Indian Journal of Science and Technology

Abstract

Objectives: In this paper, design of the mechanical system and the kinematic analysis of the regenerative braking have been presented. The mechanism has been proposed to store brake energy in a spiral spring and release it back to the vehicle transmission. Methods/Statistical Analysis: First, the mechanism was modelled in Autodesk Inventor software package and the model then imported to Solid-Works Motion for kinematic analysis. The kinematic simulation was carried out for all the three modes of operation, viz. the idle mode, braking mode and the energy recovery mode. The analysis results were as per the desired output. Once the model was established, the individual components were transferred to ANSYS Static Structural to evaluate and optimize the design. Finally, the spiral spring being the main energy storing device was analyzed for variation in moment and deflection with its thickness and width. Findings: This concept of low-cost Kinetic Energy Recovery System (KERS) can store energy that is lost during braking in a spiral spring and release it smoothly to the vehicle whenever required. The paper presents the simple and lucid design of the mechanism that uses the combinations of planetary gear and one-way clutch. The system can be implemented on bicycle where use of other energy recovery techniques is restricted due to their various limitations. A sample calculation on amount of energy to be stored has been performed to find out the spring parameters so that the calculation can be replicated and the system can be customized for each vehicle. Application/Improvements: The designed setup is flexible and can be installed with ease on a wheel hub. This system will assist the driver during acceleration and thus will improve the overall performance of the vehicle. 

Keywords: Energy Harvesting, Flat Spiral Spring, Mechanism Design, Mechanical KERS, Regenerative Braking System