Smart Regenerative Braking System Using Geared DC Motors – Energy Recovery Electric Vehicle Project Kit

Description

⚙️ Project Overview

The Regenerative Braking System Using Geared DC Motors is an innovative mechatronics project that recovers energy during braking and stores it for reuse.

When a vehicle slows down, traditional brakes waste kinetic energy as heat. In this model, however, a geared DC motor acts as a generator during braking, converting motion into electrical energy.
The produced voltage is rectified, filtered, and stored in a 6V/12V rechargeable battery, representing how real EVs (like Tesla, Tata Nexon EV, and Toyota hybrids) recover braking energy.

This working model allows students to visualize energy conversion principles, regenerative efficiency, and the electrical-mechanical interaction involved in electric vehicle power systems.

🔋 Working Principle

The project works on the fundamental principle of energy conversion — converting mechanical energy into electrical energy via electromagnetic induction.

1. Normal Drive Operation:
   The geared DC motor operates as a motor, rotating the wheel or shaft and simulating vehicle motion.

2. Braking Mode:
   When braking is applied, mechanical motion continues due to inertia.
   The motor now functions as a generator, producing DC voltage proportional to rotational speed.

3. Energy Recovery:
   The generated energy passes through a bridge rectifier and filter circuit, then charges a lead-acid battery.

4. Power Display and Output:
   The system powers LED indicators or load lamps and optionally displays voltage/current levels using an LCD display.

This mechanism effectively demonstrates how regenerative braking systems in electric and hybrid vehicles recycle power that would otherwise be lost.

🔩 Key Features

• Real-time demonstration of energy recovery through braking.

• Geared DC motors for torque-driven smooth energy generation.

• Converts kinetic energy into electrical energy efficiently.

• Bridge rectifier and filter ensure clean DC output.

• Compact frame setup for easy lab demonstration.

• Battery charging circuit integrated with feedback mechanism.

• Ideal for learning EV braking systems and hybrid energy models.

🧰 Technical Specifications

🎓 Educational Outcomes

Students will learn:

• How geared DC motors act as both motor and generator.

• Real-world application of regenerative braking in electric vehicles.

• Design of rectifier and battery charging circuits for energy feedback.

• Integration of mechanical and electrical systems in hybrid automation.

• Principles of energy conservation and dynamic braking control.

This project provides a complete understanding of green transportation technology, energy management, and electromechanical systems — making it a great choice for final-year students and EV research projects.

💡 Applications

• Electric Vehicles (EVs) and Hybrid Cars

• Smart Electric Bicycles and Scooters

• Energy-Recycling Industrial Drives

• Wind and Treadmill Power Recovery Systems

• Educational Demonstrations in Mechatronics and Power Engineering

🧩 Advantages

• Converts braking energy into useful electrical energy.

• Reduces energy loss and increases efficiency.

• Improves battery life and overall power utilization.

• Cost-effective and easy-to-demonstrate design.

• Real-world simulation of EV regenerative braking technology.

📦 Package Includes

• Dual Geared DC Motor Mechanical Assembly

• Rectifier and Battery Charging Circuit Board

• 6V / 12V Rechargeable Lead-Acid Battery

• LED Display Board (for energy indication)

• Frame and Pulley Mount Assembly

• Wiring Kit and Connectors

• Documentation (Word + PDF)

• Circuit & Block Diagram Image

• User Manual and Demonstration Guide