A PROJECT REPORT

ON

“BATTERY ELECTRIC VEHICLE WITH

REGENERATIVE BRAKING AND BATTERY
PROTECTION”

SESSION 2016-2020
DEPARTMENT OF ELECTRICAL ENGINEERING

Submitted to
AIR UNIVERSITY

GROUP MEMBERS

Muhammad Osama Nizami (160293)

Syed Shehryar (160265)
Asad Arshad (160297)

PROJECT SUPERVISOR
Dr.Muhammad Adil Khan

DEPARTMENT OF ELECTRICAL ENGINEERING

FACULTY OF ENGINEERING
AIR UNIVERSITY, ISLAMABAD
 A FINAL YEAR PROJECT REPORT

Presented to

Air University
LargeIn partial fulfillment of the requirements
for the Degree of
BACHELORS OF ELECTRICAL ENGINEERING

“BATTERY ELECTRIC VEHICAL WITH REGENRATIVE

BRAKING AND BATTERY PROTECTION”
SUBMITTED BY

MUHAMMAD OSAMA NIZAMI (160293)

SYED SHERYAR (160265)
ASAD ARSHAD (160297)

SESSION 2016-2020
DEPARTMENT OF ELECTRICAL ENGINEERING

SUBMISSION DATE MAY,2019

 APPROVAL FOR SUBMISSION
This is certify that the project entitled
BATTERY ELECTRIC VEHICAL WITH REGENERATIVE
BRAKING AND BATTERY PROTECTION
has met the required standard for submission
in partial fulfillment of the requirements
for the award of degree of
Bachelors Of Electrical Engineering
at
AIR UNIVERSITY

PROJECT SUPERVISOR
DR.MUHAMMAD ADIL KHAN

HEAD OF DEPARTMENT
DR.SHEHRAYAR SALEEM
 Acknowledgements

We are profoundly grateful to DR.MUHAMMAD ADIL KHAN for his expert

guidance and continuous encouragement throughout to see that this project rights its
target since its commencement to its completion.

We would like to express deepest appreciation towards Prof. DR.SHEHRYAR

SALEEM, Head of Department of Computer Engineering and DR.MUHAMMAD
ADIL KHAN, Project Coordinator whose invaluable guidance supported us in com-
pleting this project.

At last we must express our sincere heartfelt gratitude to all the staff members of
Computer Engineering Department who helped me directly or indirectly during this
course of work.

MUHAMMAD OSAMA NIZAMI

SYED SHEHRYAR
ASAD ARSHAD
 ABSTRACT

As the basic law of Physics says energy can neither be created nor be destroyed
it can only be converted from one form to another. During huge amount of energy
is lost to atmosphere as heat. It will be good if we could store this energy somehow
which is otherwise getting wasted out and reuse it next time we started to accelerate.
Regenerative braking refers to a system in which the kinetic energy of the vehicle
is stored temporarily, as an accumulative energy, during deceleration, and is reused
as kinetic energy during acceleration or running. Regenerative braking is a small,
yet very important, step toward our eventual independence from fossil fuels. These
kinds of brakes allow batteries to be used for longer periods of time without the need
to be plugged into an external charger. These types of brakes also extend the driving
range of fully electric vehicles. Regenerative braking is a way to extend range of the
electric vehicles. In many hybrid vehicles cases, this system is also applied hybrid
vehicles to improve fuel economy. A normal car is only about 20 percent efficient,
meaning some 80 percent of the energy it expends is wasted as heat created by fric-
tion. Regenerative braking could reclaim as much as half ofasthat wasted energy,
which equates into more motion produced by the fuel we are paying for instead of
using that fuel to create heat that is being dissipated uselessly into the environment.
The limitation of regenerative is that it can only slow down the slow moving vehicle
and for instant braking in order to bring vehicle into halt we use improved version
of conventional braking in which we have inserted thermoelectric generator which
uses the heat produce during fast braking and make electricity
Contents

1 Introduction 2
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Need for regenerative brakes? . . . . . . . . . . . . . . . . . . . . 3

2 Literature Review 4
2.1 Introduction of Regenerative Braking System (RBS) . . . . . . . . 4
2.2 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Brakes as an Electrical Generator . . . . . . . . . . . . . . . . . . . 6
2.4 Dynamic and Regenerative Electrical Brakes . . . . . . . . . . . . . 6

3 METHODOLOGY 7
3.1 Design Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1.1 Designing of Vehicle Body: . . . . . . . . . . . . . . . . . 7
3.1.2 Designing of buck boost converter: . . . . . . . . . . . . . 7
3.1.3 3.1.3 Design of Thermoelectric disc: . . . . . . . . . . . . . 9

4 BLOCK DIAGRAM 11

5 Conclusion and Future Scope 12

5.1 Discussion And Result . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

References 13
 Battery Electric Vehical With Regenrative Braking And Battery Protection

Chapter 1

Introduction

1.1 Introduction

Brakes are employed to stop or retard the motion of any moving body. Thus,
in automobiles the brakes are having the most important function to perform. In
conventional braking system the motion is retarded or stopped by absorbing kinetic
energy by friction, by making the contact of the moving body with frictional rubber
pad (called brake liner) which causes the absorption of kinetic energy, and this is
wasted in form of heat in surroundings. Each time we brake, the momentum of
vehicle is absorbed that it has gained by it and to re-accelerate the vehicle we have
to start from the scratch to redevelop that momentum by using the more power from
an engine .Thus, it will ultimately result in huge waste of energy. As the basic law of
Physics says energy can neither be created nor be destroyed it can only be converted
from one form to another. It will be good if we could store this energy somehow
which is otherwise getting wasted out and reuse it next time we started to accelerate.
That’s the basic concept of regenerative (”regent”) brakes, which provide braking
for the system when needed by converting the available energy to some usable form.
These are widely used in electric trains and the latest electric cars. Regenerative
brake is an energy recovery mechanism which slows a vehicle by converting its
kinetic energy into another form, which can be either used immediately or stored
until needed. Thus, the generated electricity during the braking is fed back into
the supply system (in case of electric trains), whereas in battery electric and hybrid
electric vehicles, the energy is stored in a battery or bank of capacitors for later
use. Energy may also be stored by compressing air or in a rotating flywheel. An
Energy Regeneration Brake was developed in 1967 for the AMC Amitron. This was
a completely battery powered urban concept car whose batteries were recharged by
regenerative braking, thus increasing the range of the automobile. Many modern
hybrid and electric vehicles use this technique to extend the range of the battery

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pack. Examples include the Toyota Prius, Honda Insight, the Vectrix electric maxi-
scooter, and the Chevrolet Volt.

1.2 Need for regenerative brakes?

The regenerative braking system delivers several significant advantages over a car
that only has friction brakes. In low-speed, stop- and-go traffic where little decelera-
tion is required; the regenerative braking system can provide the majority of the total
braking force. This vastly improves fuel economy with a vehicle, and further en-
hances the attractiveness of vehicles using regenerative braking for city driving. At
higher speeds, too, regenerative braking has been shown to contribute to improved
fuel economy by as much as 20 percent. Consider a heavy loaded truck having
very few stops on the road. It is operated near maximum engine efficiency. The 80
percent of the energy produced is utilized to overcome the rolling and aerodynamic
road forces. The energy wasted in applying brake is about 2 percent. Also its brake
specific fuel consumption is 5 percent. Now consider a vehicle, which is operated in
the main city where traffic is a major problem here one has to apply brake frequently.
For such vehicles the wastage of energy by application of brake is about 60 percent
to 65 percent.

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Chapter 2

Literature Review

Electric vehicle is mainly designed in order to get rid of pollution, use of natural
fuel and many other things. In our project we mainly focused on improving the
efficiency of the battery electric vehicle that is commonly said BEVs for this purpose
we use the concept of regeneration of lost energy during braking for storing it in a
battery of vehicle and also we have introduced a new concept of using thermoelectric
disc (thermoelectric generator inserted in a brake disk) as brake disc on a vehicle
so that the energy lost during fast braking can be reuse and this whole thing will
increase the overall efficiency of the vehicle. As we have first red some research
papers on different sites like IEEE, Research gate, Elsevier and many more. We
properly understand the working of BEV through these papers and add our own
modification in this project so in a nut shell this whole project revolves around the
improvement of efficiency of BEV through some modifications.

2.1 Introduction of Regenerative Braking System (RBS)

The Figure 2 above show the basic design for RBS. RBS is an important and useful
system to reduce the environment pollution and shortage of the fuel resources prob-
lem. According to the conservation of energy, energy cannot be created or destroyed
but it can change the type of energy. RBS is a system which can convert mechanical
energy to electrical energy. This system is used in a vehicle to recuperate the waste
energy during braking and converting it to a useful energy for conventional hydraulic
brake vehicle. The waste energy was produced when conventional brake is applied.
In RBS, the DC motor is used as a generator to recover kinetic energy from the wheel
of the vehicle into electrical energy. The conventional hydraulic brake will continue
to be used as an emergency brake. Because the RBS is only able to stop the vehicle
in a relatively long distance and time. This situation would cause accident to occur.
The RBS efficiently reduces the waste energy and regenerate energy during braking

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2.2 Brake

A brake is a device for slowing or stopping the motion of a machine or vehicle, and
to keep it from starting to move again. The kinetic energy lost by the moving part is
usually translated to heat by friction. Alternatively, in regenerative braking, much of
the energy is recovered and stored in a flywheel, capacitor or turned into alternating
current by an alternator, then rectified and stored in a battery for later use. Brakes
of some description are fitted to most wheeled vehicles, including automobiles of
all kinds, trucks, trains, motorcycles, and bicycles. Baggage carts and shopping
carts may have them for use on a moving ramp. Some Aeroplanes are fitted with
wheel brakes on the undercarriage. Some aircraft also feature air brakes designed
to slow them down in flight. Notable examples include gliders and some WWII-
era fighter aircraft. These allow the aircraft to maintain a safe speed in a steep
descent. The Saab B 17 dive bomber used the deployed undercarriage as an air
brake. Deceleration and avoiding acceleration when going downhill can also be
achieved by using a low gear. Friction brakes on cars store the heat in the rotating
part (drum brake or disc brake) during the brake application and release it to the air
gradually.

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2.3 Brakes as an Electrical Generator

Regenerative brakes are a form of dynamo generator, originally discovered in 1832

by Hippolyte Pixii. The dynamo’s rotor slows as the kinetic energy is converted to
electrical energy through electromagnetic induction. The dynamo can be used as ei-
ther generator or brake by converting motion into electricity or be reversed to convert
electricity into motion. Using a dynamo as a regenerative brake was discovered co-
incident with the modern electric motor. In 1873, Znobe Gramme attached the wires
from two dynamos together. When one dynamo rotor was turned as a regenerative
brake, the other became an electric motor. It is estimated that regenerative braking
systems in vehicles currently reach 31.3 percent electric generation efficiency, with
most of the remaining energy being released as heat; the actual efficiency depends
on numerous factors, such as the state of charge of the battery, how many wheels
are equipped to use the regenerative braking system, and whether the topology used
is parallel or serial in nature. The system is no more efficient than conventional
friction brakes, but reduces the use of contact elements like brake pads, which even-
tually wear out. Traditional friction-based brakes must also be provided to be used
when rapid, powerful braking is required, as well as to hold the vehicle stationary.

2.4 Dynamic and Regenerative Electrical Brakes

Convert the electric energy back into heat by passing the current through large banks
of variable resistors. Vehicles that use dynamic electrical brakes include forklifts,
Diesel-electric locomotives, and streetcars. If designed appropriately, this heat can
be used to warm the vehicle interior. When the energy is meant to be dissipated
externally, large radiator-like cowls can be employed to house the resistor banks.
Regenerative brakes in electric railway vehicles feed the generated electricity back
into the grid. In battery electric and hybrid electric vehicles, the energy is stored in
a battery or bank of capacitors for later use.

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Chapter 3

METHODOLOGY

First we will conduct some research on our respective project and make simula-
tion (software) and make a record of result and values obtain from software. After
software work, we will design the respective circuits and implement it on hardware.
After it we optimize it and troubleshoot if any. Procedure of designing of modules
and circuits of our project are below:

3.1 Design Procedure

3.1.1 Designing of Vehicle Body:

First we design the vehicle body through some software like AutoCAD etc then we
make it in a hardware and check its reliability that how much weight it can bears so,
that it will be reliable.

3.1.2 Designing of buck boost converter:

We will make a buck boost converter according to our project specifications. I will
give you a small overview that how we will make is as follows. A buck-boost con-
verter provides an output voltage that may be less than or greater than the input
voltage hence the name buck-boost; the output voltage polarity is opposite to that of
the input voltage. This converter is also known as inverting regulator.

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The circuit operation divided into two modes. During mode 1, transistor Q1 is
turned on and the diode Dm is reversed biased. The input current, which rises, flows
through inductor L and transistor Q1. During mode 2, transistor Q1 is switched off
and the current, which was flowing through inductor L, would flow through L, C,
Dm, and the load. The energy stored in inductor L would be transferred to the load
and inductor current would fall until transistor Q1 is switched on again in the next
cycle. The equivalent circuits for the modes are shown in figure 3.2 The waveforms
for steady-state voltages and currents of the buck-boost regulator are shown in figure
3.3 for a continuous load current.

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3.1.3 3.1.3 Design of Thermoelectric disc:

The thermoelectric disc is used as conventional disc brake in order to stop fast mov-
ing car. We will design this disc which look likes the below figure and first I will
tell you the background history of it. Automobile braking system is divided into
disc type and drum type brakes. Disc type first appeared in 1950s, with the prin-
ciple of brake pad on static calipers rubbing against rotating brake disc to realize
braking effect while brake applied. On account of the outstanding braking effect and
heat dissipation ability of disc brake, majority of automobiles are equipped with disc
brake. The structure of disc type brake is as shown in Fig 3.4 one complete set of
braking disc is composed of inner disc and outer disc which are fastened with a pole.
Heat produced from the friction action between brake pad on calipers and inner and
outer disc surfaces while brake applied is rapidly converted to the entire brake disc.

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Chapter 4

BLOCK DIAGRAM

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Chapter 5

Conclusion and Future Scope

5.1 Discussion And Result

This is a report of FYP-I, where we only we only collect data about different
components used in our project. Since we have not yet started our project so our
results are not ready which will be ready by the end of 8 semester that is in FYP-
III. First we will read about Dc-Dc converter, inverter and permanent magnet bldc
motor, which we are used to drive the car. We will do our simulation (software) work
in summer holidays and hardware part in our next semester (FYP-II). We will use
matlab for software work for computing graphs of converters and inverters. We will
make calculations of how much our system is improved from older system. In the
end we will make a specifications for our electric vehicle e.g that it uses how much
energy and how much it can travel on a battery etc.

5.2 Conclusion

The beginning of the 21st century could very well mark the final period in which
internal combustion engines are commonly used in cars. Already automakers are
moving toward alternative energy carriers, such as electric batteries, hydrogen fuel
and even compressed air. Regenerative braking is a small, yet very important, step
toward our eventual independence from fossil fuels. These kinds of brakes allow
batteries to be used for longer periods of time without the need to be plugged into
an external charger. These types of brakes also extend the driving range of fully
electric vehicles. In fact, this technology has already helped bring us cars like the
Tesla Roadster, which runs entirely on battery power. Sure, these cars may use fossil
fuels at the recharging stage – that is, if the source of the electricity comes from a
fossil fuel such as coal – but when they’re out there on the road, they can operate
with no use of fossil fuels at all, and that’s a big step forward. Regenerative braking

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allows for a vehicle to recover its kinetic energy when braking. Up to now, there
have been no systems that fully rely on regenerative, braking, however this paper
presents a method to use regenerative braking for all kinds of deceleration. The
energy gathered during the deceleration can then be used again during acceleration.
The proposed system allows a smooth braking experience while also dealing with
full stop and emergency brake situations. The smooth braking experience is achieved
by controlling the connection between the generator and its load. Full braking is
achieved by using multiple generators, each connected to the shaft with a different
gear ratio. This setup ensures that there is always one generator working efficiently
and therefore extracting kinetic energy from the system. The overall goal was to
design the Regenerative Braking System while keeping the engineering, producer
and customer models in check.

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References

[1] Cibulka, J. Kinetic energy recovery system by means of flywheel energy storage
Advanced engineering 3(2009)1, ISSN 1846-5900;

[2] . Hewko L. O; Automotive traction drive CVTs An overview; SAE paper

861355;

[3] Juan W. Dixon, Micah Ortzar and Eduardo Wiechmann*, Regenerative Braking
for an Electric Vehicle Using Ultracapacitors and a Buck-Boost Converter;

[4] https://ieeexplore.ieee.org/document/5686984

[5] https://sci-hub.tw/https://ieeexplore.ieee.org/document/
8245098

[6] https://ieeexplore.ieee.org/abstract/document/7845984

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