Kinetic Energy Recovery System by Using Piezoelectric Material

8/28/2020
Kinetic Energy Recovery

System by using
Piezoelectric Material.
Instructed by: Mr. Yasith N. Kotelawala

Supervised by: Mr. Dilum Fernando
Student Name: Ashan Indusara

Student Number: CL/HNDAME/08/40
Kinetic Energy Recovery System using Piezoelectric material
Project Name: Kinetic Energy Recovery System by using Piezoelectric Material.

Group members and details
CL/HNDAME/08/40 – Ashan Indusara Karunakalage (Group leader)
CL/HNDAME/08/44 – Nawod Vithana
CL/HNDAME/08/45 – Ashan Viduranga
CL/HNDAME/08/34 – Arunaja Induwara
CL/HNDAME/08/43 – Sheshan Mallawaarachchi
Acknowledgement
I would like to express my gratitude to our supervisor Mr. Dilum Fernando and our instructor
Mr. Yasith N. Kotelawala whose contribution in simulating suggestions and encourages us to
do this project successfully.
This project helps us to learn how to apply what I had learnt in the class in a practical
situation also in learning lot of new things.
Then I would like to thanks my parents who helped me with financing to do my studies and
also my team mates who helped me with this project.
Abstract
Hybrid and electric vehicles have a good demand in today’s society. Where the world is
running out of conventional energy sources and with the increment of the environmental
pollution, electrical energy utilization has become the trend. Due to the current rising power
demands and the search for more efficient systems designs, renewable energy sources like
wind, solar and biomass are very popular these days. There are still many problems we face
when trying to generate power/energy using these sources of energy, that’s why the
development of systems which can increase the efficiency of a systems using these sources of
energy is needed. Using Piezoelectric material is one of the ways of power harvesting which
is slowly becoming popular in the current generation. Piezoelectric materials convert
mechanical energy into electrical energy which is ideal when it comes to harvesting energy
from areas that are prone to vibrations. Many researchers have been conducted on harvesting
energy from vibrations, some materials like ceramics and crystals have the ability to build up
potential in response to mechanical pressure. Not only the production of electricity is
important, but also increasing the energy harvesting efficiency as well as recovering the
wasted energy is the best way to survive this energy crisis.
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Table of Content
 Chapter 01: Introduction
1.1 Background of the project
1.2 Problem identification
1.3 Aim and Objectives
1.4 Scope and Limitations
 Chapter 02: Literature review

2.1 Literature mapping
2.2 Literature review
2.2.1 Natural ways of harvesting electricity
2.2.1.1 Thermoelectric harvesting
2.2.1.2 Pyroelectric harvesting
2.2.1.3 Large scale energy harvesting
2.2.2 Loss of energy through automobiles
2.2.2.1 Systems where energy is wasted
2.2.3 Kinetic energy recovery systems
2.2.3.1Mechanical Energy Recovery System
2.2.3.2 Advantage
2.2.3.3 Disadvantage
2.2.4 Piezoelectric materials
2.2.4.1 Piezoelectric mechanism
2.2.4.2 History and inventions of piezoelectric materials
2.2.4.3 Harvesting electricity through piezoelectric materials
2.2.5 Electric Systems and Circuit diagrams
2.2.5.1 Villard Cascade
2.2.5.2 Buck Booster Converter
2.2.5.3 DC-DC Conversion
2.2.5.4 Buck booster working
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 Chapter 03: Methodology

3.1 Conceptual Designs
3.1.1 Conceptual Design 01
3.2 Optimum Design Justification
 Chapter 04: Design and Implementation

4.1 Design of the project
4.1.1 Brake disc design and implementation
4.1.2 Brake pads design and implementation
4.1.3 Electrical system design and implementation
4.1.3.1 The Bridge rectifier with full wave rectification
4.1.3.2 The Battery
 Chapter 05: Testing and Analysis

5.1 Method of experiment, testing parameters and setup
5.2 Results
5.2.1 Testing results of the disc brake assembly
5.2.2 Testing results of the Brake pads
5.2.3 Testing results of the Electrical system
 Chapter 06: Conclusion and Future development

6.1 Conclusion
6.2 Future development
 Chapter 07: References
 Chapter 08: Appendix
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Table of figures
 Figure 1: KERS in bicycle
 Figure 2: VI graph of PZT
 Figure 3: VI graph of parallel and series combination
 Figure 4: Electrical diagram of a piezoelectric tile
 Figure 5: Buck Booster converter
 Figure 6: Buck converter diagram
 Figure 7: Shock Absorber view 01
 Figure 8: Shock absorber view 2
 Figure 9: Piezoelectric motor
 Figure 10: Piezoelectric actuator
 Figure 11: Electrical system
 Figure 12: Brake disc design
 Figure 13: Brake disc rear view
 Figure 14: Brake pad rear view
 Figure 15: Brake pad front view
 Figure 16: Disc brake assembly
 Figure 17: Brake pads connection to brake disc
 Figure 18: Brake assemble is disengage mode
 Figure 19: Flow chart of electric diagram
 Figure 20 - A Bridge Rectifier Circuit
 Figure 21 - Without a Smoothing Capacitor
 Figure 22 - With a Smoothing Capacitor
 Figure 23 - The Smoothing effect of the Capacitor
 Figure 24 - Circuit Diagram
 Figure 25: Disc brake thermal test
 Figure 26: Temperature incensement due to braking forces
 Figure 27: Torque applied due to acceleration
 Figure 28: PZT material testing
 Figure 29: Electric system diagnosing
 Figure 30: Diagnosing the components
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Chapter 01
1.1 Background of the project
Kinetic energy is a form of natural energy which exist in the nature. In day today life we can
see how the world is running with this form of energy. Focusing on automotive sector,
transportation is done through automobiles which is a full form of kinetic energy utility. But
unfortunately, the problem is that the loss of energy though different components and systems
used in automobiles. Though there are many methods we can use to reduce these energy losses
and get the efficiency close to our 100% efficient goal. Not only that, but also our primary duty
is to increase energy efficiency. One of this method is an integration of a Kinetic Energy
Recovery System (K.E.R.S.) to the vehicle. By implementing this method, we can harvest the
kinetic energy lost in braking, power generation and transmission. And use it to give an
additional boost of power when the driver starts to accelerate again after braking or when he/she
needs it.
1.2 Problem identification
With the advancement of the technology, the energy demand is very high where a single person
costs more money to achieve his/her daily tasks. Actually, Kinetic energy is everywhere in our
environment. But the question is, do we/can we harvest that exact amount of energy for our
energy consumption?
Most probably the answer will be “NO”. But fortunately, from the First Law of
Thermodynamics we can see that “The energy cannot be created nor destroyed”. So, it tells us
that the energy is transformed. So that the Kinetic energy is dissipated as heat and sound. As
the higher percentage of Kinetic energy is converted into Heat energy and lower percentage of
Kinetic energy is converted into Sound energy. So, the work done by that form of energy is
very less. But, if there is a system at least to recover that dissipated energy, the energy loss will
be less and it would be a healthy way to match with the energy demand of the world. So, the
problems which affects to build this system is as below.
• High energy demand and low usable energy.
• Energy loss/wastage through different components and systems of automobiles.
• High cost of advanced technologies and non-renewable energy sources.
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1.3 Aim and Objectives
Aim
❖ The main aim of this project is to increase energy efficiency and decrease the loss of
energy through recovering and transforming that energy into useful work or electricity.
Objectives
✓ Designing a model of a Kinetic Energy Recovery System using piezoelectric material.
✓ Testing the model feasibility to high braking forces and temperatures
✓ Designing the electrical system to harvest energy from piezoelectric material.
✓ Diagnosing the components
1.4 Scope and Limitations
Scope
• When braking is applied, the actuator which consists of a piezoelectric material will absorb
the braking force of the vehicle through engaging with the brake disk/drum.
• Piezoelectric material generates electric pulses proportionally to the brake force applied.
• The generated electric pulses move through a smoothing circuit because the battery needs a
constant flow of energy to charge the battery. (Smoothing circuit consists of capacitors and it
changes those pulses to a constant flow of energy.)
• Then the current flow will be amplified by a buck booster (DC-DC step-up) to match the
battery requirements of charging the battery.
• Then the battery will be charged in every time when the driver pushes the brakes.
Limitations
o In practical scenarios, the piezoelectric materials which can sustain a large amount of
heat is costly.
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Chapter 02 Thermoelectric harvesting
2.1 Literature mapping

Pyroelectric harvesting
Natural ways of
harvesting electricity
Large scale energy harvesting
Loss of energy Systems where energy is

through automobiles wasted
Mechanical Energy Recovery

System
Kinetic Energy
Recovery System by Kinetic Energy
using piezoelectric Recovery Systems
material
Piezoelectric mechanism
Piezoelectric
materials
History and inventions of
piezoelectric materials
Harvesting electricity through

piezoelectric materials
Electric systems and

circuit diagrams Villard Cascade
Buck Booster
Buck converter
DC-DC conversion
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2.2 Literature review

2.2.1 Natural ways of harvesting electricity
In our living environment, there is a plenty of natural energy sources around us. We can see
them and also we can feel them. But the problem is that the way of harvesting that free energy
with a high efficiency to meet our energy demand. Such natural energy sources are light and
heat energy from the sun, wind energy, wave energy, hydropower and geothermal energy.
These energy sources are useful in generating electricity where electricity acts a major role in
the modern world.
Electricity harvesting is a different technique which the free energy is utilized to achieve daily
tasks and it will decrease the energy wastage. Also energy waste in production or output process
as heat, light, vibration and sound. Due to harvesting techniques, that energy lost is harvested
and used to create self-sustaining technologies and increase efficiency rates. The primary target
for energy harvesting developer is to create a system that can be self-sustaining and improve
efficiency of conventional systems. They use few circular methods to harvesting energy from
lost energy and regenerate as electrical energy. It is because the electrical energy is the most
efficient and powerful energy type which can store and transmit for the required purpose.
2.2.1.1 Thermoelectric harvesting
By using dissimilar objects, it can create an electric voltage by means of the temperature
difference in those two objects. Vice versa thermocouple action. By keeping those two
materials at a relatively constant temperature an electric voltage is generated as a direct
conversion of temperature difference. This method can be used to develop some technologies
such as, (Enescu, 2019)
 Temperature powered phone charger: Developed by Epiphany Labs. The ‘one puck’
thermoelectric charger get advantage of thermoelectric harvesting to create self-
sustaining system. This equipment can work by placing a hot or cold item. This allows
you to charge your phone.
 Thermoelectric generator for cars and Lorries: Those types of vehicle waste large
amount of energy when it’s operation. These generators installed into cars and Lorries
for reuse some heat given from their operation. This helps to put less stress on the
engine and it can cause to increase efficiency level. And this generator reduced fuel
consumption by around five percent.
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2.2.1.2 Pyroelectric harvesting
A certain type of material ability to generating temporary electric voltage when heat/cool
condition is introduced. In this method, electricity harvesting from material by use of gaining
current from temperature change over time.
 Pyroelectric sensor: This harvesting system can be used in passive infrared (PIR)
sensors which get heat signals from approaching motion, likewise in outdoor lightning.
The pyroelectric element creates small voltage inside the sensor. That voltage
approaching heat signals emitted from the approaching person. It is enough to power
up the light.
2.2.1.3 Large scale energy harvesting
Wind energy, solar energy, Ocean wave energy are the main large scale energy which is
harvested from the environment. Sun delivers roughly 173 trillion kilo watt of energy in every
moment. Though it gives such a large amount of energy, our technology is not that much
accurate to harvest the total energy. Solar panel is the main technology for harvesting solar
energy. But it has only 15 – 20% of energy efficiency. Also the solar panel cost is very high,
so due to that only few people can have the ability of using this energy harvesting method.
When consider about kinetic energy harvesting, wave energy and wind energy is vey much
important.
Wave energy: Oceans are a major source of energy where 97% of water is from the oceans.
But not as fresh water, it contains a large amount of energy as the wind supply power to the
ocean wave formation. We can harvest wave energy with an efficiency of 40% to fulfill our
energy demand. The kinetic energy of the waves can be harvested through different structures
like barriers (damn structure), buoy structures, cylindrical floating structures and sinkers.
Wind energy: Wind is the main energy harvesting technology which use to operate wind
powered turbines and create large amount of electricity. The kinetic energy of the wind is
harvested by those wind turbines. The efficiency of a wind turbine is 59% (Betz Limit).
Practically 50% of wind’s kinetic energy can be harvested through an accurate wind turbine.
But the fact is that the wind turbines are not very suitable for road vehicles. Whereas the
efficiency of a wind turbine varies with different reasons like the height of the turbine, and
wingspan of the turbine etc…
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Piezoelectric harvesting: Harvesting electricity from Materials by using pressure. In this

method sources that receive pressure from such things as human motion, low frequency
vibrations or acoustic noise. Piezoelectric materials provide current is proportional to the input
vibration amplitude. The power output by the piezoelectric materials are not in a form which
is can used to load circuits such as micro controllers, radio etc. The voltage and current output
by the harvester needs to be conditioned and converted to a form usable by the load circuits.
 Battery less remote controls: These types of device used human force to generate
enough electric charge to power itself. It is using energy emitted through its own
functionality. So it is known as self-sustaining. (further discussion under the topic
piezoelectric materials)
2.2.2 Loss of energy through automobiles
2.2.2.1 Systems where energy is wasted
In the early days of automobile manufacturing in the 20 th century automobile manufactures

were more concerned in making their cars more powerful and making them stand out from
their competition. Because the internal combustion engine was a new technology at the time
manufactures were experimenting on new technologies to make it more powerful rather than
making it more efficient, this is why we see many old cars with big block (high capacity) V8’s
still only making around 150-250 horsepower. Making these engines more efficient became a
priority after the 70’s gas crisis started to effect many countries and the automobile sales
declined heavily. Automobile manufactures were now experimenting new designs to make the
internal combustion engines more efficient. The end result was cars coming out of the
manufacturing line with highly efficient engines than their predecessors by getting rid of the
old inefficient carburetor systems and implementing Electronic Fuel Injection systems to their
cars and adding turbochargers, automatic transmission systems and good aerodynamics to get
at least that small amount of efficiency. Since then cars are becoming more efficient by the day
with more new designs and technologies like cylinder deactivation, high compression ratios
and improved valve timing being implemented to them. Even after implementing all these new
technologies into modern cars these days only about 20% of the fuel we dump into the car is
converted to useful energy. In modern passenger cars about 33% of energy is wasted just to
overcome friction within the engine, transmission, tires and brakes.
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A modern car uses about 340L of fuel per year just to overcome the frictional forces it’s facing,
if we multiply that amount to calculate the global wastage of fuel, just to overcome friction its
about 208,000 million liters of fuel per year. (Kenneth Holmberg, Peter Andersson, Ali
Erdemir, 2012). These fossils fuels are also a non-renewable type of energy which means the
fuel will run out by time and it is estimated that petroleum will run out in about another 40-50
years (Ecotricity, n.d.), which means using internal combustion engines is a highly inefficient
method of transport. This brings us to think about our future energy source for transportation.
Though there are other types of energy sources for transport like hydrogen powered vehicles,
electric cars are now very popular method of transport because it’s easy to use and because of
its simplicity. Electric cars work by charging the batteries by plugging the car to a charging
spot and then the batteries provide the power to the motors which in turn drive the wheels. Here
the main drawback of using electric cars nowadays is the range. (it is limited) which means it
can only go up to a certain distance before recharging again. We can increase this range if we
make the car more efficient. Many of us think that an electric car is the most efficient method
of transportation, its only true to certain extend. Though electric cars are more efficient than
cars with internal combustion engines, there are still many areas an electric car can lose energy
like still we have to overcome those frictional forces (mentioned earlier), though the forces are
lesser than an internal combustion engine car because lesser internal components. As an
example; no transmission systems flywheels. Still there is a good amount of friction acting on
it. Plus about another 20% of the energy is lost in the electric drive system. Such as; motors
and power supply cables. 10% when charging, 4% in accessory losses. As an example; power
steering, cooling systems, control systems. And about 4% in auxiliary losses such as; lights,
navigation systems and entertainment systems. (fueleconomy.gov, n.d.).
Automobile manufactures have adopted varies different methods to compensate these energy
losses like having high pressure tires to reduce the tire contact area which in turn reduce the
friction between the tires and the road (many electric cars like the Tesla model S and the BMW
i3 have their optimum tire pressures around 40PSI and up), making the cars more aerodynamic
to reduce the drag ( Automobile manufactures like Honda have gone to lengths far as removing
the side mirrors and replacing them with a small cameras in the new Honda E to reduce the
drag, this has helped the car cut off 3.4% of the drag if it had typical side mirrors)
(https://www.youtube.com/, 2020).
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These methods are still going to help increase the efficiency only by a small amount, one good
way of harnessing energy is by using a regenerative braking system. There are many types of
regenerative braking systems like electromagnetic, flywheel, etc… But still these systems have
their own inefficiencies, a typical regenerative system is about 60 - 70% efficient. A
regenerative braking system usually loses around 10 - 20% of the energy being captured and
then again the car loses another 10 – 20% of that energy when converting it to kinetic energy
for acceleration. We can make the regenerative braking system more efficient by placing piezo
electric tiles on the brake pads to harness more energy while braking. So far in this topic it’s
been shown the energy losses in vehicles that effects the vehicle in a negative way only, but
there is another type of energy loss which can describe as the energy that’s lost not creating a
negative effect to the efficiency of the car but by not being generated or being converted to a
useful form. For example if we take the suspension system, though we can’t feel much
vibrations when cruising through the highway at high speeds there are many small up and down
movements in a suspension system and when going through uneven roads there are heavy
movements so we can use the movements of the system to harness more energy to the battery
by using piezo electric materials. We can also consider tire rotations also as a energy loss like
above because we can use rotations of the tire to generate electricity by placing piezo electric
tiles on the inside walls of the tire.
2.2.3 Kinetic energy recovery systems

The globe has immensely benefitted with the advancement of technology and knowledge base
that has led to enormous socioeconomic progress and consequently raised the quality of living
of man on the far side comprehension. Among the many resources that have a serious half
within the growth, the role of fossil fuels has been undeniably quite vital. However the reserves
of those fuels area unit speedily declining and at the speed of growth of the man, the exhaustion
of those resources in close to future is inevitable. This has been the one amongst the major
causes of concern within the recent past. The opposite major concern within the gift day has
been declining state of atmosphere. In a world wherever the majority its fuel is being depleted,
conservation of natural resources has become a necessity in today’s world, particularly within
the field of renewable technology.
This drawback has been resolved with the introduction of Kinetic Energy Recovery System.
It's an approach to recover or restore the energy lost whereas braking system, transmission
systems, suspension systems. Regenerative braking could be a style of Kinetic Energy
Recovery System that has the ability to store and recover the lost energy.
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In recent years, hybrid electrical vehicles were developed so as to satisfy the demand of
reducing energy consumption, the increasing fuel costs and also the harm caused by fuel
emissions to the environment. Currently, the marketplace for hybrid vehicles is essentially
comprised of hybrid electrical vehicles. Partially or totally supercharged by electrical motors
that square measure provided electricity from rechargeable batteries.
Primarily employed in formula-1 cars for the aim of speed boosting. Braking purpose of a
vehicle is often wasted. But this energy is saved and effectively regenerated once the- brakes
are applied. The braking energy gets converted into heat that is wasted but during this situation
once the brakes are applied, the energy is passed to the motors that are mounted on the front
wheels. The motors at this stage act as a generator changing the mechanical energy to electrical
energy that is then passed to motors/flywheel. This motion energy be restored in the battery
and when needed, that energy is given to the motors then the wheels by providing the
mandatory boost in speed.
There are different types of forms in which the kinetic energy lost while braking can be stored.
They are,
 Mechanical KERS
 Electric KERS
Since kinetic energy is that the energy of movement, vehicles produce heaps of it. Capturing a
number of that kinetic energy for fuel productivity in a very hybrid automotive is somewhat
dubious, however regenerative braking is one good technique utilized by several automakers.
The automotive utilizes the energy place away within the battery to regulate the electrical
engine that drives the automotive at low speeds. Contingent upon the sort of hybrid, the
electrical engine will either work alone to maneuver the automotive or it will work operating
beside the car's gasoline-fueled engine. The braking system that once combined with eco
accommodating driving ways like moderate starts and slower vehicle rates is incredibly
important embody on the foremost fuel expert vehicles. Regenerative braking could seem to
be exceptionally hullo technical school, but the thought of having "energy-saving" in machines
is simply identical previous issue now.
2.2.3.1Mechanical Energy Recovery System
Energy recovering using a flywheel is another method. This principle can be successfully
implemented in a bicycle. A passive system like bicycle for serving the aim of reduction in
pedaling power by employing a regulator and a mechanism for engaging and disengaging
constant.
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In Kinetic Energy Recovery System bicycle, flywheel is employed to store and restore the
energy. Flywheel is mounted between frames of bicycle with aesthetic and applied science
concerns. It may be engaged with rear wheel with clutch mechanism. This mechanism consists
of clutch, free wheel and sprocket with correct gear magnitude relation for transmission.
Figure 1: KERS in bicycle

When the bicycle is descending a hill or with slow speed in holdup clutch is engaged with
flywheel to store energy and this energy is rebuilt once needed. Currently at a time once the
speed reduction is needed clutch is engaged and flywheel starts rotating storing energy in spite
of this pedaling power is small and potency of system is inflated. For analysis of system
overdrive take a look at administered and results are obtained so as to scale back pedaling
power. Vehicles with KERS will bridle a number of this motor vitality and in doing there in
capability will facilitate with braking. By a legitimate mechanism, this set away energy is
modified over back into mechanical energy giving the vehicle additional increase in power. A
flywheel will incidentally store the active vitality from the bicycle once the rider wants to
backpedal. The energy place away within the regulator is familiar with convey the wheeler
back up to cruising speed. On these lines the wheeler recuperates the energy unremarkably lost
amid braking. Additionally to inflated energy proficiency, the flywheel-prepared bike is a lot
of enjoyable to ride since the rider has the power to raise speed.
2.2.3.2 Advantage
 Low cost
 No need to battery or electric stunt
 Low implanted carbon content
 Low weight and small in size
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2.2.3.3 Disadvantage
 Developing this sort of KERS, have detailed that it is greatly hard to create, and won't
be very beneficial unless it is placed in the ideal position.
 Even it is an energy recovery system, it dissipates some amount of energy because of
the mechanical clutch.
 When ascending a hill, it is hard to paddle when the flywheel engages with the clutch.
Kinetic Energy Recovery System framework used as a section of the vehicles that satisfies the
motivation behind saving a section of the energy lost amid braking. Climate condition isn't
relevant for storing the energy, whether or not the temperature vary is high, this technique is
incredibly economical compared to the conventional braking system. Kinetic Energy Recovery
System framework features a wide extension for more advancement and therefore the energy
savings. The utilization of a lot of economical frameworks could lead on to large savings within
the economy of any nation. Here we have a tendency to square measure presuming that the
topic Kinetic Energy Recovery System got a good extension in building field to limit the energy
consumption. As currently on a daily basis, energy conservation is exceptionally necessary
issue. Here we have a tendency to existent Kinetic Energy Recovery System framework in a
very bike with a fascinating and disengaging grasp mechanism for gaining significantly a lot
of proficiency.
2.2.4 Piezoelectric materials
2.2.4.1 Piezoelectric mechanism
The displacement of ions in the crystal lattice of a piezoelectric material creates the polarization
as piezoelectricity. Positive and negative chargers in the material separate when a piezoelectric
material is placed under a force or stress, that material produces a polarization proportional to
the force applied on the material. (Only in asymmetric materials)
𝑃𝑜𝑙𝑎𝑟𝑖𝑧𝑎𝑡𝑖𝑜𝑛 = (𝑝𝑖𝑒𝑧𝑜𝑒𝑙𝑒𝑐𝑡𝑟𝑖𝑐 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 ) × 𝑆𝑡𝑟𝑒𝑠𝑠
Force, stress, strain, squeeze, twist, push, pull, pressure, impact and all these terms are a result
of kinetic energy or mechanical energy. So kinetic energy has a direct connection with
piezoelectricity. “PIEZO” is a Greek word with a meaning of “Pushing”. So in general terms
“piezoelectric” is the electricity which generates by pushing a material. In day-today life people
use different components which is related to “piezoelectric effect” with conscious or maybe
not. Such as lighters, gas burners.
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But if a material can cause piezoelectric effect, it is definitely a piezoelectric material. These
piezoelectric materials have the ability of generating internal electrical charges/ pulses
proportional to the mechanical force/stress which is applied on the material. Such materials
are;
Crystals:
 Quartz; A stable form of crystal used in frequency reference crystals for radio
transmitters and watch crystals.)
 Sucrose; table sugar
 Rochelle salt; creates a high voltage with compression and used in early crystal
microphones.
 Topaz
 Tourmaline
 Berlinite (𝐴𝑙𝑃𝑂4 ); Rare Aluminum Phosphate mineral structurally identical to
quartz.
Certain ceramics:
 Barium titanate (𝐵𝑎𝑇𝑖𝑂3); first piezoelectric ceramic discovered.
 Lead titanate (𝑃𝑏𝑇𝑖𝑂3 )
 Lead zirconate titanate (PZT); most commonly used ceramic with high
efficiency.
 Potassium niobate (𝐾𝑁𝑏𝑂3 )
 Lithium niobate (𝐿𝑖𝑁𝑏𝑂3 )
 Sodium tungstate (𝑁𝑎2 𝑊𝑂4 )
 Bismuth ferrite (𝐵𝑖𝐹𝑒𝑂3 )
 Sodium niobate (𝑁𝑎𝑁𝑏𝑂3 )
Biological materials:
 DNA
 Enamel
 Silk
 Dentin
 Bone
 Collagen
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Polymers:
 Polyvinylidene fluoride (PVDF); Used in medical textiles also can create higher
piezoelectricity comparable to quartz.
(Walter Heywang, 2008)
2.2.4.2 History and inventions of piezoelectric materials
It’s a well known fact that the discovery of fire made a fluorescence in human history where
people used fire for cooking purpose, prevent from harmful animals and as a communication
method among people as well as with the gods. The primary methods of making a fire was by
rubbing flint, fire-steel or hard, glassy stone such as quartz, jasper and agate. This process is
the piezoelectric effect. So the piezoelectricity is not a new invention. But now, the method of
utilization is different from past. In 1880 Curie brothers, Pierre and Jacques first approved the
piezoelectric effect.
(Duck, 2009), (Uchino, 2010)Also made their subject wider by researching about crystalline
structures and pyroelectric materials which can generate electric charges in response to
different temperature changes. In the research about piezoelectric materials they showed that
Quartz and Rochelle salt (Sodium Potassium tartrate tetrahydrate) has the highest piezoelectric
effects. (Voigt, 1910) According to Woldemar Voigt’s Lehrbuch Der Kristallphysik they have
found 20 of such crystalline materials. In advance, piezoelectric materials were used in World
War I and II as an ultrasonic submarine detectors, cartridges of phonographs etc…
The approach towards piezoelectric materials were strongly increased with the understanding
of the connections between crystalline structures and electromechanical actions and the
improvement of the researchers. Rather than searching for the suitable applications with the
observed properties of materials, engineers were able to utilize piezoelectric materials for
specified devices and industrial applications. Such as super sensitive microphones,
loudspeakers, laser electronics, powerful sonar devices, sonobuoys, single cylinder piezo
ignition systems, diesel injection systems, transducers, motors, sensors and actuators.
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2.2.4.3 Harvesting electricity through piezoelectric materials
One early studied performed by Umeda et al (Mikio Umeda, 1997), investigated that the energy
storage characteristics of a system which harvest power consisting of a piezoelectric material
(PZT) with a full bridge rectifier and a capacitor.
Also discussed the efficiency of the storage circuit with the effect of various parameters and
implemented a prototype following their analytical investigation with an efficiency over 35%.
That percentage was three times more than a solar cell. So the report was included with a
feasibility study about harvesting energy from piezoelectric materials.
According to (Shrimoyee Poddar, 2017) footsteps applied to some materials when pressure of
that make up their structure is disturbed and a small electric voltage is created. These types of
kinetic floor tiles was used in Paris marathon in 2013, it is generate 4.7 kilo watt hour of
electricity. Also the proper selection of the piezoelectric material is a prime importance. The
criteria of selection was the voltage output of the material with the variable of pressure applied.
PZT and PVDF materials were used as the piezoelectric ceramic material. (This research is based
on a piezoelectric tile, and its source of pressure is the mass of a person or a vehicle. But when
application changes, the brake force of a vehicle is comparably very high.)
Figure 2: VI graph of PZT

So by using piezoelectric ceramic, the pressure applied on the piezoelectric ceramic converts
into electrical energy. But the output of the piezoelectric material is not a steady current. By
using a bridge circuit and an AC ripple filter, the variable current can be converted into a linear
current flow without any further fluctuations. Then the output DC voltage can be stored in a
rechargeable battery. Though the power output of a single and a small piece of piezo-material
is very low, it has to be connected in accordingly to harvest more electrical energy.
18
 Parallel connectivity: Voltage output is low.

 Series connectivity: Voltage output increased but not in linear proportion.
So the implementation should be a combination of both series and parallel connectivity and the
output voltage was 40V with high current density.
Figure 3: VI graph of parallel and series combination
2.2.5 Electric Systems and Circuit diagrams

This is primarily a by-product of the complications that arise when connecting design
parameters to the output power. Such complexities have led to various concepts of perfect
design for specific applications, but no work has been done to understand the basic
fundamentals of technology. Here we present a method of determining the maximum power
output possible based on the limits of resonance and energy efficiency as well as the ultimate
strength of the piezoelectric element. The power limits of energy harvesters were first theorized
by considering a simple piezoelectric stock. Roundy pointed out that this would be the
maximum power output for bulk harvesting.
Pmax = k2 mA2
4C2w2
Where k is the coupling coil cents, m is the mass of the achievement, A is the magnitude of the
base acceleration, f is the mechanical wetting ratio and x is the natural frequency of the system.
This equation is a starting point for understanding the power available from a harvester and
giving an understanding of how acceleration or system natural frequency is expected to power
output. As Roundy rightly notes, bulk piezoelectric harvesters are not practical because of their
high resonance frequencies.
19
In addition, this equation does not provide the detailed understanding required for cantilever
harvesters who typically operate in low-power and vibration-level environments. Furthermore,
this power model is proportional to the square of the acceleration magnitude.
When two metal plates are arranged in two sides of a piezoelectric material. Then plates vibrate
when a sound wave hits one or two plates. The stalk receives this vibration, which converts it
into a weak AC voltage. Therefore, an AC voltage arises between the two metal plates and has
a waveform similar to sound waves. On the other hand, if an AC signal is applied to the plates,
it will cause the stalk to vibrate parallel to the signal voltage. As a result, the metal sheets
vibrate and cause acoustic disturbances.
2.2.5.1 Villard Cascade
A voltage multiplier is an electrical circuit that normally converts a low voltage into a high DC
voltage using a network of capacitors and diodes. The voltage multiplier can be used to generate
several volts for electrical equipments. Objectives such as high energy physics experiments
and lightning protection tests. The most common type of voltage multiplier is the half-wave
series multiplier, also known as the Willard Falls.
Piezoelectric generators designed for harvesting vibration are usually based on mechanical
resonators, for example cantilever beams, which can effectively and efficiently transmit
circulating energy to the active substance. These structures display normal functional zones
near a resonant frequency. The piezoelectric element of the generator is the most suitable model
for devices such as piezoelectric tiles, which is a single-mode mechanical resonator that
connects to the electric circuit through the electromechanical properties. The mechanical
displacement of the generator base and the dynamic mass on the gravity, respectively, are a
Galilean reference. Dynamic massage activates its inertial action, a restorative force due to the
mechanical structure, a viscous force due to the damper, and a piezoelectric element. On the
mechanical side, the piezoelectric element is powered by its rigid voltage regulator. On the
electrical side, the piezoelectric internal current source is controlled by a relative mechanical-
velocity. The dynamic equilibrium of the system is the model for seismic generator, the
simplest particle element commonly reported in the literature. In some cases, the model
parameters can be analytically derived from piezoelectric material properties and thematic
processing characteristics. In general, however, the values of parameters can be predicted using
a finite elemental model, starting with several measurements of the experimental prototype
considered. Despite its simplicity, this model is in good agreement with the Knight Elemental
models and has the experimental features of such generators.
20
Figure 4: Electrical diagram of a piezoelectric tile
2.2.5.2 Buck Booster Converter
Buck boost converter is a DC to DC converter and has a magnitude of output voltage. It can be
equal to or greater than the magnitude of the input voltage. The buck boost converter is similar
to the flight rear circuit and uses a single inductor instead of a transformer. There are two types
of buck converter. Buck converter and boost converter. These converters can produce an output
voltage range greater than the input voltage. The diagram below shows the basic buck boost
converter.
Figure 5: Buck Booster converter
21
2.2.5.3 DC-DC Conversion
The dynamic performance of a DC to DC converter is an unexpected variation of the input

impedance inductor current. If the switch is active, the inductor feeds the energy from the input
and stores the energy of the magnetic field. If the switch is closed, it discharges energy. The
output circuit of the capacitor is assumed to have a high time constant of an RC circuit at the
output stage. Make sure that the large time constant corresponds to the switching period and
that the constant is a constant output voltage, Vo (t) = Vo (constant), and at the load terminal.
2.2.5.4 Buck booster working
The diagram below shows the functionality of the clamp converter. The first transistor of the
buck converter is activated and the second transistor is deactivated due to the high square wave
frequency. If the gate terminal of the first transistor is greater than the current path through the
magnetic field, then C is charged and it is loaded. D1 is the Schottky diode which is deactivated
due to the positive voltage to the cathode.
Figure 6: Buck converter diagram
Inductor L is the starting source of the current. If the first transistor is deactivated using the
control unit, the current flow in the clamp operation. The magnetic field of the inductor is
broken and the back electromotive force (e.m.f) is generated as the breaking field revolves
around the polarity of the voltage across the inductor. The current flows in diodes D2, load and
diode D1 are activated. The discharge of the inductor L is reduced with the help of current. In
the first transistor, the capacitor charge in the capacitor is in one state. The current passes
through the load and keeps the Vout reasonable during off periods. So it keeps the minimum
ripple amplitude and closes to the value of Vout Vs.
22
Chapter 03
3.1 Conceptual Designs
3.1.1 Conceptual Design 01: Piezoelectric tiles in Shock Absorbers/Coil overs
How shock absorbers work is by taking the kinetic energy (from movement) of the suspension
system and converting it to mostly thermal energy (heat) and then its dissipated to the
atmosphere. We can harness some of the kinetic energy from the suspension system and
convert it to useful chemical energy by using piezo electric tiles to absorb this kinetic energy
and convert them to electronic energy and store this energy in a battery for future use. When
we travel in bumpy roads or roads with uneven surfaces there are huge forces been experienced
by the suspension system. These energies are just wasted into the atmosphere. We don’t always
need to travel on bumpy roads for this system to work, when we travel in highways we think
the road is very smooth and leveled but there are so many small imperfections and there are
many small up and down movement happening in the suspension system at a very high
frequency and the highway speeds these small vibration can produce a good amount of energy
to be stored in the battery. We attach the piezo electric tiles to the upper spring seat, so when
there’s even a slight imperfection the road the spring on the damper undergoes compression
which exerts an force on the spring seat which forces the electric charges within the crystal of
the piezo electric tile out of balance. Excess negative and positive charges appear on opposite
sides of the crystal face. The metal plate collects these charges, which can be used to produce
a voltage and send an electrical current through a circuit.
23
Figure 7: Shock Absorber view 01
Figure 8: Shock absorber view 2
24
3.1.2 Conceptual Design 02: Piezoelectric motor
Figure 9: Piezoelectric motor
Piezoelectric motors are widely use rather than electromagnetic motor. Because of,
 It gives high torque at low rpm without gear box

 Low inertia leading with low response time. When powered off, it maintaining with
high torque.
 High power to weight ratio.
The principal of a rotational piezoelectric motor is depend on setting in motion of a rotor by

friction forces induced by a stator. Piezoelectric elements are induced stress and it causes the
deformation of the stator and also it may create a progressive wave deformation at the surface
of the stator.
Rotational motor
This structure have 4 stator rings pressing two rotors connected to the motor shaft stators are
composed of several metallic blocks alternating with piezoelectric actuators.
This structure can oscillate circular (tangential mode) and axially (normal mode). Axial mode
is induced by piezoelectric actuators. Which apply a thrusts on metallic blocks in the direction
parallel to the motor shaft. These combination of the two modes gives an elliptical motion on
the contacting surface of the stator and the rotors. It drives the rotor shaft dues to the friction
between the rotor and the stator.
25
Figure 10: Piezoelectric actuator
These types of motor can generate 1 kW power range which is above a factor 100 of the power
provided by classic piezoelectric motor. Due to the large surface connects, which enable
conversion of vibration to rotor motion at high power level.
However this system is very complex when conversion of mechanical vibration efficiency into
rotor motion. It can obtained high mechanical power. That means a perfect control of normal
and tangential mode. The motor design must lead to the same mechanical resonance frequency
for the two modes. And its power supplies of normal and tangential piezoelectric actuators
must be perfectly tuned to get the proper motion of metallic blocks. And the other hand it has
a strong impact on conversion efficiency with the contact diagrams between stator and rotor,
the power transmission being linked to the total surface contact and friction co-efficient
between rotor and stator materials.
26
3.1.3 Conceptual Design 03: Disk braking system

When braking is applied on the wheels, the braking force will be given to the disc by the
hydraulic piston of the brake caliper. The braking shoes will engage with the brake disc to do
the relevant task of braking. So in here the braking shoes are a component which consist of a
piezoelectric ceramic which is PZT composite. PZT is a special kind of a piezoelectric ceramic
which can harvest more electrical energy among other piezoelectric materials. Also in this
structure the piezoelectric material is used to harvest electricity where the piezoelectric
materials generate electric pulses corresponding to a force applied on to that specific material.
The brake shoes are mounted inside the hydraulic caliper and the braking is done with the
application of brake from the driver. The kinetic energy of a moving vehicle is wasted with the
application of braking. But with this design it can harvest the wasted energy from a vehicle
when braking is applied.
An external electric circuit is attached to the negative and positive terminals of the brake shoes
to harvest the lost kinetic energy as electrical energy. That electrical energy will be useful in
powering up the electrical components in a vehicle. This is also kind of a regenerative braking
system
Four quadrant single

phase rectifier
piezo pad
NiMH
C battery
Brake disc
piezo pad
Figure 110: Electrical system
27
3.2 Optimum Design Justification

Kinetic energy is wasted in many ways of an automobile. According to our project Kinetic
Energy Recovery System using piezoelectric material, we have chosen the conceptual design
3 where any type of an automobile need braking. A high percentage of kinetic energy loose
when braking is applied to a moving vehicle. Energy wasted as heat and sound due to friction
with the brake disc/rotor and the brake pads. The braking disc is turning with the speed of the
vehicle. So the braking pads engage with the brake disc to decelerate or to stop a vehicle.
Obviously engine or the motors need more energy to recover that lost energy when braking. In
a conventional vehicle fuel is the source of powering up the vehicle. So, in hybrid vehicles with
this method it can save fuel consumption and use that wasted energy for a useful purpose.
Hybrid and electric vehicle manufacturers use a technique called regenerative braking. In
electrical vehicles source of power is electricity. So when braking kinetic energy of the vehicle
loses as well as the generated electrical energy is also wasted. So the wasted kinetic and
electrical energy can be restored by using this method. This is a kind of regenerative braking
where the lost kinetic energy of a vehicle can be restored by using piezoelectric material.
Piezoelectric materials have an ability of generating electric pulses when the material is
subjected to a pressure. So here we use piezoelectric ceramic as the material of the braking
pads of a vehicle and an external electrical circuit is used for the purpose of harvesting electrical
energy from the piezoelectric material. The generated pulses travel thought the external circuit
and that electrical energy can be stored in the battery to be re used for a different purpose such
as powering up the lights, sound system, horn and other electric components in a vehicle.
Finally the problems which I have identified in the previous chapter have been solved with this
design.
 High energy demand and low usable energy.

 Energy loss/wastage through different components and systems of
automobiles.
 High cost of advanced technologies and non-renewable energy sources.
28
Chapter 04
4.1 Design of the project
4.1.1 Brake disc design and implementation
Figure 111: Brake disc design
The above design have been implemented by using SOLIDWORKS 2018 software. This is a
design of a disc braking system rotor of a vehicle. Brake disc is an important component in the
braking system. Due to the friction between the brake disc and the brake pads the braking
process of a vehicle take place. This action slows the motion of the wheels and decelerate the
vehicle. When comparing with the drum brakes, disc brakes gives a better performance and
efficient braking experience. Also less responsible for brake fade due to the good contact with
air and ventilated. So overheat does not happen and the recovering process happens quickly
than drum brakes. The braking force applied by the driver is proportional to the pressure applied
on the brake disc. So the driver and the passenger onboard experience a smooth and quick
braking. The disc braking improves the safety of the vehicle as well as the efficiency of braking.
29
Figure 112: Brake disc rear view
Design parameters
 Outer diameter of the disc: 286mm
 Inner diameter of the disc: 165mm
 Area of the disc: 400032.53𝑚𝑚2
 Perimeter of the disc: 3301.81mm
 Vent holes: 5*20
 Thickness of the disc: 23mm
 Disc material: Grey cast iron
Material properties
Property Value Units

Elastic Modulus 6.61781e+10 N/m^2
30
Poisson's Ratio 0.27 N/A

Shear Modulus 5e+10 N/m^2
Mass Density 7200 kg/m^3
Tensile Strength 151658000 N/m^2
Compressive Strength 572165000 N/m^2

Yield Strength - N/m^2
Thermal Expansion 1.2e-05 /K
Coefficient
Thermal Conductivity 45 W/(m·K)
Specific Heat 510 J/(kg·K)
Material Damping Ratio - N/A
4.1.2 Brake pads with piezoelectric material

Brake pads are an important component in the braking system of an automobile. These brake
pads are mounted inside the brake caliper assembly. There are two types of brake calipers. One
is floating type caliper and fixed type caliper. The fixed caliper cannot move with the disc and
it has a less ability to withstand the irregularities of the brake disc. Sometimes it consist with
one or more pistons to clamp from each sides of the disc. The floating type caliper can move
with the disc along a parallel line. So the piston in one side of the caliper pulls the brake pad
of that side and with the contact of the brake pad with the disc, the brake pad of the other side
of the caliper pulls to the disc from the other side. There the body of the caliper acts as the
piston and the cylinder.
31
Figure 113: Brake pad rear view
Here in this design, the braking pads have been implemented by using piezoelectric material
called PZT (Lead Zirconium Titanate). This material is a composite material which shows
piezoelectric effect. So when brake pedal is pressed by the driver, the pressure applied on the
brake pads engage with the brake disc and the vehicle will decelerate. While the braking
process is going on, the lost kinetic energy through braking in the vehicle has been recovered
with the piezoelectric material.
PZT is also called as an electro ceramic because of its unique properties. This material
generates a voltage across two faces when a pressure is applied on that material. Not only that,
this material is also pyroelectric and ferroelectric. This material can generate a voltage with the
changing temperatures and this material has electric dipole moment. So by anyway the material
will generate a voltage which can be helpful in charging a 12V battery which can be used for
powering up the electronic and electrical components inside the vehicle.
32
Figure 114: Brake pad front view
Figure 115: Disc brake assembly
33
Figure 116: Brake pads connection to brake disc
Figure 117: Brake assemble is disengage mode
34
4.1.3 Electric system Design
Vibration (Energy Source)
Piezo electic
material
Power
Management Load
System
Energy
storage
Figure 118: Flow chart of electric diagram
How a piezo electric material works is; it will produce an alternating current when it
experiences any kind of force or stress being applied to it, this happens because normally the
charges in a piezo electric material are exactly balanced and the charges exactly cancel out
leaving no net charge on the crystal faces and this piezo electric material is placed in between
two metal plates, when we apply a mechanical pressure we force the charges out of balance
and the excess negative and positive charges appear on the opposite sides of the crystal face
which creates a voltage difference and the metal plate collects these charges and sends through
– and that’s called piezo electricity! Which we can use to run electrical appliances.
These piezo electric materials are producing alternating currents (AC) which can’t be used to
charge up a battery because the batteries require DC current in order to charge it, so we need
to convert this AC current to DC current and for that we need to use a rectifier. A rectifier is a
device that is made up of one or more diodes that converts AC (current which changes direction
periodically) into DC (single direction flowing current), this process is called rectification.
There are mainly two types of rectifiers: Uncontrolled rectifiers and Controlled rectifiers,
uncontrolled rectifiers are a type of rectifiers were the output voltage cannot be controlled
whereas in the controlled rectifiers the output voltages can be varied or changed.
35
There are many types of controlled and uncontrolled rectifiers which include Full wave
rectifiers, half wave rectifiers and Bridge rectifiers. A half wave rectifier (as the name suggests)
converts only the half cycle of the alternating current (AC) into direct current (DC), a full wave
rectifier covert both the positive and negative half cycles of the AC into DC it also provides
double the voltage compared to the half wave rectifier which is ideal to our application.
4.1.3.1 The Bridge rectifier with full wave rectification
A bridge rectifier uses 4 diodes to convert both the half cycles of the input AC into DC output
(Figure 2 shows how the diodes are connected in a bridge rectifier).
But still even after using a full wave rectifier it leaves a pulsating voltage which is also
known as a High Ripple because a rectifier works only from the lower half-wave upwards
and it’s still hard to charge a battery like that, so now we must use a smoothing capacitor to
smooth these voltages.
Figure 20 - A Bridge Rectifier Circuit
The smoothing capacitor helps to smooth the curves by charging up when the voltage
coming out of the full wave rectifier rises above that of the capacitor an then when the
rectifier voltage starts to drop the capacitor provides the required current from its stored
charge, this will not help provide total voltage stability there will be some slight variations in
the voltage which is manageable in many circuits. To increase the ‘smoothing’ effect it’s
better to use a higher value capacitor cause the greater the capacity higher the smoothing
effect. Figure 3 and 4 shows how the capacitor helps to smooth the curves.
36
Figure 21 - Without a Smoothing Capacitor
Figure 22 - With a Smoothing Capacitor
Figure 23 - The Smoothing effect of the Capacitor
37
4.1.3.2 The Battery
Now the only thing required to complete this circuit is the energy storage device cause we
need a place to store all this energy generated by the piezo electric circuit, we can choose a
NiMH (Nickel Metal Hydride) battery because they have a very high charge density unlike
Lithium ion batteries and they do not require any type of charge controller or a voltage
regulator to be incorporated I the circuitry which is ideal for our application. The simplicity
of this circuit permits it to be developed minimally and without extra segments that would
cause any additional power dissipation (Figure 6 shows a schematic of the circuit we use for
our application).
Figure 24 - Circuit Diagram
38
Chapter 05
5.1 Method of experiment, testing parameters and setup
The testing parameters and setup of the disc brake assembly is the thermal test and a static
tests. When a braking force is applied on a brake disc by the driver, the braking pads and
braking disc need to be considered very much. So from the material selection to the enduring
point of the component is important. All the following simulations were done by using
Solidworks 2018 software. The testing and analysis is as below.
Figure 25: Disc brake thermal test
39
Figure 26: Temperature incensement due to braking forces
Figure 27: Torque applied due to acceleration
40
Figure 28: PZT material testing
Figure 29: Electric system diagnosing
41
5.2 Results
5.2.1 Testing results of the disc brake assembly
Brake Disc Information
Model name: brake disc

Current Configuration: Default
Solid Bodies
Document Name and Document Path/Date
Treated As Volumetric Properties
Reference Modified
Fillet3
Mass:8.64026 kg
Volume:0.00120004 m^3 D:\Educational\1st
Density:7200 kg/m^3 Sem\Computer aid
Solid Body
Weight:84.6745 N drawing\SW\brake.SLDPRT
Aug 26 22:49:36 2020
42
Study Properties
Study name Thermal 1
Analysis type Thermal(Transient)
Mesh type Solid Mesh
Solver type FFEPlus
Solution type Transient
Total time 3 Seconds
Time increment 0.1 Seconds
Contact resistance defined? No
Result folder SOLIDWORKS document
(D:\Educational\1st Sem\Computer aid
drawing\SW)
Units
Unit system: SI (MKS)
Length/Displacement mm
Temperature Kelvin
Angular velocity Rad/sec
Pressure/Stress N/m^2
Material Properties
Model Reference Properties Components
Name: Gray Cast Iron (SN) SolidBody 1(Fillet3)(brake)
Model type: Linear Elastic Isotropic
Default failure criterion: Mohr-Coulomb Stress
Thermal conductivity: 45 W/(m.K)
Specific heat: 510 J/(kg.K)
Mass density: 7200 kg/m^3
Curve Data:N/A
43
Thermal Loads
Load name Load Image Load Details Function Curve

Entities: 309 face(s)
Initial 273 Kelvin
temperature:
Temperature-
1
Entities: 309 face(s)

Convection 600
Coefficient: W/(m^2.K)
Time variation: Off
Temperature Off
Convection-1 variation:
Bulk Ambient 273 Kelvin
Temperature:
Time variation: On
Time curve
Mesh information
Mesher Used: Standard mesh
Automatic Transition: Off
Include Mesh Auto Loops: Off
Jacobian points 4 Points
Element Size 10.6291 mm
Tolerance 0.531454 mm
Mesh Quality Plot High
44
Mesh information - Details

Total Nodes 75749
Total Elements 44661
Maximum Aspect Ratio 37.874
% of elements with Aspect Ratio < 3 82.6
% of elements with Aspect Ratio > 10 0.488
% of distorted elements(Jacobian) 0
Time to complete mesh(hh;mm;ss): 00:00:12
Computer name: INDU’s Prime machine
45
Study Results
Name Type Min Max
Thermal1 TEMP: Temperature at 2.180e+01 Kelvin 1.486e+02 Kelvin
Step No: 30(3 Seconds) Node: 8357 Node: 5678
Brake disc-Thermal 1-Thermal-Thermal1
46
5.2.2 Testing results of the Brake pads
Brake Pad Information
Model name: brake pads

Current Configuration: Default
Solid Bodies
Document Name and Document Path/Date
Treated As Volumetric Properties
Reference Modified
Boss-Extrude4
Mass:0.339315 kg D:\Educational\1st
Volume:4.71271e-05 m^3 Sem\Computer aid
Solid Body Density:7200 kg/m^3 drawing\SW\brake
Weight:3.32529 N shoe.SLDPRT
Aug 26 23:57:30 2020
47
Study Properties
Study name Static 1
Analysis type Static
Thermal Effect: On
Thermal option Include temperature loads
Zero strain temperature 298 Kelvin
Include fluid pressure effects from Off
SOLIDWORKS Flow Simulation
Solver type FFEPlus
Inplane Effect: Off
Soft Spring: Off
Inertial Relief: Off
Incompatible bonding options Automatic
Large displacement Off
Compute free body forces On
Friction Off
Use Adaptive Method: Off
Result folder SOLIDWORKS document
(D:\Educational\1st Sem\Computer aid
drawing\SW)
Units
Unit system: SI (MKS)
Length/Displacement mm
Temperature Kelvin
Angular velocity Rad/sec
Pressure/Stress N/m^2
48
Material Properties
Model Reference Properties Components
Name: PZT (PIEZO) SolidBody 1(Boss-
Model type: Linear Elastic Isotropic Extrude4)(brake shoe)
Default failure criterion: Mohr-Coulomb Stress
Tensile strength: 1.51658e+08 N/m^2
Compressive strength: 5.72165e+08 N/m^2
Elastic modulus: 6.61781e+10 N/m^2
Poisson's ratio: 0.27
Mass density: 7200 kg/m^3
Shear modulus: 5e+10 N/m^2
Thermal expansion 1.2e-05 /Kelvin
coefficient:
Curve Data:N/A
Loads and Fixtures
Load name Load Image Load Details

Entities: 2 face(s)
Reference: Axis1
Type: Apply torque
Torque-1 Value: 1000 N.m
Contact Information
Contact Contact Image Contact Properties
Type: Allow
Penetration
Components: 1
Global Contact component(s)
49
5.3.3 Testing results of the Electrical system
Figure 30: Diagnosing the components
50
(Inman, 2005)
51
Chapter 06
6.1 Conclusion
From this project we learnt to build a Kinetic Energy Recovery system using piezoelectric
material for a braking system. The design is very well working with the given conditions. The
disc brake assembly is suitable for bicycles, motor cycles, cars, vans and other domestic
vehicles. Also we learnt that the kinetic energy loss of an automobile could be restored by
using piezoelectric materials. PZT is a very efficient and suitable material for this purpose.
But there is a draw back in PZT material that it contain Pb(Lead). Lead could be harmful for
the environment as well as the animals. Also we came across difficulties with the charging of
the battery that the 12V NiMH battery need a voltage of at least 13.5V to charge the battery.
Also we have to be keen on SOLIDWORKS and MATLAB software some more to do
advance simulations on them. But with the basic knowledge we have, at least we tried and
succeeded to implement and test the components up to a good level.
6.2 Future development

We can further develop this system by using piezoelectric materials to the places where the
kinetic energy is been wasted in an automobile. This material has the ability of withstand forces
and give good supply to the battery.Today, the most common of these methods are the vibration
energy harvesting via suspension systems and kinetic energy regeneration via braking systems.
Several designs of energy harvesting suspension systems have been presented and optimized
in order to ensure a better performance for different applications. Through various- energy
harvesting suspension systems, that have been designed, the mechanical energy of road-
induced vehicle vibrations has been successfully recovered in varying quantities. Moreover,
regenerative braking has existed for over 100 years and has already been available and applied
to hybrid and electric vehicles commercially. However, both the energy harvesting suspension
systems and regenerative braking technology is still under continuous development.
Flywheel kinetic energy recovery system technology is definitely practical because many car
companies are looking into using the system in average everyday cars. Volvo in partnership
with Flybrid, officially announced that they intend to develop and produce a vehicle that uses
the flywheel based kinetic energy .recovery system. With improvement in technology, KERS
will definitely become even more efficient and affordable. The main driving force which will
launch flywheel-based kinetic energy recovery systems into the automotive industry is the low
cost in comparison with fully hybrid vehicles. Any vehicle could be designed and fitted with a
flywheel-based kinetic energy recovery system, but the area most affected by this technology
52
would, be any vehicle with a start-stop cycle of driving. This technology has already been
tested in FLYBUS (a flywheel hybrid system developed for buses).
The Flywheel KERS is a technology of great importance and potential. With more
advancements and refinements, this system would increase the efficiency of hybrid vehicles. It
can reduce fuel- consumption and at the same time increase power. Its lower CO2 emissions
reduce air pollution. Probably the biggest advantage of this system is its ability to be retrofitted.
The flywheel KERS does not come without flaws, however developments- still need to be
made in reducing the forces that act upon the flywheel. With these forces minimized, the system
would have much higher efficiency and would be able to store energy longer. It would rival
hybrid electric vehicles in efficiency and range.
 Our concept can be used for any vehicle

 This system will help in the future the pollution that the word facing.
 12v battery life increases
 This method can be improved and the hybrid vehicle battery can be charged.
 The electricity generated can also active the vehicle component.
 Microprocessor can be used to calculate the braking effort required to stop in specific
distance to effectively control the speed
 The KERS system promises to be a technology of the future..
 KERS storage technology provides boost acceleration and braking force. FES supports
starting and guarantees light, silent and emission free starts of Combustion engine.
KERS also supplies all electric appliances, stabilizes on-board power supply and offers
stable air-condition. Kinetic recuperation based on braking energy stored in flywheel is
without cycle loading, unlike braking energy repeatedly stored in battery.
53
References
1. Anon., 2020. https://www.youtube.com/. [Online]
Available at: https://www.youtube.com/watch?v=NCrOp0zFWaE
2. Anon., n.d. Ecotricity. [Online]

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ev.shtml
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consumption due to friction in passenger cars. In P. A. Kenneth Holmberg, Tribology
International (pp. 221-234). Elsevier Ltd.
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25. Estimates primarily based on analysis of a 2012 Nissan Leaf. Charging losses based
on tests of several EVs by Argonne National Laboratory.
26. Lohse-Busch, H., et al. 2013. Ambient Temperature (20°F, 72°F and 95°F) Impact on
Fuel and Energy Consumption for Several Conventional Vehicles, Hybrid and Plug-In
Hybrid Electric Vehicles and Battery Electric Vehicle. SAE 2013-01-
1462, https://doi.org/10.4271/2013-01-1462.
27. Lohse-Busch, H., et al. 2012. Advanced Powertrain Research Facility AVTA Nissan
Leaf testing and analysis.
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Vehicle Dynamometer Results. SAE 2014-01-2562, https://doi.org/10.4271/2014-01-
2562.
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Evaluation of Vehicle Auxiliary Loads. SAE Int. J. Fuels Lubr.
9(1):2016, https://doi.org/10.4271/2016-01-0901.
30. Rhodes, K., D. Kok, P. Sohoni, E. Perry, et al. 2017. Estimation of the Effects of
Auxiliary Electrical Loads on Hybrid Electric Vehicle Fuel Economy. SAE Technical
Paper 2017-01-1155, https://doi.org/10.4271/2017-01-1155.
31. Pannone, G., B. Betz, M. Reale, and J. Thomas. 2017. Decomposing Fuel Economy
and Greenhouse Gas Regulatory Standards in the Energy Conversion Efficiency and
Tractive Energy Domain. SAE Int. J. Fuels Lubr. 10(1):202-216,
2017, https://doi.org/10.4271/2017-01-0897.
32. Inman, H. A. S. a. D. J., 2005. Generation and Storage of Electricity from Power
Harvesting Devices , s.l.: Gyuhae Park .
56
Chapter 08: Appendix
Figure 31: Testing and analysis of braking system
Figure 32: Piezoelectric energy harvesting
57
Week No. 1 2 3 4 5 6 7 8 9
Confirmation
of tile
Synopsis
Submission
Search about
Piezoelectric
material
Study about
piezoelectric
Write
Interim
Report
Interim
Report
Submission
Select
Piezoelectric
material
Design
suspension
system using
piezoelectric
Design brake
pad using
piezoelectric
Design motor
using
piezoelectric
Research
about
prototypes
Write final
report
Submit final
report
58

Kinetic Energy Recovery System by Using Piezoelectric Material

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8/28/2020

Kinetic Energy Recovery

Instructed by: Mr. Yasith N. Kotelawala

Student Name: Ashan Indusara

Project Name: Kinetic Energy Recovery System by using Piezoelectric Material.

 Chapter 02: Literature review

 Chapter 03: Methodology

 Chapter 04: Design and Implementation

 Chapter 05: Testing and Analysis

 Chapter 06: Conclusion and Future development

 Chapter 07: References

 Chapter 08: Appendix

1.2 Problem identification

• High energy demand and low usable energy.

• Energy loss/wastage through different components and systems of automobiles.

• High cost of advanced technologies and non-renewable energy sources.

1.3 Aim and Objectives

✓ Designing a model of a Kinetic Energy Recovery System using piezoelectric material.

✓ Testing the model feasibility to high braking forces and temperatures

✓ Designing the electrical system to harvest energy from piezoelectric material.

✓ Diagnosing the components

1.4 Scope and Limitations

Chapter 02 Thermoelectric harvesting

2.1 Literature mapping

Loss of energy Systems where energy is

Mechanical Energy Recovery

Harvesting electricity through

Electric systems and

2.2 Literature review

2.2.1.1 Thermoelectric harvesting

2.2.1.2 Pyroelectric harvesting

2.2.1.3 Large scale energy harvesting

Piezoelectric harvesting: Harvesting electricity from Materials by using pressure. In this

2.2.2 Loss of energy through automobiles

2.2.2.1 Systems where energy is wasted

In the early days of automobile manufacturing in the 20 th century automobile manufactures

2.2.3 Kinetic energy recovery systems

2.2.3.1Mechanical Energy Recovery System

Figure 1: KERS in bicycle

2.2.4 Piezoelectric materials

2.2.4.1 Piezoelectric mechanism

𝑃𝑜𝑙𝑎𝑟𝑖𝑧𝑎𝑡𝑖𝑜𝑛 = (𝑝𝑖𝑒𝑧𝑜𝑒𝑙𝑒𝑐𝑡𝑟𝑖𝑐 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 ) × 𝑆𝑡𝑟𝑒𝑠𝑠

2.2.4.2 History and inventions of piezoelectric materials

2.2.4.3 Harvesting electricity through piezoelectric materials

Figure 2: VI graph of PZT

 Parallel connectivity: Voltage output is low.

Figure 3: VI graph of parallel and series combination

2.2.5 Electric Systems and Circuit diagrams

2.2.5.1 Villard Cascade

Figure 4: Electrical diagram of a piezoelectric tile

2.2.5.2 Buck Booster Converter

Figure 5: Buck Booster converter

2.2.5.3 DC-DC Conversion

The dynamic performance of a DC to DC converter is an unexpected variation of the input

2.2.5.4 Buck booster working

Figure 6: Buck converter diagram

Figure 7: Shock Absorber view 01

Figure 8: Shock absorber view 2

3.1.2 Conceptual Design 02: Piezoelectric motor