MID SEMESTER REPORT [MED320], Semester II 2011-12

A Design of Regenerative Electro-mechanical braking system in Cycle Rickshaws with Differential Action

Anshul Kapoor 2009ME20656

Nikhil Gupta 2009ME20671

Harshit Jain 2009ME20137

Supervisor: Prof. Sudipto Mukherjee

Department of Mechanical Engineering IITD 15 February, 2012.

A Design of Regenerative Electro-mechanical braking system in Cycle Rickshaws with Differential Action

Introduction
Rickshaw was first invented in Japan by a western missionary, Jonathan Gobble, in 1871. The name comes from the Japanese word ji rikishaw meaning a vehicle propelled by man. In India the first cycle rickshaw was introduced in Shimla around 1880 and later in Calcutta. In India cycle rickshaw was first reported in Bengal in 1930. It did spread to other towns and cities as it not only made the pullers job more dignified and easier but it introduced higher speed also. It has been found that a pedal-driven vehicle causes a reduction of human effort by a factor of almost four. This enables a person to travel much faster (about three times the walking speed) and to carry a greater load. As the puller sits on a seat his weight is not carried by the legs resulting in reduced tiring effect. The original version of the cycle rickshaw first introduced in Bengal has remained the basic model for all models of pedal driven vehicles in India. However, very little modifications have been incorporated to improve the performance characteristics. Fortunately, it has been recognized by a number of Institutions and government establishments that some development and innovation can not only improve the performance characteristics but can also widen the scope of usage of the omnipresent vehicle.

Problems with Conventional cycle rickshaw:

1. Cycle rickshaw poses serious threat to smooth traffic flow because Rickshaw being manually driven takes more time as compared to power driven vehicles Difficult to bend it on turns 2. Every time a puller stops (or slows down) the kinetic energy is lost. To regain it he has to spend his muscle energy again. This leads to a large amount of unnecessary wastage of pullers energy on each working day. 3. The cycle rickshaw has to reduce its speed while taking turns due to absence of differential mechanism, which in turn also causes energy wastage on part of puller.

Regeneration of Energy and Regenerative Brake:

Regeneration of energy refers to storing energy in some form while reducing speed or stopping and retrieving it back when restarting or speeding up. A braking system which can accomplish this is called a Regenerative Brake (RGB).
While slowing /stopping with regenerative brake Regenerative Brake Mechanism While speeding up after releasing RGB

Vehicle

Energy Storage

Schematic of the function of a regenerative brake

Some of the desired features of RGB are1. On applying RGB, it should be able to stop the vehicle. 2. It should be able to store the major portion of the change in kinetic energy of cycle rickshaw. 3. Its application should not put much strain on the puller. 4. It should provide energy to start the rickshaw from zero-velocity. 5. The system should be compact, light & should be possible to incorporate in cycle rickshaws with minimum amount of modification.

Literature Review
1. Development of Regenerative Brake for Cycle Rickshaw By Amitabha Ghosh and Ashok Kumar Mallik, October 1995, IIT Kanpur

Train of spur gears was used along with one chain and sprocket connection between the main axle and the spring winding shaft. Above design includes spur gears which need rigid, firm & accurate structure which is not feasible in case of cycle rickshaw as it adds in a lot of weight and such precision device is not suitable for cycle rickshaw. 2. Mechanical students form IIT Delhi has tried to analyse the economic aspects of regenerative braking in HPV under their mini Project with topic - An econometric study of the feasibility of using Regenerative Brakes in Human Powered Vehicles. In their project they have analysed different type of energy storing elements springs, battery, etc. After finalising to use springs they have studied different types of spring, their specifications like weight, dimension, torque, etc. These were their conclusions Rectangular wire spiral springs are found to be most suitable for storing maximum energy and minimum space. Solenoid based devices controlled using micro processor will be used as actuation devices for controlling reverse clutches

Objectives
To design a regenerative braking system for a cycle rickshaw with differential action. We are not fabricating the mechanism in the present project. Our design should have following features1. Provide differential action i.e. different torque to each wheel while taking turns 2. Able to store the major portion of change in kinetic energy of the system during braking 3. Provide stored energy when starting from zero velocity or during upslope 4. Rickshaw puller can also charge its springs while pedalling, so that he can use it later 5. Selective loading and unloading of springs

Work Plan
The work plan includes following tasks Estimate Force, Energy & Torque during normal braking and energy per unit volume and weight in a spring block. Study of different type of springs like spiral, constant torque, etc Study of different type of brakes likes electromechanical brake, power off brake, etc Design motion reversing mechanism Design a spring module that can regulate energy flowing out of it. Study of differential mechanism equal power and torque type. Analysis of design i.e. performing force and stress analysis of components. Study of micro controllers & sensor to control module. Designing a control system that regulates which 1. Springs to be loaded while storing energy 2. Springs to be unloaded while supplying energy 3. Provide differential action to cycle rickshaw Feasibility of Design and its effect on rickshaws performance

Methodology
1. Firstly we have to estimate the forces acting on a rickshaws elements of concern to us during normal use. This provides limiting values of forces and torques to be produced by our mechanism. This also involves the study of the amount of torque produced by the rickshaw brakes to stop the rickshaw under a particular set of conditions. This tells us the minimum values of torque that the brake should be able to produce if required to stop the rickshaw under a similar situation. Also this data would be required when we have to find spring specifications. 2. Then we have to study different type of springs & brakes that we can use in our design satisfying constraints like space & weight constraints, maintaining smooth braking, resistance to jerks, etc. 3. Design a motion reversing mechanism that can be regulated and is smooth in transition from one direction to another.

4. Design a spring module that can store and provide energy as per requirement and we can use numerous such modules to store large amount of energy or providing high torque. 5. Study differential mechanism of both types- equal power differential and equal torque differential mechanism. Now we incorporate differential action in our design and make changes if required. 6. To find element required to control direction of motion of shaft during energy release and storage was our next step. The shaft connected to the spring must reverse its direction while braking so as to wind the spring. 7. Use of micro controllers for switching and control was considered. For this we chose clutching mechanisms which would be compatible with magnetic actuators or actuators using devices like solenoids which can provide a sudden boos of energy to actuate the elements. 8. We then incorporate solenoid actuators, etc in our design and produce a design that can regulate output torque as well as output energy on each of the wheel indivually by use of microcontrollers. 9. Finally, we check the feasibility of the design and measure the improvement in the rickshaws performance on using it.

As per the feasibility of the design for regenerative mechanical braking system, we will continue this mini project as BTP and would work on the fabrication part of it.

Work accomplished so far:

The first thing to be accomplished was to come up with values of energy, forces, torques and distances to get an idea of the dynamics of the problem. Further a mechanism had to be devised that could handle these values and provide us desired output. Calculations Property Energy Dissipated Value =1/2 mv2 =3.75 KJ Remarks Mass m =300 kg Velocity v =18km/hr=5m/s

Angular Velocity Stopping Retardation Stopping Time Torque on each wheel Friction Torque Torque by RGB Torque on each wheel by RGB Torque Per Spring

=v /r =12.5 / sec =(v -u )/2s=- 1.57 = (v-u)/a = 3.18 sec P/wavg = Eeach/ (t /2) = 62.9 Nm = 3T = 188.7 Nm = 188.7 Nm = 94.35 Nm = 94.35/ n
2 2

r= 0.40 m S=8m, v=0 a= 1.57 m/s2 avg=/2, Eeach =E/3 T = 62.9Nm = 3 T* = (3/2)T* n= No. of spring to be used

Spring Specifications: Let number of spring be n one each side so total spring will be 2n and spring constant be K Energy per spring will be Etotal/ 2n. Energy of each spring is K 2, Equating K 2= Etotal/2n, we get K= 9.375/n . Thus, rotation of each spring when all spring are charged = 20 radians Torque produced by each spring = K = 187.5/n on each side. Total available torque on each side= n K = 187.5 Nm So far we have examined the problem and come up with certain tasks that the complete mechanism can be divided into. These mechanisms are: 1. Energy distribution mechanism: Transferring work generated by rickshaw driver to both wheels separately. 2. Motion reversing mechanism: As the springs get charged during forward motion of the vehicle, direct usage of spring energy would lead to backward motion of the vehicle. Hence a reversing motion has to be installed. 3. Repeatable spring module: A repeatable spring module has to be devised so that the energy can be selectively stored in and restored from various numbers of springs. This selectivity reduces jerks during energy storage and release and also helps in controlling torque on wheels. 4. Differential action: To ease the turning action of the vehicle, we must be able to control torques on both wheels. 5. Coupling and decoupling: During the usage of the rickshaw, it goes from many states where it has to charge springs, use their energy, discharge them directly, keep energy stored in a redundant form etc. After this we listed out the various cases of motion that can occur in real life that our system must be able to tackle with: 1. 2. 3. 4. 5. 6. 7. To start the vehicle from zero velocity with all springs uncharged. To stop pedalling and harness energy stored in springs. To stop pedalling and not to harness spring energy, motion by momentum. Charging springs directly by pedalling. Charging springs while braking. Harnessing springs energy to attain motion from zero velocity. Releasing all springs with any vehicle motion.

To systematically work with so many cases, we employ microcontroller on the rickshaw for controlling various states of springs and brakes. This controller controls all systems depending upon employment of brakes or pedals or restoration system by the user. To attain the above objectives, we went across a number of reversing systems, electromagnetic brakes, clutches, springs, method of spring activation (series and parallel) and ruled out all those options that were unable to satisfy our objectives.

Given below is brief description of some mechanism that we came across but then rejected due to some problems. However one particular system seems to accomplish all tasks effectively and that has been explained.

The motion distribution mechanism: The chain coming from the driver rotates a shaft using a ratchet; on both ends of this shaft is a ratchet that can further provide motion to independent driving systems. By this, one wheel can move faster than the other. Reversing mechanism: Most reversing mechanisms employ gears for the purpose. However gear require high precision for proper working thus a heavy structure is required for their usage. Hence use of gears must be avoided. Hence the last mechanism explains reversing without gears. For coupling, differential torque maintenance and spring module, a number of configurations were tried. The most successful has been explained below with solidworks models. Step for working of the design: 1. As the driver pedals, it rotates an outer drum on each side of rickshaw with is temporarily coupled to outer ring of an electromagnetic power off brake. An electromagnetic power off brake can rigidly couple or decouple its inner and outer rings depending upon voltage provided to it. Hence a charges spring can be kept charged by locking using brake. The inner ring of this brake is attacked to a central shaft using a ratchet. The torsion spring is attached rigidly to outer and inner rings of em brake. 2. The central shaft consists of various such em brake modules in itself. On the end of this is an electromagnetic particle brake for controlling net output torque wheel the other can be coupled or decoupled to the wheel shaft using a clutch.

3. In case of braking the particle brake can tightly hold the central shaft while the wheel shaft can be coupled to the outer drum, also the clutch is disengaged. In this manner the springs can be charged by momentum of the vehicle.

4. The relative movement of the outer drum relative to central shaft charges the springs. The outer ring of em particle brake is coupled to outer drum, for this purpose a proper mechanism is yet to be looked upon. However a tentative design is shown below.

5. For release of energy the em power off brake is released and central shaft is coupled to wheel shaft. This transfers torque to wheels controlled to em particle brake. The overall design so far is shown below. However still many more points have to be looked upon.

Summary
Cycle rickshaw is a main source of transportation not only in rural but also in semi urban and urban areas of India. Its an easy source of employment in India considering its salient features like low cost, easy in maintenance, easy employment, etc. But there are some problems associated with the conventional cycle rickshaw like absence of differential mechanism, large amount of unnecessary wastage of pullers energy in crowded streets & threat to smooth traffic flow. Regenerative mechanical braking Regeneration of energy refers to storing energy in some form while reducing speed or stopping and retrieving it back when restarting or speeding up. A braking system which can accomplish this is called a Regenerative Brake (RGB). We will design a regenerative mechanical braking system which stores the change in kinetic energy of the system while braking and provides the same energy back to system when regenerative braking is disengaged. Hence we will be able to prevent wastage of pullers energy while braking. Also the puller can charge the spring or store energy while pedalling and can use that energy later. We will also try to introduce differential action in the cycle rickshaw without using the conventional differential mechanism gear box available as it need rigid, firm & accurate structure which is not feasible in case of rickshaw. Also there are weight constraint associated with gear box and will require high maintainability. We may need to use electromagnetic particle brake to control the output torque on each of the wheel. In our design we use selective loading and unloading of multiple springs which can be controlled by use of microcontrollers. Similarly we can also control the amount of energy to be extracted from each spring module. To hold the energy in spring module we will use electromagnetic power off brakes which hold the energy when power is not supplied to it. We may also use solenoid actuators to perform selective loading of springs in place of electromagnetic power off brakes as they will space, reduce weight, provide higher torque, reduce power requirement, etc. So our final design will be able to regulate the output torque and output energy on each of the wheel of rickshaw indivually. Finally after the completion of the design we will find the feasibility of the design and measure the improvement in rickshaws performance on installing this new design. Based on the feasibility of the design we will continue with the fabrication of the design as our B-tech Project.