A seminar on

Kinetic Energy
SUPERVISED BY:
Recovery
AASHISH MOGREKAR.
SYSTEM.
Prepared By:
SAURABH K JOSHI
Mechanical Engineering- 6th
Semester
D.Y.P.I.E.T, AMBI
D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, PUNE.
 CONTENTS
KERS- INTRODUCTION.
THE THREE MAIN COMPONENT OF KERS.
MGU AND PCU.
WORKING PRINCIPLE.
TYPES OF KERS.
ELECTRICAL KERS.
MECHANICAL KERS.
ADVANTAGES & DISADVANTAGES OF KERS.
KERS IN FORMULA ONE.
CONCLUSION.

D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, PUNE.

 WHAT IS KERS?

KERS stands for Kinetic Energy Recovery System.

Kinetic energy recovery systems (KERS) store energy when the
vehicle is braking and return it when accelerating.
During braking, energy is wasted due kinetic energy is mostly
converted into heat energy or sometimes sound energy that is
dissipated into the environment.
By a touch of a button, this stored energy is converted back into
kinetic energy giving the vehicle extra boost of power.

D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, PUNE.

The three main components of
the KERS are as follows:
An electric motor positioned between the fuel tank and the
engine is connected directly to the engine crankshaft to
produce additional power.

Flywheels used to store and deliver quick energy.

A KERS control box monitors the working of the electric motor

when charging and releasing energy.

D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, PUNE.

 MGU (MOTOR/GENERATOR UNIT)

While a motor-generator set may consist of distinct motor and

generator machines coupled together, a single unitmotor-
generatorwill have both rotor coils of the motor and the generator
wound around a single rotor, and both coils share the same outer
field coils or magnets Working in two modes, the MGU both creates
the power for the batteries when the car is braking, then return the
power from the batteries to add power directly to the engine, when
the KERS button is deployed.

D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, PUNE.

 PCU (Power Control Unit)

It serves two purposes, firstly to invert & control the switching of

current from the batteries to the MGU and secondly to monitor
the status of the individual cells with the battery. Managing the
battery is critical as the efficiency of a pack of Li-ion cells will
drop if one cell starts to fail. A failing cell can overheat rapidly
and cause safety issues. As with all KERS components the PCU
needs cooling.

D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, PUNE.

 WORKING PRINCIPLE

Basically, its working principle involves storing the energy involved

with deceleration and using it for acceleration. That is, when a car
breaks, it dissipates a lot of kinetic energy as heat. The KERS tries to
store this energy and converts this into power, that can be used to
boost acceleration.
A standard KERS operates by a charge cycle and a boost cycle. As
the car slows for a corner, an actuator unit captures the waste kinetic
energy from the rear brakes. This collected kinetic energy is then
passed to a Central Processing Unit (CPU) and onto the storage unit.
The storage unit are positioned centrally to minimize the impact on the
balance of the car.

D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, PUNE.

D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, PUNE.
 TYPES OF KERS

There are two basic types of KERS systems:

Electrical
Mechanical

The main difference between them is in the way they convert

the energy and how that energy is stored within the vehicle.

D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, PUNE.

 ELECTRICAL KERS
Construction of Electrical KERS:
This type of KERS converts thekinetic energyinto electrical energy and
stored it in batteries for use when required.
It consists of three major components:
MGU(motor/generator unit): This consists of the rotor coils of the motor
and generator wound around the same rotor. They share the same outer
field or magnets.
Storage unit: It consists of the batteries for storing the electrical
energy. Mostly Lithium ion battery is used for this purpose due to its
lower weight and higher power storage capability.
PCU(power control unit): The PCU performs two functions. It inverts and
controls the switching between the battery and MGU and it also monitors
the status of individual cells in the battery. This is essential because the
efficiency of the LI-ion battery cell may decrease leading to battery
failure and subsequently rapid overheating, leading to safety issues.

D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, PUNE.

Electrical Kinetic Energy
Recovery System

D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, PUNE.

How Electrical KERS System Works

Charge Cycle:
When the brakes are applied, the gearbox output shaft rotates the
MGU and it acts as an electrical generator.
The generator produces electrical energy.
The PCU unit transfers the electrical energy to store it in the battery
unit.

Boost Cycle:
When the additional acceleration is required, the PCU unit releases the
stored electrical energy to the MGU.
The MGU now acts as a motor.
The motor converts the electrical energy to rotational energy.
The kinetic energy is then transferred to the drive wheels through the
gear box.
 MECHANICAL KERS

Construction of Mechanical KERS:

The mechanical KERS systems use high speed flywheel, kept inside a
vacuum sealed container, as the energy storage device.
The fly wheel in mechanical kinetic energy recovery system is
equivalent to the MGU of the electrical KERS system.
A continuously variable transmission (CVT) is connected between the
drive train and the flywheel. Please note, this flywheel is separate
from the one that is fitted on engine.
The CVT is used to control the transfer of energy between the KERS
flywheel and the drive train.
The CVT is controlled by an electro-hydraulic control system.
The function of the control system is controlling the connection /
disconnection of the CVT with drive train and controlling the speed at
which the KERS flywheel will rotate.

D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, PUNE.

Mechanical Flywheel Based Kinetic Energy
Recovery System
Working of Mechanical KERS System

Storage Cycle:

In case of braking, the CVT connect the KERS flywheel system with
the drive shaft.

The KERS flywheel starts rotating and absorbs kinetic energy from
wheels.

Boost Cycle:
As and when there is a requirement for additional acceleration, the
flywheels kinetic energy get transferred to the wheels again
through the CVT.

The electric KERS require a number of energy conversions leading

to efficiency losses. Mechanical KERS have a greater efficiency of
70% when compared to the electrical KERSs 31% efficiency.
The kinetic energy recovery system are used effectively in Formula
1 racing. The energy lost by the car in the curves is stored and is
can be used when a boost is required or in straight track. The KERS
are also finding their way into passenger cars like RSR variant of
Porsche 918
D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, PUNE.
 ADVANTANGE OF MECHANICAL
KERS OVER ELECTRICAL KERS

Battery-based electric hybrid systems require a number of energy

conversions each with corresponding efficiency losses. On
reapplication of the energy to the driveline, the global energy
conversion efficiency is 3134%. The mechanical hybrid system
storing energy mechanically in a rotating fly wheel eliminates the
various energy conversions and provides a global energy
conversion efficiency exceeding 70%, more than twice the
efficiency of an electric system.

D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, PUNE.

 ADVANTAGES OF KERS
This potential advantages and features of this technology in the field of
automobiles are:

High power capability.

Light weight and small size.
Long system life of upto 250,000 kms.
Completely safe.
A truly green solution.
High efficiency storage and recovery.
Low embedded carbon content.
Low cost in volume manufacture.

D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, PUNE.

 DISADVANTAGES OF KERS
Electronic KERS, as they store charge in the battery and as
they charge and discharge very quickly, get hot very quickly.
There is also a risk of the user or any other individual getting a
shock when KERS is activated. So the driver is protected by
well insulated dress and the other individuals get to see a
warning light that says when the KERS is on or not.
60 kw is the maximum input and output power of the KERS
system.
The energy recovery system is functional only when the car is
moving.
The recovery system must be controlled by the same
electronic control unit.
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.

D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, PUNE.

 KERS IN FORMULA ONE
KERS was introduced by the International Automobile Federation (FIA) with
a view to increase overtaking during Formula One Grand Prix races, as the
boost button provides extra power. In effect, the KERS has also been used
to act as a defensive tool to block a faster car, inhibiting overtaking.
In the 2009 season KERS was not a huge success, the system had a FIA
cap on the amount of energy that could be re-used, only 400kJ could be
stored, which when used for 6.7s per lap, the car gained some 80hp. Thus
although a 0.3s boost to lap times was achieved, the system was
ultimately limited in its potential to improve lap times.
The original CVT based Formula One KERS

D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, PUNE.

 FEATURES OF KERS IN F1
The original Kinetic Energy Recovery System (KERS) was a small and
light device designed to meet the FIA regulations for the 2009 Formula
One season.
The key system features were:
Aflywheel made of steel and carbon fibre that rotated at over 60,000
RPM inside an evacuated chamber.
The flywheel casing featured containment to avoid the escape of any
debris in the unlikely event of a flywheel failure.
The flywheel was connected to the transmission of the car on the
output side of the gearboxvia several fixed ratios, a clutch and a
Continuously Variable Transmission.
60 kW power transmission in either storage or recovery.
400 kJ of usable storage (after accounting for internal losses).
A total system weight of 25 kg.
A total packaging volume of 13 litres.

D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, PUNE.

 CONCLUSION
Its a technology for the present and the future because its
environment-friendly, reduces emissions, has a low production
cost, increases efficiency and is highly customizable and
modifiable. Adoption of a KERS may permit regenerative braking
and engine downsizing as a means of improving efficiency and
hence reducing fuel consumption and CO2 emissions.
The KERS have major areas of development in power density, life,
simplicity, effectiveness and first and foremost the costs of the
device. Applications are being considered for small, mass-
production passenger cars, as well as luxury cars, buses and
trucks.

D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, PUNE.

Thank you

D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, PUNE.