Retrofit regenerative braking?

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Protege5 2003
I know this would be hideously expensive to do as a one off, and it may be impractical, but at $3.80 a gallon (and rising), one tends to fantasize a bit.

My automatic P5 is mostly driven in the city where it turns in around 22 mpg. Each direction is around 20 minutes and consists of about 20 cycles of cruising up to 35 mph and then braking down to zero. There is about 2-3 mpg loss in the automatic (as compared to what people report for city driving in manuals) and, I'm guessing, something like 10 mpg that could be recovered by regenerative braking. Which got me thinking, how hard would it be to retrofit a car with (electrical) regenerative braking?

Since the P5 is a front wheel drive internal combustion vehicle there isn't much one could do to attach such a system to the front wheels. On the other hand, there is a fair amount of space around the rear wheels, and retrofitting there seems like it could be possible. Braking on just the back wheels isn't ideal but should be ok for average deceleration in traffic conditions. The original brakes are still there for use in more rapid braking or above city speeds. For instance, a narrow "disk like" electric motor could replace the chunk of axle between the bearing and the disk brake. This would have to be braced against the suspension somehow in order to handle the torque needed for braking and acceleration. These two motors do not need to be all that powerful. It isn't necessary to store nearly as much energy as a Prius, just the kinetic energy of the car moving around 35 mph. In other words, don't try for full electric operation, just stop wasting so much energy bouncing the speed up and down. Waves hands - 4 inches across the whole bottom of the trunk should be more than enough for the electronics and batteries (or capacitors) to hold that. The rear wheel motors should actually trim off some of the efficiency loss from the automatic, since they would deliver power directly to those wheels without losing anything in the transmission.

There would probably be some loss in handling, since the weight of the suspended parts in the rear would increase. And maybe some loss in acceleration due to the extra 100 pounds or so of electrical equipment. Maybe, because electric motors tend to provide a lot of torque for their weight, so it's possible the rear axle motors could actually give the car a bit of a boost in acceleration. Think of it as an 80/20 temporary four wheel drive.

For controlling this system there could be a simple variable acceleration dial (only active when the car is running and the parking brake off). Turn it negative to slow, positive to accelerate. The car's computer should be able to deal with this since it is exactly the same as changing the slope of the road, which it can handle now. Safety first - the retrofit wouldn't affect the existing brakes. In fact, touching the brakes (easily detected as there is already a switch for that) would disable the retrofit. Obviously there would have to be an indicator when the (limited) batteries were fully charged, since at that point the retrofit would have to stop braking through the electrical motors to keep from lighting the trunk on fire, and the normal brakes would have to be applied by the driver.

To some extent the retrofit could even be used on the highway. When tweaking the speed up and down slightly twiddle the dial, rather than using the brake and accelerator.

I know, I know, this is not gonna happen. Wish it would. I'd rather spend my money on this sort of mod than than the equivalent amount on gas. Or a heck of a lot more on a different but more fuel efficient car.
 
intake, exhaust, light throttle pressure, drive slower, shift sooner, inflate tires higher = more mpg gains at less price.



Fun to think about though.
 
intake, exhaust, light throttle pressure, drive slower, shift sooner, inflate tires higher = more mpg gains at less price.

In stop and go traffic none of this makes very much of a difference. In that sort of driving there isn't much choice but to burn gas getting up to speed and then immediately dissipate it as heat when stopping again. A manual would help a bit (2-3 mpg) in that it wouldn't waste quite so much energy in the transmission. I keep the tires at 32-33 psi - more than that is going to trade off tire wear for mpg, and probably end up costing money with uneven tire wear more than offsetting the tiny increase in mpg.

Fun to think about though.

Yeah.

I'm thinking the electric motor could probably be braced to the brake caliper mounts, since the calipers have to be fixed in place well enough to handle the torque from the disks when the brakes are applied. So the electric motors working as brakes would be equivalent (or less) force. Unclear if the stock caliper mounts could handle the torque from the e-motors driving the car forward. That force is in the opposite direction from normal braking, and it would be equivalent to driving backwards very fast and then putting on the brakes. One would hope that the caliper mounts could handle that force, but they might have been designed to do so only very rarely, not once a minute.
 
i'd say it's probably not that hard to capture the energy wasted by brakes and store it in batteries. the difficult part would be making use of that power. maybe you could just store it and plug your house into it when you get home? like a solar panel? probably easier than developing a shared drive system
 
i'd say it's probably not that hard to capture the energy wasted by brakes and store it in batteries. the difficult part would be making use of that power. maybe you could just store it and plug your house into it when you get home? like a solar panel? probably easier than developing a shared drive system

That's an idea. Let's see how much energy that is. A protege5 weighs about 3000 pounds with a full tank and a driver, how much energy in the moving system at 35mph?

E = 1/2 * m * v^2.

m = 3000 lb = 3000/2.2 kig ~ 1400 kg
v = 35 mph ~ 60 kph ~ 17 m/s.
E = .5 *1400 * 17 *17 = 202300 joules.

(With lots of rounding errors.)

Electrical energy storage is usually given in Watt-hours, which is
1 joule/s * (60 * 60)s = 3600 joules. So at 100% efficiency, the energy stored when braking down from 35 mph in a P5 is

E per stop ~ 200,000 joules ~ 56 W-h.

20 stops each way, 40 per day, total energy stored would be about 2240 W-h.

The "off the shelf" electrical energy storage options are: Lithium ion batteries at 120 W-h/kg, Lead acid batteries at 30 W-h/kg, and Ultracapacitors at 5 W-h/kg (see for instance
http://www.maxwell.com/pdf/uc/datasheets/MC_Cell_Power_1009361_rev9.pdf
).

So in rough numbers it looks like one probably could store this much energy in 20 kg of lithium ion battery. However, charging and discharging those batteries all the way would wear them out pretty fast, since most are only rated for 300-500 full charge cycles. Very expensive to have to replace all those batteries every year. (This is why Toyota doesn't want people running the Prius in full electric mode - the large swings in charge state will kill the batteries.) Also the charge rate from regenerative braking is likely too high for any of the batteries to withstand directly, and so they would need 10 kg of ultracapacitors to absorb that burst of energy and then feed it slowly into the battery. The life cycle for most capacitors is rated at at least a million cycles (at 40 per day, that works out to 68 years).

Since a generator is pretty much a motor running backwards, it doesn't seem like it would be all that much more work to enable drive as well as energy storage. By reusing the stored energy as quickly as possible one could dispense with the batteries and just use the capacitors, which would have to be present even for the pure energy storage solution.
 
That's an idea. Let's see how much energy that is. A protege5 weighs about 3000 pounds with a full tank and a driver, how much energy in the moving system at 35mph?

E = 1/2 * m * v^2.

m = 3000 lb = 3000/2.2 kig ~ 1400 kg
v = 35 mph ~ 60 kph ~ 17 m/s.
E = .5 *1400 * 17 *17 = 202300 joules.

(With lots of rounding errors.)

Electrical energy storage is usually given in Watt-hours, which is
1 joule/s * (60 * 60)s = 3600 joules. So at 100% efficiency, the energy stored when braking down from 35 mph in a P5 is

E per stop ~ 200,000 joules ~ 56 W-h.

20 stops each way, 40 per day, total energy stored would be about 2240 W-h.

Doesn't electricity cost like 6 or 8 cents per kW-h? And I don't have any knowledge of the technology involved, but I would be really surprised if the efficiency is anywhere near 100%, so let's say it's 50%. That's 8 cents per day, or so. $30 per year. Hardly enough to be worth the trouble of doing the mod...

What you could that's easier and doesn't need power storage, is hook the generating brakes up to some neons and flashing lights on your car which light up when you brake. :D bling bling!
 
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reading this whole thread I couldn't help think... why make a hybrid, when you can buy one?

Cost of a new Prius: more than $20k.

Number of small front wheel drive cars in the US which could potentially be retrofitted in this manner: tens of millions.

Price of a retrofit people might buy (especially as gas keeps going up): $1000 - $2000.

Potential market for retrofits at that price: many tens of billions of dollars.
 
get an engine management unit and tune your car for fuel economy.

That might help a bit, but it doesn't do anything about the energy wasted by the "stop' in "stop and go" driving.

BMW has a system which puts the energy back into the battery (not a normal lead acid battery though) which lets the motor burn less gas turning the alternator. If you think about it a bit one could nearly eliminate the alternator and just let the regenerative brakes "drag" slightly to keep the battery charged. Except not quite, because if one had to sit idling for a long time in traffic the battery would die.

http://www.autoblog.com/2007/01/13/bmw-5-series-gets-regenerative-braking-but-not-why-you-think/

It isn't just for the BMW 5, they are putting this into the Mini too (where they claim 72.4 mpg for the Cooper D!):

http://www.gizmag.com/go/7365/

I wonder how efficient thermoelectric generators are? If all you wanted to do was to get rid of the alternator one could attach a thermoelectric generator to the side of the block, or better yet, the exhaust manifold. That would still "run" even when the car wasn't moving, which would eliminate the need for an alternator and its belt.
 
bmw is actually making a steam motor that will drop into the rear axle of almost any of its vehicles that runs off the heat wasted in the exhaust. adds 15-30% economy and can be installed at bmw dealers with warranty. not sure when its coming out.
 
If there was a car-free path between my home and my work I would consider it. Driving next to heavy traffic each day, the vast majority of it without even the nominal safety of a bike lane, is a sure way to get squashed (eventually).

So change your lifestyle. Move. Get a different job. Live elsewhere.

You're willing to spend time and money on a hybrid retrofit but fundamentally changing the way you live is a foregone conclusion.

Good luck.
 
Strip out the whole interior & shave evry ounce possible off the car & get ems & put a bike in back. There, covers it all. Or you could convert it over to burning french fry oil from fast food places.
 
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