Design and Evaluation of an Energy-Efficient Regenerative Braking System
Abstract
Regenerative braking systems (RBS) offer a promising solution to improve energy efficiency in modern electric and hybrid vehicles by recovering kinetic energy otherwise lost as heat during braking. This study presents the design, simulation, and experimental validation of a prototype regenerative braking system aimed at maximizing energy recovery and minimizing wear on conventional brake components. A stainless steel disc brake was designed using Fusion 360 and analyzed for thermal and structural performance under braking conditions using ANSYS Workbench. The prototype integrates a 775 DC motor functioning as a generator, converting braking energy into electrical output, which is visualized using an LED load indicator. Simulation results indicate that the disc brake reaches a peak steady-VWDWHWHPSHUDWXUHRIDSSUR[LPDWHO\ௗ&ZLWK maximum heat flux observed at the brake pad contact zone, validating the model’s thermal behavior. Experimental testing demonstrated successful energy recovery, with an output voltage UDQJLQJ EHWZHHQ ௗ9 DQG ௗ9 DW PRWRU VSHHGV RI – ௗ5307KHILQGLQJVFRQILUPWKHIHDVLELOLW\RIWKHSURSRVHG system for small-scale energy harvesting applications and provide a foundation for further development of efficient and adaptable regenerative braking systems for sustainable vehicle technologies.
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