DESIGN AND IMPLEMENTATION OF KINETIC ENE

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 6, Issue 4, April (2015), pp. 101-108© IAEME
101
DESIGN AND IMPLEMENTATION OF KINETIC ENERGY
RECOVERY SYSTEM (KERS) IN BICYCLE
Nishad Kumbhojkar
1
, Kunal Mohite
2
, Anand Kulkarni
3
, Sanket Patil
4
1,2,3,4
Department of Mechanical Engineering,
Sinhgad College of Engineering, Pune, Maharashtra, India
ABSTRACT
Kinetic energy recovery system (KERS) is a technology used in formula-1 cars for
recovering the energy lost in braking of the car and thus providing boost to the vehicle motion. Same
concept i.e. regenerative braking can be applied in bicycle which uses a flywheel which will be
mounted between the frames of the bicycle, the flywheel can store the braking energy by rotating and
this energy can be given back to the system which will reduce the pedaling power required to drive
the bicycle. This Flywheel Energy Storage (FES) system uses flywheel with suitable clutch
mechanism along with sprocket and chains. Further this project concludes about efficiency and
pedaling power in flywheel bicycle.
Keywords: Kinetic Energy Recovery System, Regenerative Braking, Flywheel
1. INTRODUCTION
KERS (Kinetic energy recovery system) is a type of regenerative braking concept which is
primarily used in formula-1 cars for the purpose of speed boosting. The energy which is applied for
braking purpose of a vehicle is normally wasted; however this energy can be saved and effectively
utilized as and when required. Generally when the brakes are applied, the braking energy gets
converted into heat which is wasted however in this scenario when the brakes are applied the energy
is passed to the motors which are mounted on the front wheels. The motors at this stage act as
generator converting the mechanical energy to electrical which is then passed to motors/flywheel
arrangement resulting in rotation of flywheel. This rotational energy as and when required can be
restored by the means of motors to the wheels thus providing the necessary boost in speed.
This principle can be successfully implemented in a passive system such as bicycle for
serving the purpose of reduction in pedaling power by using a flywheel and a mechanism for
engaging and disengaging the same.
INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING AND
TECHNOLOGY (IJMET)
ISSN 0976 – 6340 (Print)
ISSN 0976 – 6359 (Online)
Volume 6, Issue 4, April (2015), pp. 101-108
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 6, Issue 4, April (2015), pp. 101-108© IAEME
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In KERS bicycle, flywheel is used to store and restore the energy. Flywheel is mounted
between frames of bicycle with aesthetic and ergonomic considerations. The flywheel is mounted on
the shaft and shaft is supported by means of frames. Flywheel can be engaged with rear wheel with
clutch mechanism. This mechanism consists of clutch, free wheel and sprocket with proper gear ratio
for transmission.
When the bicycle is down hills or with slow speed in traffic jam clutch can be engaged with
flywheel to store energy and this energy can be restored when required. Now at a time when the
speed reduction is required clutch is engaged and flywheel starts rotating storing energy in spite of
this pedaling power can be decreased and efficiency of system can be increased.
For analysis of system overdrive test is carried out and results are obtained in order to reduce
pedaling power. The assembly and parts modeling is done in CATIA and Solid Works software. For
simulation and analysis purpose ANSYS software is used.
Fig.1 KERS Bicycle
2. WORKING
The components used in the system are flywheel, clutch, chain drive, Bearing, frame.
Flywheel which is mounted on the frame is driven by the rear wheel through the chain drive and
clutch mechanism. When one has to apply the brakes the mechanism is such that clutch gets engaged
with the flywheel and it starts rotating thus storing the braking energy. The mechanism designed is
such that by manually pressing the lever (Rear brake lever of the bicycle) the clutch can engage with
the flywheel this depends upon the convenience of the biker. The stored energy is utilized when the
speed of bicycle decreases below the average range of speed i.e. rear wheel speed. The flywheel
energy by the means of chain in this case can be restored back to the bicycle thus fulfilling its torque
requirement.
Consider for instance riding on a slope or in the case of mountain biking, when the speed of
bicycle is more than average speed range the engagement of flywheel is facilitated and the flywheel
keeps on rotating for a certain period of time mainly due to inertia this motion can be transferred
back to the rear wheel thus assisting the forward motion of the bicycle.\
Objectives
• Reduction in pedaling power required to drive bicycle
• Increase the system efficiency
• Imparting the simplest possible operation & mechanism

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 6, Issue 4, April (2015), pp. 101-108© IAEME
103
Components Designed
1) Flywheel
2) Selection of clutch mechanism
3) Shaft
4) Frame
5) Bearing Selection
3. FABRICATION PROCESS
Step 1: Frame Modification
In order to mount a flywheel an additional frame mounting is imperative as frame is the
support structure for the flywheel. Frame mounting is the first step in manufacturing of the flywheel
bicycle. Steel tubes are used as the frame structure, they are joined by welding .One end of the frame
is to the front end of the bicycle (below the handle) and other end is connected near the rear sprocket.
The frame is connected to the bicycle structure by spot welding. However certain considerations are
made so the geometry of the frame does not hinder the riding comfort of the driver.
Fig.2 Frame modification
Step 2: Flywheel Manufacturing
The flywheel is manufactured by performing lathe operations and certain considerations were
made earlier for considering the weight of the flywheel, The weight of the flywheel should be
optimum if it exceeds a particular value it will make the bicycle bulky, however even the lesser
weight will not offer the required inertia to empower the rear wheel of the bicycle. Material selected
for flywheel is MS (mild steel).A hole is bored centrally in the flywheel for mounting the ball
bearings so that the shaft rotates with the rotation of the flywheel.
Step 3: Shaft and Support Fabrication
Considering the inner diameter of the ball bearing and by carrying out shaft design the
diameter of shaft is decided. Thus accordingly shaft and the related shaft support structure on the
frame is manufactured.

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 6, Issue 4, April (2015), pp. 101-108© IAEME
104
Fig.3 Assembly of mechanism
Step 4: Miscellaneous Parts Fabrication or Procurement
Another important part manufactured is the clutch plate, Clutch plate is a disc type plate of
mild steel which can play a role of engaging and disengaging the flywheel from the bicycle as and
when required, Helically connected discs are used for moving the clutch plates to and fro.
The helically connected discs and clutch plate is a single structure, thus the movement of the discs is
the movement of the plate. Sprocket of larger diameter and freewheel is procured from market which
will be mounted on the rear wheel and the front assembly respectively, they are connected to each
other by means of a chain.
Step 5 Mounting
The parts manufactured namely the flywheel with shaft and clutch plate helical disc assembly
is mounted on the frame structure, which completes the manufacturing phase of the bicycle.
Fig.4 Mounting

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 6, Issue 4, April (2015), pp. 101-108© IAEME
105
4. RESULT AND ANALYSIS
The flywheel bicycle increases efficiency on rides where the rider slows often. The additional
weight is outweighed by the ability to recover energy normally lost during braking. Thus the addition
of extra weight does not make it difficult for the rider. Also clutch provided helps in deciding the
time period of activity. The overall result is that KERS system is efficient in storing the energy
normally lost in braking and returns it for boosting.
Weight and Performance
Normally energy stored in the flywheel is directly proportional to the weight and radius.
Hence increase in weight proves to improve the performance. But as we know that the maximum
safe weight that can be used is limited due to frame properties and rider compatibility. And also after
some extent the radius can’t be increased and the energy storage thus seems to be limited to some
particular extend. This is also because of the fact that the total running speed is being reduced due to
weight. Energy storage capacity increases with increase in weight but limitation seems to be the
speed driving the flywheel. And performance of system is directly linked with the energy stored.
Thus a graph can be plotted between performance and weight. Optimum value lies between 5 and 8
kg.
Energy stored in flywheel,
Ek=1/2ω^2
Where, I‟ is the moment of inertia”
ω‟ is the rotational velocity (rpm)”
Moment of inertia, I = ^2
Where, k‟ is inertia constant (depends on shape)”
M‟ is mass of the disc”
R‟ is the radius”
Thus, Ek is directly proportional to the mass of the disc. The flywheel and transmission add
weight to the bicycle. The increased weight will add to the energy required to accelerate the bicycle
and to ride it uphill. However, once the rider has provided the energy to reach a cruising speed, the
flywheel reduces the energy cost of slowing down from this speed since it aids in subsequent
acceleration. Roads are optimal environment for the flywheel bicycle because it’s flat and there are
lots of reasons for the cyclist to slow down.