Kinetic energy recovery system for bicycle

CHAPTER 1

INTRODUCTION

A kinetic energy recovery system abbreviated as KERS is an automotive system

which recovers the kinetic energy of a moving vehicle under braking. The energy
recovered is stored in terms of potential energy a reservoir for later use for acceleration.
Examples of reservoir are high voltage batteries, flywheels, hydraulic coupling, etc.
The selection of reservoir largely depends on the purpose.

In recent days recovering Kinetic energy has become an interesting area of

research for many. Let us first find out why? The total energy in this universe can be
broadly divided into two parts Potential Energy and Kinetic Energy. The Potential
Energy is the energy possessed by the body due to its position or state where as the
Kinetic Energy is the energy the body gains due to its motion. As we know notion is a
relative concept so as the Kinetic energy. For example a car possess some Kinetic
energy with respect to road but with respect another car moving at same speed it has no
Kinetic energy. So when we need to impart motion into a body we have to convert
some amount potential energy into Kinetic energy. When that body has to come to rest,
that amount of kinetic energy needs to get converted into Potential energy. But in
nature the form of potential energy to which the Kinetic energy gets converted is of a
lower grade, in most of the cases, and is very difficult to reuse. Taking the example of a
car, when we run a car we burn petrol and convert the potential energy of the petrol into
the Kinetic energy of the car and when we apply the brakes the kinetic energy converts
into heat energy in the brake callipers and eventually gets diffused into the atmosphere.
If this energy would have been saved it could have been used.

There are two type of Kinetic Energy Recovery Systems which have gained
popularity in recent days. One is Electrical KERS and another is Mechanical KERS.
Both have their respective pros and cons. The electrical system is less efficient but it
can store power for a longer duration and gives us the agility to manipulate the torque
and rpm output as per our requirement.

Dept. of Mechanical Engineering, MCE, Hassan 1

 Kinetic energy recovery system for bicycle

In the other hand the mechanical system has a better efficiency (nearly twice as
that of the prior one) but it is prone to decay due to its inherent property of friction,
though it is very small in value, hence cannot be stored for loner period and need to be
used within a short period of time. In the real world we can find many situations where
we need to use the recovered Kinetic energy with in very short span of time of its
recovery and we don’t even need a wide range of torque and rpm output as a particular
range of torque & rpm combinations satisfy our requirements completely. A bicycle is
a perfect example of this kind.

This is why KERS for bicycle has been chosen as the final year project. There
has been a lot of work related to this topic but this topic still needs more research.
During the project the goal will be to design an optimised mechanical KERS which
will improve the storing time of the kinetic energy as well as improve the compatibility
and manufacturability of the system.

Dept. of Mechanical Engineering, MCE, Hassan 2

 Kinetic energy recovery system for bicycle

CHAPTER 2

LITERATURE SURVEY

The first of these systems to be revealed was the Flybrid. This system weighs 24
kg (53 lbs) and has an energy capacity of 400 kJ after allowing for internal losses. A
maximum power boost of 60 kW (81.6 PS, 80.4 HP) for 6.67 seconds is available. The
240 mm (9.4") diameter flywheel weighs 5.0 kg (11 lbs) and revolves at up to 64,500
rpm. The maximum torque generated at the flywheel is 18Nm (13.3 ft-lbs), and the
torque at the gearbox connection is correspondingly higher for the change in speed.
The system occupies 13 litres of volume.[1]

Two small accidents were reported during testing of various KERS systems in
the year 2008. The first incident happened with Red Bull Racing when the team tested
their KERS battery for the first time in July, the battery malfunctioned and accidentally
caused a fire, to avoid any causality evacuated the building. The second incident
happened within a week. A BMW Sauber mechanic got an electric shock when he
touched Christian Klien's KERS-equipped car during a test at the Jerez circuit.[2]

Formula one has stated that they support environment friendly technology and
thy have allowed use of KERS in 2009 F1 championship. Due to the previous
accidents with KERS system many teams did not use it in their cars. Only four teams
opted for KERS in 2009 session that to in few races only. Ferrari, BMW, Renault and
McLaren were the fore teams using the KERS in their cars.[2] Due to some
malfunctioning BMW and Renault stopped using this system during the season.
Vodafone McLaren Mercedes was the first team to win a F1 GP using a KERS
equipped car on July 26, 2009 at the Hungarian Grand Prix. Lewis Hamilton was
driving that car to become the first driver to win a pole position with a car equipped
with KERS. In that race only their car which was also equipped with KERS finished
fifth. Kimi Räikkönen won Belgian Grand Prix with KERS equipped Ferrari on 30th
August 2009. [2]

Dept. of Mechanical Engineering, MCE, Hassan 3

 Kinetic energy recovery system for bicycle

Fig.2: Ferrari F1 car

WilliamsF1 was the first to develop their own flywheel-based KERS system.
Unfortunately they could not use it in their F1 cars because of packaging issues. Thus
they developed an electrical KERS system of their own. They even set up Williams
Hybrid Power to sell their developments in the field of KERS. In the year 2012 Audi
announced to use Williams Hybrid Power in its Le Mans R18 hybrid car. By the year
2014, the power accumulation capacity of KERS systems has increased from 80bhp to
160bhp. F1 started using 1.6 litre V6 engines with an integration with KERS devices
instead of2.4 litre V8 engines.[3]

In the field of motor racing Bosch Motorsport Service is a pioneer and it is

developing a KERS that can be used in motorbikes. In the year 2009 KTM racing boss
Harald Bartol announced that during the 2008 season-ending the factory raced with a
KERS secretly fitted to Tommy Koyama's motorcycle in 125cc Valencian Grand Prix.
This use of KERS was illegal, hence the team was banned from using that equipment in
future.[3]

KERS system can also be used on a bicycle. Students of the University of

Michigan working with EPA has developed a system called RBLA (hydraulic
Regenerative Brake Launch Assist). [3]

Dept. of Mechanical Engineering, MCE, Hassan 4

 Kinetic energy recovery system for bicycle

2.1 COMPARATIVE STUDY OF DIFFERENT TYPE OF KERS:

As we can see there are various ways of regenerating and reusing the kinetic energy of
the a system, a comparative study of different Kinetic energy recovery systems is
required to realise their respective pros and cons.

a) Mechanical KERS:

Mechanical KERS utilises a flywheel as a flywheel as the energy storage

device and a variable drive transmission to control and transfer the energy to
and from the driveline [4].Energy is transferred from the vehicle to the
flywheel. In doing this the speed of the vehicle decreases and that of the
flywheel increases which we can effectively call as a braking [5]. At the start of
braking process the vehicle has a higher speed than the flywheel, giving a
certain speed ratio between them whereas at the end of braking the vehicle has a
lower speed than the flywheel so the ratio of speeds has changed [6].
Examination of the energy transfer shows that the ratio between vehicle speed
and flywheel speed necessarily changes continuously during the energy transfer
event [5] [6].

b) Electrical KERS:

Electrical kinetic energy recovery system converts the kinetic energy into
chemical energy for storage and an electric motor generator system is used as
the energy transfer and control media [7]. The common components used in
battery storage type kinetic energy recovery system are Electric Propulsion
Motor /Generator, Power Electronics –Inverter, and the Quad Flywheel Storage
[7] [8] [9]. Capacitors are fundamental electrical circuit elements that store
electrical energy in the order of microfarads and helps in filtering [10] [11] [12]
[13]. The main function of a capacitor is to get charged and discharged
electricity [13] [14] [15]. A super-capacitor is an upgraded version of a
capacitor having special features such as long life, rapid charging, low internal
resistance, high power density, and simple charging method as compared to
capacitors and batteries [16][17]

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 Kinetic energy recovery system for bicycle

Dept. of Mechanical Engineering, MCE, Hassan 6

 Kinetic energy recovery system for bicycle

c) Hydraulic KERS:

Regenerative braking in vehicles using a variable displacement

hydraulic pump/motor together with a hydro pneumatic accumulator has
attracted considerable interest during the last 20–25 years. Such a system is
particularly suitable for application in city [18] [19] [20] [21] [22] [23].
Despite the significant gains in the efficient use of energy that the use of this
system has not attained great popularity [22] [23]. The added cost, which
may represent 10–15% of the total for the vehicle, is one of the major
drawbacks of this system [25] [26] [27].

d) Hydro-electric KERS:

A hydraulic electric synergy system (HESS) is a hydraulic

accumulator and battery hybrid energy system [28]. This system follows
hybrid energy structure to integrate a high specific energy battery with a
high power hydraulic accumulator to get required output [22]. Hence it
overcomes the drawbacks of a single energy storage source type KERS.

A thorough study by Radhika Kapoor and C. Mallika Parveen In their paper

“Comparative Study on Various KERS” [3] have shown the following points:

I. A flywheel is capable of offering maximum steady voltage and power levels

as compared to other types of storage systems. Even flywheels are
independent of load, state of charging and temperature. Next to the flywheel
storage system, comes the Li-ion battery system. It has also been mentioned
that super capacitors have the lowest ever stability, i.e. around 30%.

II. Flywheels are the most robust power storage systems having a wide range
of temperature withstanding capability, going from -40°C to 150°C. In the
other hand Lead-Acid batteries have the shortest range starting from -15°C
to 50°C. In case of temperature range super- capacitors come next to
flywheels.

III. In case of efficiency super capacitors are the best in the list followed by the
hydraulic system, then the flywheel system and lastly the battery system
which has the least efficiency.

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 Kinetic energy recovery system for bicycle

IV. If the KERS systems are listed in terms of reduction in fuel uses the list
will be something like this:

a. Super capacitors (best)

b. Flywheel system
c. Hydraulic system

V. Finally if the cost of these devices are taken into account it can be seen that
the battery system is the cheapest among all the KERS devices. Next to
battery system comes flywheel system. The super capacitor system is twice
the cost of flywheel system and the hydraulic system costs even more than
thrice the cost of a flywheel system.

2.2 KERS RELATED RESEARCH WORK

From the history of KERS we can see that there has been sufficient amount
of work in the field of kinetic energy recovery system for high end vehicles.
Though some amount of the work is done in the field of two wheelers, which is not
sufficient to get an optimum kinetic energy recovery system. In India a huge
percentage of its population depends on two-wheelers for transport. So KERS for
two wheelers needs a lot more research and improvement. Following are some of
the papers who have worked on Kinetic energy recovery system for bicycles. They
have focused on energy storage improvement. The following are the observations
by Sreevalsan Et. All in their paper “Design and analysis of kinetic energy recovery
system in bicycles”. They have mentioned some of the most basic requirements of a
KERS for bicycle [1].

The aesthetics of the product should be good otherwise it won’t get its share
in the market. It should be adaptive to the existing models of bicycles. It should not
obstruct normal riding. If the device interferes with the riding experience in a bad
way it won’t be a desirable product. And last but not the least the driver should have
a controlled over the release of power from the KERS system.

Energy should be stored during braking. This is the most fundamental

requirement of this device. Its name suggests that. The energy recovery should be

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 Kinetic energy recovery system for bicycle

rider friendly and should meet all his needs. Energy should be returned to the
bicycle to start up.[1]

There must be simple way release the energy that is stored during braking in a
positive way. The system must get fit to the bicycle otherwise it is irrelevant to
design a model that cannot be used. The designer must keep in mind the space
available while designing the system. The KERS system should be of light weight.
Otherwise the weight of the system will increase unnecessarily and there won’t be
any advantage in installing an over weighted KERS system. The KERS should be
able to slow down the system considerably when the rider applies it. The stopping
range should be less. In case of requirement of sudden brakes there should be
provisions for application of sudden brakes. The stopping force should be large.
Larger the stopping force higher is the rate of charging of the flywheel. The system
should be inexpensive and must be affordable. Otherwise the product won’t make
any profit. The KERS system should be safe to use and must be environment
friendly. Safety is the most vital concern of a consumer product. The product must
be economical and cheaply available in the market. It should be reliable and have a
long life of operation. The product should be easy to manufacture. In order to make
a product economical in production, its manufacturability should be of greatest
concern. [1]

2.3 IMPORTANCE OF FLYWHEEL

Rotating wheels have long been used to store energy and to deliver it hen
required since ancient times. Potter’s wheel is one of the first inventions that
resembles a flywheel. This has existed for nearly 4,000 years. In 1784 the first
appearance of the word flywheel occurred during the time of industrial revolution.
In those times flywheels were used on steam engine trains, boats and even used as
energy accumulators in industries. With drop in price of iron and steel flywheels
became more and more popular during the time of industrial revolution flywheels
used to be huge to store high amount of potential energy at low speed. During
1950’s Gyro buses used flywheel for the first time on road vehicles in Switzerland.
That flywheel was 1500kg in weight and 1.626m in diameter.[2] It was capable of
storing 3.3e7 joules of energy when fully charged. Flywheels are now found in
almost all road, sea, air and space vehicles. In power plants flywheels are used tis

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 Kinetic energy recovery system for bicycle

tor energy and to control voltage. Flywheel has gained even more attention now
days due to raised concerns regarding environment.

Invention of carbon fibre has made flywheel technology useful. Now

flywheels can spin faster, safer and release more energy than ever before with
smaller size. Flywheels can always remembered as large spinning masses from
industrial age, but now they are finding innovative uses in various fields due to
recent development in the field of material science.[2]

High power density is the most distinctive feature of a flywheel. With the
development in the field of carbon fibre it is now possible to make small and light
weight flywheels that can store very high amounts of energy safely. They can be
charged very quickly and can discharge high amounts of power. These kind of
application can be seen from their uses in nuclear fission plants [2]. These are olso
the most pollution free energy storage systems. In short run flywheels are got
efficiency near one hundred percent. The efficiency drops with increase in storage
time. The rate of decay of energy greatly depends on the housing and establishment
of the flywheel. Transmission has been one of the greatest concerns in flywheel
energy storage system. Inefficient transmission can cut the output energy by even
half or more. The design of transmission systems often decides the upper limit of
speed at which the flywheel can operate Flywheels are replacing electrochemical
batteries in road vehicles and other applications due to their pollution free nature.
Flywheels have a longer life time than batteries, can get charged faster, have high
energy density and are lighter in weight. Flywheels don’t have an economic
advantage over batteries yet, since flywheel technology for road vehicles is not
completely developed, but there is a promising future for flywheel hybrid cars.[2]

Dept. of Mechanical Engineering, MCE, Hassan 10

 Kinetic energy recovery system for bicycle

CHAPTER 3

OBJECTIVE AND IDEAS

Any project at its starting comprises of setting the objective. Then comes ideas
and their comparison to get to the best method to achieve the objective. Similarly for
this project a lot of brain storming resulted in a good and efficient model of KERS
system for a bicycle.Let us take the normal chain system based KERS system can
give us a smoother starting after braking it has the limitation that it keeps the KERS
system always engaged even the rider doesn’t want to use KERS in some
circumstances. In the other hand for the clutch based KERS system we have the
liberty to engage and disengage the KERS system any time we want but this system
also has its limitations. In a clutch based KERS system the initial jerk when the
KERS system is actuated is very high. So in this project it has been tried to develop a
hybrid between a clutch type and a normal chain system type KERS system.

3.1 IDEA 1

First when the project was undertaken the idea was to develop a completely
clutch based KERS system and to reduce the initial jerk to make it more handy. The
thought behind this was when the brakes are to be applied the rider first actuates the
KERS and the flywheel charges. After some time the speed of the cycle will reduced
and then the rider will disengage the KERS system and will apply the brakes. For this
function the brake wires are connected the right brake handle; both the front an rear
brakes

Clutch Clutch

Flywheel

Fig.3.1 (a) clutch disengaged Fig.3.1 (b) clutch

engaged

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 Kinetic energy recovery system for bicycle

Fig.1a and Fig.2b represents the KERS system in the disengaged and engaged
state respectively. This system has its limitations. They are

 This KERS system is not user friendly.

 Braking is a very important thing when it comes to mobile vehicles. Here the
rider has to plan many thing before braking. Like when to apply the Kers
when to disengage it and then to apply the brakes. During all this work he may
lose concentration and there is a chance of accident.
 Both front and rear brakes are connected to only one rider handle. So the mild
braking is not possible. Every time the rider applies the brakes it is a hard
brake.
 Again to get acquainted to this new type of braking system is tedious task.
 Customers will not prefer this product.

Due to all these disadvantages is idea is ruled out.

Dept. of Mechanical Engineering, MCE, Hassan 12

 Kinetic energy recovery system for bicycle

3.2 IDEA 2

The second idea was to go for a completely normal chain system based KERS
system for the bicycle. The plan here was that there will be no clutch instead the rear
wheel will be connected to the flywheel directly through a chain drive. This means
the flywheel is always connected to the system. During starting the rider has to keep
a high gear ration to charge the flywheel fast and during discharging he has to keep a
low gear ratio to increase the time of discharge and to get the maximum benefit. In
this case the brake system is free and the chance of accident is completely avoid. So
the safety part is done. Now coming to the actuation part of the KES system, for that
the driver has been provided a controller (mechanical controller) to change the gear
ratio as per his requirement.

Flange

chain

Flywheel sprocket

Rear wheel

Fig.3.2 Normal chain system based KERS

Fig.2 shows a schematic diagram of a normal chain system based KERS system.The
main limitations of this system are:

 The starting effort required is very high.

 As the road is always unpredicted, sometimes this may happen that the rider
has completely discharged his KERS system and he comes across an upward
slant. The effort required will increase many fold.
 Due to all time engagement the system may undergo sever wear and tear.
 Also this high engagement time causes losses due to friction at the flywheel.

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 Kinetic energy recovery system for bicycle

3.3 IDEA 3

The next idea is a hybrid of the above two Ideas. In this case the clutch
system is optimised and variable transmission (instead of Normal chain system)
system is used to get the optimum output of the KERS mechanism. This system has
advantages over the above two methods and eliminated their respective limitations.
In this paper the working principle, design and manufacturing process if this model is
elaborately discussed.

The advantages of this system are:

 This is user-friendly.
 The braking system is completely independent avoiding any chance of
misshape.
 This is less costly.
 Avoids completely the initial jerk.
 Avoids the application jerk up to a large extent.
 Easy to fit.
 Marketable.
 Easy to manufacture.

Dept. of Mechanical Engineering, MCE, Hassan 14

 Kinetic energy recovery system for bicycle

CHAPTER 4

METHODOLOGY

The working principle of the KERS system is described below in details.

1. To actuate the KERS the lever near the left brake is to be actuated. This pulls
the wire connected to the clutch drive and rotates it by some angle less than
180°.
2. Due to the rotational motion of the clutch drive it undergoes translational
motion, because its counterpart is fixed.
3. The translational motion of the clutch drive pushes the clutch plate to bring it
in contact with the flywheel.
4. In this design we have connected the KERS actuator on the opposite side of
the left brake lever so when clutch is actuate brake is not actuated (which is
the default position) and when the brake will be actuated the clutch will
automatically disengage.
5. The clutch plate is a continuously moving part as it is connected with the front
sprocket using three keys.
6. The front sprocket is driven by the rear sprockets through a chain drive.
7. The rear sprockets are a set of sprockets on which the chain can change
position to get different gear ratios. These are interconnected and rotate at
same RPM as the rear wheel.
8. During charging of the flywheel, power flows as follows
Rear Wheel Rear Sprocket Chain Drive Front Sprocket Clutch
Flywheel
9. During the discharging cycle, power flows exactly in the reverse direction.
Flywheel Clutch Front Sprocket Chain Drive Rear Sprocket
Rear Wheel.
10. As there are 5 sprockets on the rear sprocket system we can have 5 different
gear ratios and can manipulate them to get the required charging and
discharging conditions.
11. During charging it is preferred to use a higher gear ratio (Rear: Front) so that
the flywheel can get charged within less time. But this will cause higher initial
jerk while engaging.

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 Kinetic energy recovery system for bicycle

12. So it is preferred to engage the clutch at the lowest gear ratio and then increase
the gear ratio to the maximum.
13. This has an additional advantage. With every increasing gear ratio the relative
velocity of the flywheel as compared to the rear wheel decreases. Thus
additional torque acts on the flywheel and accelerates it to even higher speed.
This way the flywheel can attain its maximum desired RPM smoothly.
14. Now the flywheel has its maximum potential energy. So if the driver wants to
brake, he simply applies the brake and the flywheel automatically disengages
as the string that actuate the flywheel is connected to the opposite end of the
left handle brake as mentioned earlier.
15. Now coming to the discharging of the flywheel. Discharging can be done for a
long time if we keep the sprocket ratio (rear: front) low. But if the gear ratio is
more the torque will be more.
16. We need higher torque when discharging starts and low but continuous
discharge when the cycle attains some speed.
17. From the previous discussion we can see that at the end of the charging cycle
the gear ratio is at maximum. So when the discharging starts we simply need
to reduce the gear ratio in successive intervals.
18. This has another advantage. When the gear ratio is lowered the relative
velocity of the flywheel becomes more as compared to the rear wheel. So the
power flows from the flywheel to the rear wheel and the cycle accelerates.
19. The gear changer for the KERS system will also be on the left hand side. So
the driver has to concentrate only on hand to operate this system. And when he
needs to brake (sudden brake) he simply can apply brakes. The cycle will stop.
20. The starting effort will be a little more but not that more because while starting
the gear ratio is at minimum. Or if the driver is a bit smart he can apply the
brake lever slightly and accelerate the bicycle easily. At that condition the
KERS will be disengaged and the brakes are not also applied.

Dept. of Mechanical Engineering, MCE, Hassan 16

 Kinetic energy recovery system for bicycle

CHAPTER 5

COMPONENTS OF KERS BICYCLE

5.1 SPROCKET
Sprockets are used with chain to transmit power from rear wheel to flywheel via
clutch and vice versa .Two sprockets must be used. The gear ratio is to be taken in to
account here. One sprocket with higher number of teeth is to be selected and another one
having lesser number of teeth. The smaller sprocket is to be placed at the axle end and
larger sprocket at the rear wheel end. This is just to ensure that we can provide maximum
flywheel rotations so that energy storage increases.

Fig 5.1 Diagram of smaller & larger sprocket

5.2 FLYWHEEL

In principle, a flywheel is nothing more than a wheel on an axle which stores and
regulates energy by spinning continuously. The flywheel is the component which harvests
kinetic energy, when the vehicle brakes, by increasing its rotational speed. It is used
for temporary storage of energy. It acts as a source of energy while accelerating. It
stores energy by virtue of its inertia. The ability of flywheels to store energy is explained
by the relation between the flywheel’s inertia, angular velocity and kinetic energy

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 Kinetic energy recovery system for bicycle

Fig 5.2 Flywheel

5.2.1 Mechanism Involved in KERS Flywheel

The flywheel energy storage is based on the principle of regenerative braking.
Regenerative braking is a mechanism which reduces the vehicle speed, converting the
kinetic energy into another useful form of energy mechanical energy, electrical energy or
the like. Flywheel energy storage (FES) works by accelerating a rotor (flywheel) to a
very high speed and maintaining the energy in the system as rotational energy. When
energy is extracted from the system, the flywheel's rotational speed is reduced as a
consequence of the principle of conservation of energy; adding energy to the system
correspondingly results in an increase in the speed of flywheel .Generally in a battery
powered hybrid, an electric motor is connected to the wheels. When the vehicle brakes,
the motor rotates in the opposite direction acting as a generator and in the process slows
down the vehicle. The electricity produced is then sent to the battery which stores the
energy as chemical energy. When desired, the battery supplies the stored energy
back to the wheels, giving an additional “boost” of power.

When the brakes are applied or the vehicle decelerates, the clutch connecting the
flywheel system to the driveline/ transmission is engaged, causing energy to be
transferred to the flywheel via chain drive. The flywheel stores this energy as
rotational energy and can rotate up to a maximum speed of 2000 rpm.

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 Kinetic energy recovery system for bicycle

When the vehicle stops, or the flywheel reaches its maximum speed, the clutch
disengages the flywheel unit from the transmission allowing the flywheel to rotate
independently. Whenever this stored energy is required, the clutch is engaged and the
flywheel transmits this energy back to the wheels, via the chain drive. Compared
with other ways to store electricity, FES systems have long lifetimes (lasting decades
with little or no maintenance; full-cycle lifetimes quoted for flywheels range from in
excess of 105, up to 107, cycles of use), high energy density (100–130 W ·h/kg, or
360–500 kJ/kg), and large maximum power output. The energy efficiency (ratio of
energy out per energy in) of flywheels can be as high as 90%. Typical capacities
range from 3 kWh to 133 kWh. Rapid charging of a system occurs in less than 15
minutes.

5.2.2 Design of Flywheel

The equation for the energy stored in a flywheel reads as follows:
1
E= 2 I𝟂2

Where E is the energy (Joules); I is the inertia of the flywheel (kgm2), and 𝟂 is the
angular velocity (red/sec) of the flywheel.
The equation for the inertia of a flywheel is:
1
I= 2 m (r12-r22)
Where 𝑚 is the mass of the flywheel; 𝑟2 and 𝑟1 are the inner and outer radius of the
flywheel respectively.

Combining we get:
1
E= 4 m (r12 -r22)

From equation 3, a flywheel's energy is proportional to its mass, and proportional to

the square of its rotational speed or angular velocity. In other words, by doubling the
mass, the energy stored is also doubled, and by doubling the speed, the energy
stored is quadrupled. Thus by increasing the speed of the flywheel it will be possible
to reduce the mass and size of it, to a level where its weight is insignificant while
analyzing fuel efficiency.

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 Kinetic energy recovery system for bicycle

The amount of energy that can safely be stored in the rotor depends on the point at
which the rotor will wrap or shatter. The hoop stress on the rotor is given by

𝜎𝑡 = 𝜌𝑟2𝜔2
Where 𝜎𝑡 is the tensile stress on the rim of the flywheel; 𝜌 is the density, r is the

outer radius of the flywheel and 𝜔 is the angular velocity of the rotating flywheel.

The flywheel can be fabricated using different materials based on the maximum
rotational speed requirements and other design constraints. High speed flywheels for
speeds above 30000 rpm are usually composed of high strength carbon fiber. A large
mass is not desired for high speed flywheels because extra mass means more energy
will be needed to accelerate the vehicle. On the other hand, low speed flywheels
with speed values below 20000 rpm, are generally made of steel or other metals for
low cost. The weight of the flywheel is a very important factor in determining the
efficiency of the system. Here flywheel is required for maximum speed 2000 rpm so
material is not a major concern we can use mild steel because it is available at low
cost. Yield strength of mild steel is 250 MP a so it is safe to use as a material of
flywheel.

5.2.3 Calculation for the mass of flywheel

As already discussed, Flywheel works as a source of energy, so it is responsible to
accelerate the bicycle. This can be achieved by having proper values for mass & radius
of flywheel. Radius cannot be more than 30 cm because of the structure of bicycle.
Now, mass of flywheel is the only factor which can be varied according to
requirement. Calculations for the mass of flywheel are as follows-

The equation for the energy stored in a flywheel reads as follows:

1
E= 2 I𝟂2
Where 𝑚 is the mass of the flywheel; 𝑟2 and 𝑟1 are the inner and outer radius of the
flywheel respectively Taking the values r1 =15cm, 𝑟2 =1cm, 𝜔 will be around
39.25 rad/sec because gear ratio is 2.5.
Now, Kinetic energy of a system is
1
Ek = 2 (mf+ md +mc) V2
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 Kinetic energy recovery system for bicycle

Where 𝑚𝑓is the mass of flywheel, 𝑚𝑐 is the mass of cycle, 𝑚 is the mass of driver and
linear velocity of system is

𝑉 = 𝑟𝑤 𝜔1

Where 𝑟𝑤 the radius of rear is wheel and 𝜔1 is the angular velocity of rear wheel

From equation we get,

1
EK = 2 (mf + mc + md) rw2𝟂12

For a general case, taking the values 𝑚𝑐= 18kg, 𝑚𝑑=65kg, 𝑟𝑤 = 40cm, we need to

rotate by min 𝜔1 =2.1 rad/sec and assuming a power lost factor k is 0.6.

By equating both equations we get,

1 1
4
mf (r12 – r22) k𝟂2= 2 (mf + mc + md) rw2𝟂12

Where r1 =15cm, 𝑟2 =1cm, 𝜔 will be around 39.25 rad/sec,𝑚𝑐= 18kg, 𝑚𝑑=65kg,

𝑟𝑤 = 40cm, 𝜔1 =2.1 rad/sec.

We get

5.17×mf = (mf+83) ×0.35

5.17×mf=0.35mf+29.05
4.82mf=29.05
mf= 6.02kg
From the calculations we got the value for 𝑚𝑓 is 6.02 kg that is acceptable for our
design so now , flywheel can be made up of mild steel having outer diameter 30cm and
inner diameter 25 mm .

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 Kinetic energy recovery system for bicycle

5.2.4 Fabrication of Flywheel

First of all, flywheel is made circular from a square shaped plate and metal
removal processes is performed in order to balance its weight. To make a hole on
centre drilling is performed. Then the flywheel has to be bored centrally in order to
place a ball bearing so that flywheel can rotate over the axle. Also flywheel has to be
selected so that the selected weight does not affect the bicycle physics and riding
performance of the rider. The performance of KERS system mainly depends upon
the flywheel selection. For clutch accessories there should be provisions in the
flywheel which is used to deliver and release energy from flywheel. The works done
on flywheel is shown in figure below.

5.3 KERS FRAME

KERS cannot be installed in existing frame of bicycle so we need to modify it.
The frame modification is the first part of the fabrication that has to be done. The
frame has to be modified by adding steel tube or pipe. This is used to hold the
flywheel and clutch assembly. So that the frame should have enough strength so as
to carry the flywheel and the additional forces that comes to play. The modification
should not hinder normal riding. Also the modified frame should have enough space
in order to accommodate flywheel and clutch assemblies. It should not carry too much
weight and it should be balanced.

In fabrication part of modification of KERS frame, heavy steel pipes are joined by
welding and its one end is welded at rear wheel end while another end is welded at
handle end. Provisions are kept there for axle alignment, clutch cable, spring for
return mechanism.

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 Kinetic energy recovery system for bicycle

5.4 CLUTCH
A clutch has to be provided so as to control the power delivery and release
from the flywheel. This can be achieved by providing a clutch plate that is linearly
moved to and from by applying a lever mechanism incorporated with a spring
assembly for providing return mechanism. Linear clutch movements have to be made
possible. For this purpose two cylindrical rods can be used. One end of the each rod
was variably cut. This variable length is female part of another. One part of this is
fixed near the frame side. This can be achieved by welding the part. Another part is
made rotatory. This part can be rotated by applying force on it from lever via cable.
This moves only partially over fixed one and firstly this is hold in position by a
spring arrangement. A friction disc is used with a solid plate to rotate flywheel.
Some other mechanism can also be as a clutch mechanism

Fig 5.4 clutch

5.5 SHAFT
The axle has to be made so as to carry the flywheel and clutch units. The
flywheel can be inserted after bearing is added to it and if variable diameter is provided
on shaft within mid-point the flywheel can be made to be inserted from one end and
it automatically locks in the middle of the shaft over which it rotates. Also the clutch
units sequentially clutch plate and the fixed and moving rods along with its
mechanism can be mounted over the shaft.

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 Kinetic energy recovery system for bicycle

The provision for shaft placement is provided in the modified frame. The shaft should
withstand the forces coming to play.

In fabrication of shaft, first of all the diameter of the shaft is reduced uniformly throughout
the length. Step is formed to restrict the linear movement of flywheel. Provisions are
also made at both ends to lock it with KERS frame.

Fig 5.5 Shaft

5.6 CHAIN
The chains are made up of rigid links which are hinged together in order to
provide the necessary flexibility for warping around the driving and driven wheel.
The wheels have projecting teeth and fit into the corresponding recesses in the links
of the chain. The wheels and the chain are thus constrained to move together
without slipping and ensure perfect velocity ratio. Chain mechanism is generally used
to avoid slipping. The chains are mostly used to transmit motion and power from one
shaft to another, when the distance between the centers of the shaft.

Fig 5.6 - Chain

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 Kinetic energy recovery system for bicycle

5.7 OTHER ACCESSORIES

5.7.1 Bearings
A bearing is a machine element that constrains relative motion and reduces
friction between moving parts to only the desired motion. Bearings are placed on the
axle with flywheel and clutch plate. It is provided for the free rotation of the
flywheel.

Fig 5.7.1- Ball bearing

5.7.2 Clutch Cable and Lever

These are the essential components of clutch mechanism. Pressure is applied
through the clutch cable by lever to engage the clutch with flywheel.

Fig 5.7.2 - Clutch cable and lever

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 Kinetic energy recovery system for bicycle

5.7.3 Springs
This is also an important part of clutch mechanism. Two springs are used in it.
Both springs are used for return mechanism, springs are stretched when clutch is
engaged and when pressure is removed then springs pull back clutch plate into its
initial position.

Fig 5.7.3 - spring

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 Kinetic energy recovery system for bicycle

CHAPTER 6
FABRICATION OF KERS BICYCLE

Fig 6 - Fabrication Flowchart of KERS Bicycle

1. Frame Modification
It is the very first part of the fabrication of KERS bicycle. It has been discussed in
detail in section 5.3.

2. Lathe Work on Flywheel

It includes fabrication part of flywheel which is also already discussed in detail in
section 5.2.3

3. Axle alignment
The axle alignment is the most important part we have to concern because it is the
base of the flywheel, clutch units and sprocket crank mechanism. The clutch units
sequentially clutch plate and the fixed and moving rods along with its mechanism can
be mounted over axle. The provision for axle placement is provided in the modified frame

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 Kinetic energy recovery system for bicycle

4. Flywheel mounting
As per the mounting of the flywheel, it will be placed over the bearing so that it
can rotate over the axle as the axle is going to be fixed. For clutch accessories there
should be provision in the flywheel which is used to deliver and releases energy from
flywheel.

5. Clutch mounting
As per the clutch mounting is concerned , it can be achieved by providing a clutch
plate that is linearly moved to and fro by applying a lever mechanism incorporated with a
spring assembly for providing return mechanism.

6. Sprocket and crank mechanism

Sprocket and crank mechanism is equally important in this design. In this mechanism
two sprockets has to be used. The gear ratio has to be taken into account that’s why one
sprocket with higher no. of teeth is to be placed at the rear wheel end and smaller
sprocket at the axle end. This is to ensure that we can provide larger flywheel
rotation so that energy storage increase

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 Kinetic energy recovery system for bicycle

CHAPTER 7
KERS BICYCLE WORKING
A crank wheel connected to the rear wheels always rotates the clutch plate, connected
in the flywheel axle. This is being achieved by using chain transmission at a specified
gear ratio, crank to clutch sprocket helps us to increase the overall speed of flywheel.
Now at a time when a speed reduction is required, clutch is applied which makes the
contact between the clutch and flywheel. Then the flywheel starts rotating, also the speed
of bicycle is decreased. Thus are generative braking system is achieved. On course
energy is stored in flywheel. In case the brake has to be applied fully then after flywheel
rotations clutch is disengaged and the brake is applied

Now when we again rides the bicycle during which we would apply clutches at
this time as rear wheel rotation is lesser compared to flywheel the energy gets
transmitted from the flywheel to the wheels. Now also we can reduce the overall pedaling
power required in course of overrides by having clutch fully engaged. We can reduce overall
pedaling power by 10 per cent. Also situation arises such as traffic jam, down climbing a
hill where we do not intend to apply brake fully. For such cases we can apply outsmart
braking system which would allow us to decelerate and allow us to boost acceleration
after this during normal riding and distance that can be covered by pedaling can also
improve.

During normal rides situations may arise we need to reduce the speed without braking
fully such as traffic jams taking turns etc. we can store the energy that would normally be
wasted due to speed reduction by the application of clutch. When the clutch is engaged
that time due to initial engage the flywheel rotation consumes energy which would
result in speed reduction thus a braking effect. After some instances the energy is being
stored in the flywheel this can be reused by the engage of clutch plate and energy transfer
from the flywheel occurs whenever the rotation is high enough to rotate rear wheel.Thus if
sudden braking then applied we can disengage the flywheel connections so that flywheel
energy is not wasted and going to take ride the speed of rear wheel is null and hence
engage would help in returning the energy from the flywheel to rear wheel.

While riding downhill we always use braking for allowing slowdown. This is the

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 Kinetic energy recovery system for bicycle

best case where we can store maximum amount of energy in our flywheel

CHAPTER 8

FINITE ELEMENT ANALYSIS

Finite element analysis of every component has become necessary for any design
process. Every designed thing should be checked whether it can take the desired load
and sustain the working environment. Product life cycle is an important term coined in
this field. FEA helps us to identify the mistakes in our designs. It shows the tress
concentration and strain at different desired points. Even it helps to directly find out the
factor of safety for a component. The best part is we can change the part material and
test as many times as we want without losing any raw material. In this project also
extensive FEA analysis has been done on different components to check their integrity
and sustainability. All the results of those works have been mentioned below:

8.1 CALCULATIONS

Weight of the person riding the bicycle = 70kg

Weight of bicycle = 10kg

Other payloads = 10kg

Allowance for flywheel weight = 10kg

Total weight =100kg

Let us assume that the flywheel stores enough energy to take the whole system
from rest
to 10km/hr in 5sec.
V = 10km/hr = 50/18 = 2.78m/sec
U = 0km/hr = 0m/sec
Time = 5sec
a = (V-U)/Time

Energy of the system when it reaches 10km/hr = E

E = ½mv2 = 385.8 joules

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 Kinetic energy recovery system for bicycle

So let us calculate the rpm or speed of the wheel and the flywheel

DR = Diameter of the bicycle wheel = 29inch ≅ 750mm

Number of revolution made by the wheel at 10kmph per sec

v
2 πRr = 1.179rps

=70.74rpm
Force required to take the bicycle from rest to 10kmph in 5 sec

Fa = ma = 55.56N
Now considering the rolling resistance of the bicycle

FR = 20 watt at 10kmph = 7.2N

Note: We are not considering the resistance due to gradient as we are doing the
calculation for the straight road.

Aerodynamic drag=
FA

FA = CdρAv2

Where Cd = coefficient of drag = 0.75(worst case)

= 1.25 kg/m3 at
𝜌 density of air 25°C
= 1m2 (let us
A = projected area assume)
v = velocity of bicycle = 2.78m/sec
FA = 6.94N

Other frictional resistances

Ff = 4N
Total requirement of force = F

F = Fa + Fr + FA + Ff = 71.69N

Torque required at the center of the wheel to get this required force = Tw

Tw = F × r = 71.69 × 0.75 ÷ 2 = 26.884 Nm

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 Kinetic energy recovery system for bicycle

8.2 FLYWHEEL
Flywheel is the most rigid component among the components of a KERS system which has the least
amount of chance to undergo a failure.

Forces acting on the flywheel:

 Gravitational force
 Rotational inertia force (66.66rps)

Speed of rotation when the cycle runs at 30Kmph amd the sprocket ratio is maximum (s=3)

v
ω = 2π
πD

2× 30× 5
ω= ×3 = 66.66 rad/sec
0.75× 18

 Force due to actuation of clutch (373.4N)

Tw 26.88
T=
S
= 3
= 8.96 Nm

TF 8.96
Fc =
0.006 µ
= 0.006 ×0.4
= 373.4 N

From analysis we can see that

 Maximum deflection = 6.708e-8 m

 Maximum equivalent stress = 572.2 KPa

 Maximum equivalent strain = 4.6661e-6

The above data shows that design of flywheel is completely safe

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 Kinetic energy recovery system for bicycle

Total deformation

Equivalen
t Stress

Equivalent Elastic Strain

Fig 8.2 Analysis of flywheel

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 Kinetic energy recovery system for bicycle

8.3 CLUTCH

Clutch is the most vulnerable component of the KERs system. It is exposed to continuous
engagement and disengagement with the flywheel. Force acting on clutch:

 Force due to actuation of the clutch F = 373.4N

 Rotational velocity is 66.6 rad/sec

from the analysis we can see that

 Maximum deflection = 4.6553e-5 m

 Maximum equivalent stress = 19.157 MPa

 Maximum equivalent strain = 1.809e-4

The above data show that the design if the front sprocket is completely safe and there is no chance
of any kind of failure

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 Kinetic energy recovery system for bicycle

Total deformation

Equivalent stress

Equivalent strain

Fig 8.3 Analysis of clutch

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 Kinetic energy recovery system for bicycle

8.4 CENTRAL SHAFT

This part is made of stainless steel SS304. As all the components rests on this particular part this
part needs to be strong. To increase this parts life this part has been made of Stainless Steel SS304.
Forces acting on the shaft:

 Weight of flywheel = 65.02

 Weight of other components = 20N

Structural supports:Two end point fixed supports

From the analysis we can see that

 Maximum deflection = 3.8368e-6 m

 Maximum equivalent stress = 577.9 KPa

 Maximum equivalent strain = 2.8962e-5

The above data show that the design if the front sprocket is completely safe and there is no chance
of any kind of failure

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 Kinetic energy recovery system for bicycle

Total deformation

Equivalent stress

Equivalent strain

Fig 4.4 Analysis of Shaft

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 Kinetic energy recovery system for bicycle

CHAPTER 9
TURNING MOMENT DIAGRAM
The turning moment diagram  is the graphical representation of the turning moment or crank-effort
for various positions of the crank. It is plotted on cartesian co-ordinates, in which the turning
moment is taken as the ordinate and crank angle as abscissa

In any machine there is at least one point where energy is supplied, and at least one other point
from which energy is delivered. In an ideal machine no energy would be lost and these two would
be equal. In practice this state of affairs does not exist since it is inevitable that some energy is
absorbed in over coming friction at the various joints, couplings and bearings.

In order to plot the turning moment diagram for flywheel in KERS system, we consider pedaling
angle along X axis and torque along Y axis we obtain maximum torque of 7.12 N-m

Turning moment diagram

8
7
6
5
Torque N-m

4
3
2
1
0
1.57 3.14 4.71 6.28
Pedaling angle (Ө)

Turning moment diagram

Graph- Turning moment diagram

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 Kinetic energy recovery system for bicycle

CHAPTER 10
RESULTS AND DISCUSSION

The 3D model of the KERS system is done with optimum precision. The model
is simulated in SOLIDWORKS to check its working. Finite element analysis of the
components is done to check the products robustness and product life. Initially all the
components are designed using aluminium but some components like front sprocket,
clutch drive and central shaft faced failure. Thus these are again redesigned with little
modification and using SS304. The clutch also faced failure initially but its material is
not changed because that will increase the weight, instead it is redesigned again and
again to get the optimum design with maximum factor of safety

This test was carried out to find out how much pedaling power can be saved by
having KERS bicycle. This was done by riding the bicycle on a road and initial pedaling
was given same and noted down the distance at which the bicycle stops when flywheel
is not being connected. Then taken 10 m back point from the stopping distance. The
experiment was again done by riding cycle with flywheel coupled from 10 m side and
noted down the extra distance that is covered by the bicycle. The result was tabulated.

Table 10 Drive Test

Distance Covered after pedaling is stopped

No. of trials Flywheel Disengaged Flywheel Engaged

1 10 meters 14 meters

2 10 meters 12.8 meters

3 10 meters 13.6 meters

4 10 meters 14.2 meters

CHAPTER 11

CONCLUSION
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 Kinetic energy recovery system for bicycle

 In this project a flywheel based KERS system was designed. The product
designed in this project is a hybrid of clutch and normal chain system based
KERS systems effective and efficient manufacturing procedures for the
components of the KERS were also found out.
 Using FEA analysis the components are tested and modified to avoid failure.
This project can guide anyone to fabricate his own KERS system for his bicycle
very easily. It was found that all the components were safe under the extreme
operating condition.
 Different types of KERS systems and their uses were also studied. It was found
that flywheel can be used instead of battery to store and deliver energy
efficiently.
 As use of flywheel in bicycle is a new concept, this field has a huge scope and
wide range of implementation ahead.

Scope for future work

This project has a huge future scope. The design in this project can be fabricated. The
KERS system can be automated using PID controllers. Instead of using lever arm servo
motors can be used. The flywheel weight can be optimised. Multilayer flywheel can be
designed using lighter material at the centre and heavier material at the periphery. The
design of the flywheel can be optimised. Instead of chain drive efficient belt drive
normal chain system can be used to improve the power transmission. Design of a
KERS with multi sprocket front sprocket system can be done. This allow the use of
even broader range of sprocket ratios and will increase the efficiency. Research work
can be done to shift the flywheel to the rear wheel centre that will save lot of space and
reduce the amount of complexity. Design of the left handle with required mechanical
advantage and aesthetics can be done. Design of the KERS housing can be dome. As
all the manufacturing procedures for the KERS components are described elaborately in
this project can be used to develop a production line for large scale production this
product can be brought to the market.

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 Kinetic energy recovery system for bicycle

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