Regenerative Braking Increases e-Bike Range

REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE
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.
1
Introduction of regenerative braking with self-power generating electrical

bicycle
Fig. 1.1 Introduction of regenerative braking with self-power generating electrical bicycle
2
CHAPTER 2
LITERATURE SURVEY
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
3
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
4
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.
5
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.
Fig.3.1.1 block diagram of process
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
To identify all the information and requirement such as hardware and

software, planning must be done in the proper manner. The planning phase have two
main elements namely data collection and the requirements of hardware and software
6
3.2.2 Data collection
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.
3.1.2 Steps of Methodology
7
3.3 OPERATION INVOLVED MANUFACTURING
3.2.1 Introduction of manufacturing:
The word manufacturing is derived from the Latino manufactures, meaning

made by hand. Manufacturing involves making products from raw materials by
various processes or operations. Manufacturing is generally a complex activity,
involving people who have a board range of disciplines and skills and wide verity of
Machine, equipment, and tooling with various levels of automation, including
computers, robots and material handling equipment or devices.
Manufacturing is the process of converting the raw material, components or

parts into the finished product that meet a customer’s expectations or specifications.
Manufacturing process are the steps through which the raw materials are transformed
into which the design is made. These materials are then modified through
manufacturing process to become the required part. Manufacturing processes can
include treating (such as heat treating or coating)’ Machine or reshaping the material.
The manufacturing process can also include tests and checks for quality assurance
during or after the manufacturing and planning the production process prior to
manufacturing.
Manufacturing is the production of merchandise for use or sale using labor,

Machine tools, chemical & biological processing or formulation. The term may 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.
3.2.3 Performed operations:
In our project we performed some manufacturing operating operations so as to

complete our project and to perform those operations we used followings some
manufacturing processes they are:
1. Cutting.
8
2. Drilling.
3. Grinding.
4. Tapping.
5. Welding.
6. Finishing.
7. Hammering.
3.3.4 Cutting Operation:-
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
3.3.6 Drilling operation:-
Drilling is a cutting process that uses a drill-bit to cut or enlarge a hole of

circular cross section in solid materials. The drill bit is a rotary cutting tool, often
9
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.
In our project we performed a drill operation on end surface plate which is

used to connect the air connection, pressure gauge, regulating valve inside the
cylinder. The drill is required to allow filter air to the air conditioning effect.
3.3.7 Grinding operation:-
Grinding may be defined as the act of shaping or wearing down a surface or

sharpening an edge by means of the cutting action of thousands of abrasive grains on
the surface of the grinding wheel. Excessive grinding shortens the useful life of a tool.
Taping is the manufacturing process used in produce the thread. Threading is

the process of creating a screw thread.
Fig.3.3.2 Grinding on plane surface of angle
10
Fig.3.3.3 Grinding on welding joint
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.
Welding: -3.3.4 for welding the angles together.
11
In arc welding, the intense heat needed to melt metal is produced by an

electric arc. The arc is formed between the actual work and an electrode (stick or
wire) that is manually or mechanically guided along the joint. The electrode can either
be a rod with the purpose of simply carrying the current between the tip and the work.
Or, it may be a specially prepared rod or wire that not only conducts the current but
also melts and supplies filler metal to the joint. Most welding in the manufacture of
steel products uses the second type of electrode.
Welding: - 3.3.5 for welding the angles together.
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.
3.4 Fixture Arrangement:
The fixture assembly that brings all of the system together. These come in a
variety of configurations, vertical, horizontal, freestanding, or mobile cart.
12
Fig. 3.4.2 Fixture Arrangement
3.5 OPERATION INVOLVED MANUFACTURING
3.5.1 Introduction of manufacturing:
The word manufacturing is derived from the Latino manufactures, meaning

made by hand. Manufacturing involves making products from raw materials by
various processes or operations. Manufacturing is generally a complex activity,
involving people who have a board range of disciplines and skills and wide verity of
Machine equipment, and tooling with various levels of automation, including
computers, robots and material handling equipment or devices.
Manufacturing is the process of converting the raw material, components or

parts into the finished product that meet a customer’s expectations or specifications.
Manufacturing process are the steps through which the raw materials are transformed
into which the design is made. These materials are then modified through
manufacturing process to become the required part. Manufacturing processes can
include treating (such as heat treating or coating)’ Machining or reshaping the
material. The manufacturing process can also include tests and checks for quality
assurance during or after the manufacturing and planning the production process prior
to manufacturing.
Manufacturing is the production of merchandise for use or sale using labor,

Machine es, tools, chemical & biological processing or formulation. The term may
13
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.
3.5.2 Performed operations:
In our project we performed some manufacturing operating operations so as to

complete our project and to perform those operations we used followings some
manufacturing processes they are:
1. Cutting.
2. Drilling.
3. Grinding.
4. Tapping.
5. Welding.
6. Finishing.
7. Hammering.
3.5.3 Cutting Operation:-
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.
3.5.4 Drilling operation:-
Drilling is a cutting process that uses a drill-bit to cut or enlarge a hole of

circular cross section in solid materials. The drill bit is a rotary cutting tool, often
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.
14
In our project we performed a drill operation on end surface plate which is

used to connect the air connection, pressure gauge, regulating valve inside the
cylinder. The drill is required to allow filter air to the air conditioning effect.
3.5.5 Grinding operation:-
Grinding may be defined as the act of shaping or wearing down a surface or

sharpening an edge by means of the cutting action of thousands of abrasive grains on
the surface of the grinding wheel. Excessive grinding shortens the useful life of a tool.
Taping is the manufacturing process used in produce the thread. Threading is

the process of creating a screw thread.
Welding: - For welding the angles together.
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.
In arc welding, the intense heat needed to melt metal is produced by an

electric arc. The arc is formed between the actual work and an electrode (stick or
wire) that is manually or mechanically guided along the joint. The electrode can either
be a rod with the purpose of simply carrying the current between the tip and the work.
Or, it may be a specially prepared rod or wire that not only conducts the current but
also melts and supplies filler metal to the joint. Most welding in the manufacture of
steel products uses the second type of electrode.
15
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.
Fig. 3.5.2 Welding Process
16
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 STANDARD PART OF ASSEMBLY
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.
17
Fig. Chassis Design
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:
 It is the simplest of all arc welding processes.

 The equipment is portable and the cost is fairly low.
 A big range of metals and their alloys can be welded.
18
Fig. Fabrication of motor frame
Fig. Fabrication of regenerative brake
Fig. Fabrication chain mechanism
19
Experimental Setup and Parts

Components of Electric Bike
The Electric bike consists of the following components i.e. DC motor, motor
controller, throttle, two poles 6 way switch, bridge rectifier, battery, generator.
DC Motor
DC Motor is an electrical device which converts electrical energy into

mechanical energy. A simple DC motor has a stationary set of magnets in the stator
and an armature with one or more windings of insulated wire wrapped around a soft
iron core that concentrates the magnetic field. The windings usually have multiple
turns around the core, and in large motors there can be several parallel current paths.
The ends of the wire winding are connected to a commutator. The commutator allows
each armature coil to be energized in turn and connects the rotating coils with the
external power supply through brushes. (Brushless DC motors have electronics that
switch the DC current to each coil on and off and have no brushes. DC motors can
operate directly from rechargeable batteries, providing the motive power for the first
electric vehicles and today's hybrid cars and electric cars as well as driving a host of
cordless tools. Today DC motors are still found in applications as small as toys and
disk drives, or in large sizes to operate steel rolling mills and paper machines. Large
DC motors with separately excited fields were generally used with winder drives for
mine hoists, for high torque as well as smooth speed control using thyristor drives.
These are now replaced with large AC motors with variable frequency drives.
Fig. 1. DC Motor
20
Generator
If external mechanical power is applied to a DC motor it acts as a DC

generator, a dynamo. This feature is used to slow down and recharge batteries on
hybrid car and electric cars or to return electricity back to the electric grid used on a
street car or electric powered train line when they slow down. This process is called
regenerative braking on hybrid and electric cars. In diesel electric locomotives they
also use their DC motors as generators to slow down but dissipate the energy in
resistor stacks. Newer designs are adding large battery packs to recapture some of this
energy.
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.
21
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.
ADVANTAGES OF REGENERATIVE BRAKING SYSTEMS

 Improved Performance.
 Improved Fuel Economy-Dependent on duty cycles, power train design,
control strategy, and the efficiency of individual components.
 Reduction in Brake Wear –Reducing cost of replacement brake linings, cost of
labor to install them, and vehicle down time.
 Operating range is comparable with conventional vehicles-a problem not yet
overcome by electric vehicles.
22
LIMITATIONS OF REGENERATIVE BRAKING SYSTEMS

 The main limitation of regenerative brakes when compared with dynamic
brakes is the need to closely match the electricity generated with the supply.
With DC supplies this requires the voltage to be closely controlled and it is
only with the development of power electronics that it has 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 Regenerative braking is necessarily
limited when the batteries are fully charged.
 Because the additional charge from regenerative braking would cause the
voltage of a full battery to rise above a safe level, our motor controller will
limit regenerative braking torque in this case.
 Increases the total weight of vehicle by around 25-30 Kilograms.
APPLICATIONS
 For recovering Kinetic energy of vehicle lost during braking process.
 One theoretical application of regenerative braking would be in a
manufacturing plant
23
CHAPTER 5
PROCESS SHEET
5.1. PROCESS SHEET FOR FRAME -
Component: V Shape Angles
Material: Mild Steel
OPERATION MACHINES MEASURING TOTAL HRS

TOOLS INSTRUMENT
Cutting Cutter Linear Scale 1
Welding Welding m/c --- 1
Drilling Drilling m/c Vernier 2
Total --- --- 4
Table No. 5.1.1 Process Sheet For Frame
24
5.2 TIME STUDY OF OPERATION –
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
6 Cad diagram and starting of calculation

10 days
of component
7
Calculations 5 days
8 Finalizing the calculations and preparing

5 days
the final cad diagrams with dimensions
9
Starting manufacturing 15 days
10 Buying the standard component from

3 days
market
11
Testing of model 2 days
12
Soft copy of report 5 days
13
Final report 7 days
Table No. 5.2.1 Time Study of Operation
25
CHAPTER 6
COST ESTIMATION
6.1 Cost of Material:
Sr. No Part Name Weight Rate/kg Total cost
1 Ms plate 0.430g 30 30
2 streep 0.300g 25 25
TOTAL 55/-
Table No. 6.1.1 Cost of Material
26
6.2 Cost of Machining:
Sr. No Part Time Rate/hr Total Cost
1 Streep Bending 20m 60 20
2 Grinding m/c 10m 50 10
3 Drilling m/c 30m 100 30
4 Welding m/c 1hr 200 200
5 Gas Welding 30m 300 150
5 Lathe machine 1hr 200 200
7 Cutting m/s 20m 100 30
Rs. 640/-
Table No. 6.2.1 Cost of Machining
27
6.3 Cost of Standard Parts:
Sr. No Part Quantity Rate/unit Total Cost
1. Power Supply Circuit 1 100 100
2. Nut and bolt 4 40 40
Small Screw
Gear lever (Nut bolt)
3. Switching Circuit 1 300 300
4. Dynamo 1 500 500
5. Regenerator 1 500 500
6. Switch 1 20 20
7. Wire 1 30 30
8. Multimeter 1 300 300
Rs. 1790/-
Table No. 6.3.1 Cost of Standard Parts
28
6.5 Total Project Cost:
Cost of material + Cost of machining + Cost of std. part
= 55+640+1790
=2885/-
29
 RESULT AND DISCUSSION

It is clearly seen that the electrical bicycle gives a clean and more economical
solution to the energy crisis. People use bikes and fuelled vehicles for even travelling
short distances without making use of bicycles and other non – fuelled vehicles. Most
number of people from the list have been those which think riding a cycle is
equivalent to providing extra effort for cycling. In order to avoid this electric
assistance has been provided to the cycle that will ease the user to ride the unit with
the help of a motor.
Even the hardship of climbing slopes and riding on rough terrains has been
reduced. All these aspects are available keeping in mind the factor of pollution being
affected at all.
The factors that our prototype design of bicycle provides to the raider are:
• Simplified riding with minimal effort on flat as well as gradients.
• Easiness of riding on rough terrains.
FUTURESCOPE
Regenerative braking systems require further research to develop a better
system that captures more energy and stops faster. As the time passes, designers and
engineers will perfect regenerative braking systems, so these systems will become
more and more common. All vehicles in motion can benefit from these systems by
recapturing energy that would have been lost during braking process.
Future technologies in regenerative brakes will include new types of motors
which will be more efficient as generators, new drive train designs which will be built
with regenerative braking in mind, and electric systems which will be less prone to
energy losses.
30
 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.
31
 REFERENCE
1. C. Abagnalea, M. Cardoneb*, P. Iodicea, R. Marialtoc, S. Stranoa, M. Terzoa,

G. Vorraro aDepartment of Industrial Engineering, University of Naples
Federico II, [1]
2. 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]
3. Sachin Chouhan, Sanjiv Kumar, Krishna Veer Choudhary, Kuldeep Singh &
Mr.Vivek Sharma (Assiastant Professor) Department of Electrical
Engineering, SKIT, Jaipur[3]
4. 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]
5. Pierfrancesco Spagnol, Matteo Corno, Roberto Mura and Sergio M. Savaresi
[5]
32
PHOTO GALLERY
Arrangement of motor
Arrangement of motor stand
33
Regenerative braking
Switch
34
Proposed model
35

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REGENERATIVE BRAKING SYSTEM WITH SELF-POWER GENERATING ELECTRICAL BICYCLE

Introduction of regenerative braking with self-power generating electrical

Fig.3.1.1 block diagram of process

To identify all the information and requirement such as hardware and

3.2.2 Data collection

3.1.2 Steps of Methodology

3.3 OPERATION INVOLVED MANUFACTURING

3.2.1 Introduction of manufacturing:

The word manufacturing is derived from the Latino manufactures, meaning

Manufacturing is the process of converting the raw material, components or

Manufacturing is the production of merchandise for use or sale using labor,

3.2.3 Performed operations:

In our project we performed some manufacturing operating operations so as to

3.3.4 Cutting Operation:-

3.3.6 Drilling operation:-

Drilling is a cutting process that uses a drill-bit to cut or enlarge a hole of

In our project we performed a drill operation on end surface plate which is

3.3.7 Grinding operation:-

Grinding may be defined as the act of shaping or wearing down a surface or

Taping is the manufacturing process used in produce the thread. Threading is

Fig.3.3.2 Grinding on plane surface of angle

Fig.3.3.3 Grinding on welding joint

Welding: -3.3.4 for welding the angles together.

In arc welding, the intense heat needed to melt metal is produced by an

Welding: - 3.3.5 for welding the angles together.

3.4 Fixture Arrangement:

Fig. 3.4.2 Fixture Arrangement

3.5 OPERATION INVOLVED MANUFACTURING

3.5.1 Introduction of manufacturing:

The word manufacturing is derived from the Latino manufactures, meaning

Manufacturing is the process of converting the raw material, components or

Manufacturing is the production of merchandise for use or sale using labor,

3.5.2 Performed operations:

In our project we performed some manufacturing operating operations so as to

3.5.3 Cutting Operation:-

3.5.4 Drilling operation:-

Drilling is a cutting process that uses a drill-bit to cut or enlarge a hole of

In our project we performed a drill operation on end surface plate which is

3.5.5 Grinding operation:-

Grinding may be defined as the act of shaping or wearing down a surface or

Taping is the manufacturing process used in produce the thread. Threading is

Welding: - For welding the angles together.

In arc welding, the intense heat needed to melt metal is produced by an

Fig. 3.5.2 Welding Process

4.2 STANDARD PART OF ASSEMBLY

Fig. Chassis Design

 It is the simplest of all arc welding processes.

Fig. Fabrication of motor frame

Fig. Fabrication of regenerative brake

Fig. Fabrication chain mechanism

Experimental Setup and Parts

DC Motor is an electrical device which converts electrical energy into

If external mechanical power is applied to a DC motor it acts as a DC

ADVANTAGES OF REGENERATIVE BRAKING SYSTEMS

LIMITATIONS OF REGENERATIVE BRAKING SYSTEMS

5.1. PROCESS SHEET FOR FRAME -

Component: V Shape Angles

Material: Mild Steel

OPERATION MACHINES MEASURING TOTAL HRS

Welding Welding m/c --- 1

Drilling Drilling m/c Vernier 2

Total --- --- 4