Utilizing a Spring as a Utilizing a Spring as a Kinetic Regenerative Kinetic Regenerative

Braking System in Braking System in VehiclesVehicles

Eugene LeeEugene Lee

Source: US Department of Energy

WastedWasted80%80%

Not WastedNot Wasted20%20%

Source: US Department of Energy

Num

ber

of

cars

(m

illio

ns)

World Passenger Car Fleet, 1950-2004

Source: AAMA, DRI WEFA, Global Insight

3600 lb car at 60mph3600 lb car at 60mph587,320 Joules587,320 Joules

1.3 grams of gasoline1.3 grams of gasoline

World FleetWorld Fleet352,392 Gigajoules352,392 Gigajoules

253,700 gallons of fuel253,700 gallons of fuel

$659,620 worth of fuel$659,620 worth of fuel

4,921,780 pounds of CO4,921,780 pounds of CO22

9200 households for a year

NeedNeed

2850 g = gallon

Gallon = 19.4 lb of carbon dioxide

Source: US Department of Transportation

US Carbon Dioxide Emissions in 2007

BrakingBraking

Electrical Regenerative BrakingElectrical Regenerative Braking

Hydraulic Regenerative BrakingHydraulic Regenerative Braking

Flywheel Regenerative BrakingFlywheel Regenerative Braking

Motor

Vex RoboticsVex Robotics Vex Robots will be used to simulate a Vex Robots will be used to simulate a

vehiclevehicle

Model Design PlanModel Design Plan

Motor

Motor Motor

Wheels

Wheels

Vex RobotBatteryBattery

RatchetRatchet

Spring Spring Activator Activator MotorMotor

Rubber dots act Rubber dots act as Face Gearsas Face Gears

SpringSpring AxleAxle

Rack and Rack and Pinion GearsPinion Gears

Processing UnitProcessing Unit

Gear separates, Gear separates, allowing wheels allowing wheels to turnto turn

Turns Spring Turns Spring Activator MotorActivator Motor

Turns Movement Turns Movement MotorsMotors

Activate Activate MotorsMotors

‘‘Gears’ intermesh, Gears’ intermesh, causing the Spring to causing the Spring to spin on one endspin on one end

Spring attaches Spring attaches onto static gearonto static gear

Spring has tensionSpring has tension

Spring attaches Spring attaches onto wheel, onto wheel, releases energyreleases energy

MATLABMATLAB

ADVISOR - a system for regenerative braking Example code and graphical view

Leonard et al (2003)Leonard et al (2003)– Tension spring modelTension spring model

Leonard, Peter; Resciniti, Michael; Peshkess, Adi; Leonard, Peter; Resciniti, Michael; Peshkess, Adi; Regenerative Braking SystemRegenerative Braking System; ME 59; 9-2003-02; ME 59; 9-2003-02

http://designscience.umich.edu/pdf%20files/APD-2003-04.pdf

Spring

PullingMechanism

GearTrain

Spring

PullingMechanism

GearTrain

Spring

PullingMechanism

GearTrain

Spring

PullingMechanism

GearTrain

Li et al (2008) Li et al (2008) – Torsion Spring setupTorsion Spring setup– Microcontroller and CVTMicrocontroller and CVT

Torsion SpringCVT

Accelerometer and MCU

Engine

Li, Chenghan; Wang, Cunzhe; Leng Pelie, Woo Pak; Wei, Thia; “Li, Chenghan; Wang, Cunzhe; Leng Pelie, Woo Pak; Wei, Thia; “Kinetic Energy Recovery System for VehiclesKinetic Energy Recovery System for Vehicles”; Nanyang ”; Nanyang Technological Institute, School of Electrical and Electronic Engineering, School of Mechanical and Aerospace Engineering; Technological Institute, School of Electrical and Electronic Engineering, School of Mechanical and Aerospace Engineering; 7 October, 20087 October, 2008

Martinez (et al 2008) Martinez (et al 2008) – flywheel regenerative modelflywheel regenerative model– Used braking patternsUsed braking patterns

Martinez-Gonzalez, Pablo; Diego-Ayala, Ulises; Pullen, Keith; Martinez-Gonzalez, Pablo; Diego-Ayala, Ulises; Pullen, Keith; A Simple Mechanical Transmission A Simple Mechanical Transmission System For Hybrid Vehicles Incorporating A Flywheel; City University of London; December 8, 2008System For Hybrid Vehicles Incorporating A Flywheel; City University of London; December 8, 2008

Source: US Environmental Protection Agency

Michael (et al, 2000)Michael (et al, 2000)– Used MATLAB to simulate Regenerative Braking in a Used MATLAB to simulate Regenerative Braking in a

vehiclevehicle– Also used braking patternsAlso used braking patterns

Panagiotidis, Michael; Delagrammatikas, George; Assanis, Dennis; Panagiotidis, Michael; Delagrammatikas, George; Assanis, Dennis; Development Development and Use of a Regenerative Braking Model for a Parallel Hybrid Electric Vehicleand Use of a Regenerative Braking Model for a Parallel Hybrid Electric Vehicle ; The ; The University of Michigan, SAE 2000 World Congress; March 6, 2000University of Michigan, SAE 2000 World Congress; March 6, 2000

http://146.164.33.61/termo/Motores/trabalhos%2007/P2000_04.pdf

Figure 1. SIMULINK block diagram schematic of ADVISOR used in research

PurposePurpose

Save energySave energy Reduce CO2 emissionsReduce CO2 emissions Little cost Little cost Allow for smaller engine sizeAllow for smaller engine size

Engineering GoalsEngineering Goals

To create a working system that:To create a working system that:– successfully is able to use energy lost successfully is able to use energy lost

from braking to forward momentumfrom braking to forward momentum– allows for greater energy production allows for greater energy production

than energy lost through its frictionthan energy lost through its friction

BudgetBudget

VendorVendor Order #Order # Quantity Quantity DescriptionDescription PricePriceTotal Total priceprice

Vex RoboticsVex Robotics 276-2330-EASYC276-2330-EASYC 11 VEX RobotVEX Robot

Vex RoboticsVex Robotics 276-2184276-2184 11Advanced Advanced Gear KitGear Kit $19.99 $19.99 $19.99 $19.99

Vex RoboticsVex Robotics 276-2163276-2163 11 Motor KitMotor Kit $19.99 $19.99 $19.99 $19.99

Vex RoboticsVex Robotics 276-2162276-2162 11 Servo KitServo Kit $19.99 $19.99 $19.99 $19.99

Stock Drive Stock Drive ProductsProducts A 1B14-24012A 1B14-24012 22

Ratchet and Ratchet and PawlPawl $7.10 $7.10 $14.20 $14.20

TotalTotal $74.17$74.17

Available at schoolAvailable at school

https://sdp-si.com/eStore/Direct.asp?Exp1=38460&GroupID=473

FlowchartFlowchartVex RobotVex Robot MATLABMATLAB

With Equipment (friction +

weight)

Distance traveled / # of rotations

Energy captured

Compare two results, should not be significantly different from each other

Without Equipment (control)

With unattached Equipment (weight)

With Equipment (friction +

weight)

Without Equipment (control)

With unattached Equipment (weight)

n=100

Determine energy output of spring devicen=100 Determine energy output of spring device

Compare results, should not be significantly different from each other

Distance traveled / # of rotations

Distance traveled / # of rotations

Distance traveled / # of rotations

Compare spring output energy with spring energy losses

Analyze through SPSS after processing

Physical TestingPhysical Testing Computer SimulationComputer Simulation

Do-abilityDo-ability

VEX robot is easy to use and adjustVEX robot is easy to use and adjust

No large or costly materialsNo large or costly materials

Prior experience with programming and Prior experience with programming and other roboticsother robotics

Going to Stony Brook Engineering CampGoing to Stony Brook Engineering Camp

BibliographyBibliography Hewitt, Paul G.; Hewitt, Paul G.; Conceptual PhysicsConceptual Physics; New York: Addison Wesley; 2003; New York: Addison Wesley; 2003 Li, Chenghan; Wang, Cunzhe; Leng Pelie, Woo Pak; Wei, Thia; Li, Chenghan; Wang, Cunzhe; Leng Pelie, Woo Pak; Wei, Thia; Kinetic Kinetic

Energy Recovery System for VehiclesEnergy Recovery System for Vehicles; Nanyang Technological ; Nanyang Technological Institute, School of Electrical and Electronic Engineering, School of Institute, School of Electrical and Electronic Engineering, School of Mechanical and Aerospace Engineering; 7 October, 2008Mechanical and Aerospace Engineering; 7 October, 2008

Leonard, Peter; Resciniti, Michael; Peshkess, Adi; Leonard, Peter; Resciniti, Michael; Peshkess, Adi; Regenerative Regenerative Braking SystemBraking System; ME 59; 9-2003-02 ; ME 59; 9-2003-02

Kilcarr, Sean; Kilcarr, Sean; Shifting for fuel economyShifting for fuel economy; Fleet Owner; February 1, ; Fleet Owner; February 1, 20062006

Harrington, Winston; Harrington, Winston; A Lighter Tread? Policy and Technology Options A Lighter Tread? Policy and Technology Options for Motor Vehiclesfor Motor Vehicles; Environment; September 1, 2003; Volume 45 #9; ; Environment; September 1, 2003; Volume 45 #9; Page 22Page 22

Martinez, James; Martinez, James; Brake energy regeneration in F1 by 2009Brake energy regeneration in F1 by 2009; Motor ; Motor Authority; June 5, 2007; <http://www.motorauthority.com/brake-Authority; June 5, 2007; <http://www.motorauthority.com/brake-energy-regeneration-in-f1-by-2009.html>energy-regeneration-in-f1-by-2009.html>

Martinez-Gonzalez, Pablo; Diego-Ayala, Ulises; Pullen, Keith; Martinez-Gonzalez, Pablo; Diego-Ayala, Ulises; Pullen, Keith; A Simple A Simple Mechanical Transmission System For Hybrid Vehicles Incorporating A Mechanical Transmission System For Hybrid Vehicles Incorporating A Flywheel; City University of London; December 8, 2008Flywheel; City University of London; December 8, 2008

Ogando, Joseph; Ogando, Joseph; A different Kind of HybridA different Kind of Hybrid; Design News, July 16, ; Design News, July 16, 2007; Volume 62 #10; Page 752007; Volume 62 #10; Page 75

http://www.hevc08.org.uk/PDF/08.%20U.Diego-Ayala_HEVC08.pdf