
fuel is decreasing day by day, e-bike battery
regeneration is good field for research and
development.
 There will be less number of fuel stations in future
as there will be increment in number of e-bikes.
 We regenerate the e-bike not only by applying the
brakes but also by messing the light friction pulley
constantly with the center hub of the wheel to get
continuous voltage which is also a good field for
R&D.

8. REFRENCES
[1] Electric Power Systems Research 1988, 14(3) 183-190
K.Rajashekara, R.Martin. Journal of Circuits, Systems and
computers, 1995, 5(1), 109-129

[2] XXN Fisita Congress - Total Vehicle Dynamics,

1992,2,33

[3] Electric Vehicle Technology. LB.Unnewehr, S.A.Nasar,

1982, Wiley

[4] M.J.Shemmans, D.Sedgwick, ASekarsky. Electric

Vehicles: A Decade of Transition, 1992, SAE pt-40, 75-78

[5] W.W.Max, W.J.Walsh, P.C.Symons. Energy Conversion

and Management, 1992, 33(9), 843-847.

[6] kl. Appleby. Joumal of Power Sources, 1995, 53(2), 187-

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