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www.ierjournal.org International Engineering Research Journal (IERJ) Special Issue 3 Page 252-254, 2016, ISSN 2395-1621
© 2015, Page 1
ISSN 2395-1621
Kinetic Energy Recovery System
#1
Birudev Devkate, #2
Pravin Gosavi, #3
Umakant Suryawanshi, #4
Harichadra Atole
#1234
Department of Mechnical Engeering, ISB&M Scool of Technology, Pune, Savitribai Phule
Pune University
ABSTRACT
ARTICLE INFO
Kinetic energy recovery system (KERS) is a system for recovering the moving vehicle’s
kinetic energy under braking load. This system converts loss of kinetic energy of vehicle
and store in the form of Spiral spring. Mechanical KERS uses a innovative planetary
gear train and dedicated disk brake system to recover the loss of kinetic energy from the
front wheel axle of the vehicle and store it in a spiral spring. Spiral spring set-up
controlled by using a one directional clutch. This system is very compact, and a very low
cost required for this system. In this system mechanical energy first converted into the
electrical energy and then this electrical energy converted in form of spiral spring (i.e.
mechanical energy). Due to this loss of energy is used again and again (recover) and
increases the efficiency of vehicle. Also save the fuel loss.
Keywords: Scroll spiral spring, Gears, Bearing housing, Brake lever, Motor, Belt, Shaft.
Article History
Received :29th
February 2016
Received in revised form :
1st March 2016
Accepted : 4th
March 2016
Published online :
6th
March 2016
I. INTRODUCTION
More fuel efficiency and high performance are the two most
important requirements for the modern automobile
industries, manufacturers and buyers. KERS is a collection
of parts like gears train, bearings, scroll spiral spring which
takes some of the kinetic energy of a vehicle under
deceleration, stores this energy in the form of mechanical
energy and then releases this stored energy back into the
drive train or gear train of the vehicle, providing a more
power or energy to that vehicle. During braking, both first
and rear wheel are near the initial condition due to this
energy is wasted because kinetic energy is mostly converted
into heat energy or sometimes sound energy. By a proper
mechanism, this stored energy is converted back into kinetic
energy which giving the vehicle extra energy or power.
There are two basic types of KERS systems, first is
Electrical and second is Mechanical. The main difference
between them is in the way they convert the energy in
vehicle.Main purpose of this system is to stored the energy
and utilise this stored energy if needed. Kinetic energy
recovery system increased efficiency of the vehicle and
saved fuel loss.
II. SCOPES
There are several sides of the project in which one of the
most important is there is no such an application is yet to be
invented as simple as this. There are no Present systems
accomplishing this problem completely as they all restrict
the both motions of the wheel. So as per our perspective this
project lead towards the revolution in present automobile
industry.
III. METHODOLOGY
The system comprises of disk brake mounted on wheel hub,
the wheel axle, planet gear, sun gear fastened to the wheel
axle, recovery
ring. When the vehicle is in motion the wheel
hub rotates freely, planet gear is idling, i.e. it rotates freely
in between the recovery ring and the sun gear.Kinetic
energy recovered from the vehicle motion after braking is
now stored in the scroll spring .this energy can be used
further whenever required to accelerate the vehicle.The
plane scroll spring is released by releasing the green band.
This energy released from the spring onto the axle in short
time (instantaneously) will accelerate the vehicle without
consuming any fuel by utilizing the recovered kinetic
energy while breaking the moving vehicle earlier.
Steps:
1. Data collection.
2. System design.
www.ierjournal.org International Engineering Research Journal (IERJ) Special Issue 3 Page 252-254, 2016, ISSN 2395-1621
© 2015, Page 2
3. Selection of material and.
4. Drawings of demo model.
5. Design of each element.
6. Cost Estimation.
7. Actual Manufacturing / Fabrication.
8. Assembly.
9. Implementation and testing.
INFRASTRUCTURE AND MACHINERY REQUIRED
1 .Lathe
2. Milling
3. Drilling
4. Electrical arc welding
MAN POWER REQUIRED
1. Turner
2. Miller
3. Machinist
4. Welder.
IV. DESIGN METHODOLOGY
In our attempt to design a special purpose machine
we have adopted a very a very careful approach, the total
design work has been divided into two parts mainly;
System design
Mechanical design
System design mainly concerns with the various
physical constraints and ergonomics, space requirements,
arrangement of various components on the main frame of
machine no of controls position of these controls ease of
maintenance scope of further improvement; height of m/c
from ground etc.
In Mechanical design the components are categorised
in two parts.
Design parts
Parts to be purchased.
Fig. No. 1 Design of scroll spring
Fig. No.1 Scroll spiral spring
DIMENSIONS:-
INPUT DATA :
Maximum bending moment = Torque transmitted = 0.48 x
103 N-mm
Where t = thickness of spring = 1mm
Assuming width of spring = 20 t
Length of spring = 1100 mm
Material of spring = EN48 D
Young’s modulus E = 200 kN/mm2
Maximum stress (σ ) = 800 N/mm2
Maximum bending moment = σ x b x t2 /12 = 800x 20 x 1
2
Mmax = 16000 N-mm
AS Mmax (16000)> M (4800)….spring is safe
No. of turns to wind up spring:
θ = 12 M l / E b t3
= 12 x 16000 x 1100 / 200 x 1003 x 20 x 1
3
θ =52.8 rad
Since one spring turn is 2 π radians, therefore
No. of turns of spring to wind up = 52.8/ 2 π =8.4 turns
Material of spring = EN48 D
V. ASSEMBLY AND WORKING
In this mechanism the planetary gears are attached
to the planet carrier by using studs and bolts. During normal
motion of vehicle, both the planet gear and carrier rotates
about the same axis i.e. axis of shaft. Thus no motion is
transmitted to the ring gear and is at a standstill position
which thereby results in no energy is being transmitted and
stored into the spring. However when the brake is applied to
stop the vehicle, the planet carrier stops rotating about the
axis of shaft and as a result the gears start rotating about its
own axis with the help of bearing which are previously
bored into the planetary gears. Now the motion is
transmitted to the ring gear and ring gear starts rotating in
opposite direction as that of the wheel. As the drum and ring
gear are coupled together, as soon as the ring gear starts
rotating; the drum also starts rotating in the same direction
as that of the ring gear. Since the internal end of the spring
is brazed with the drum, as the drum rotates spring also
starts winding. The winding of spring results in compression
of spring and in this way the energy is stored into the spiral
spring. In this way the spiral spring plays a vital role in
Kinetic Energy Recovery System as main energy storing
element. The clutch restricts reverse motion of spring (i.e.
involuntary unwinding of spring) and only allows spring to
be winded.
Fig no. 2 BLOCK DIAGRAM OF KERS SYSTEM
www.ierjournal.org International Engineering Research Journal (IERJ) Special Issue 3 Page 252-254, 2016, ISSN 2395-1621
© 2015, Page 3
VI. CHOICE OF PLATFORM
In this case of designing this system, we have selected four
wheelers particularly due to:-
1. The Kinetic Energy Restoration System can be mounted
easily inside four wheeler’s rim.
2. Latest environmental norms for pollution control require
better fuel efficiency of four wheel vehicles.
3. Four wheelers are most widely used means of transport
and employing this system will result in a huge impact.
VII. ADVANTAGES
Reduced CO2 Emissions/Pollutants
Enhanced Performance
Environmentally Sound
High power capability
Light weight and small size with Long system life
Completely Safe and a Truly Green Solution
High efficiency Storage and Recovery
VIII. DISADVANTAGES
Only one KERS for car which has only one braking
system.
The energy recovery system is functional only
when the car is moving.
If in case the KERS is connected between the
differential and the wheel the torque applied to
each wheel must be same.
It is very costly. Engineers are trying hard to make
it more cost effective.
IX. CONCLUSION
KERS 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.
KERS system has a wide scope for further development and
the energy savings. The use of more efficient systems could
lead to huge savings in the economy of any country. Here
we are concluding that the topic KERS got a wide scope in
engineering field to minimize the energy loss. As now a
day’s energy conservation is very necessary thing. Here we
implemented KERS system in a bicycle with an engaging
and disengaging clutch mechanism for gaining much more
efficiency. As many mating parts is present large amount of
friction loss is found in this system which can be improved.
Boost is reduced because of friction. Continuously variable
transmission can be implemented to this system which
would prove in drastic improvement in energy transmissions.
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