Regenerative Braking for
Hybrid and Electric Vehicles
- KTP between Tata Motors
European Technical
Centre and the School of
Engineering, Design, &
Technology at the University
of Bradford.
The Company
“Bradford’s input on this project
exceeded expectations”
Dr. John Richmond, Chief Engineer
Project Objectives
The aim of the project was to enable TMETC to deliver a highly
proficient, integrated and optimised regenerative braking capability
for low carbon vehicles.
About the Case Study
This project was key for TMETC to develop its engineering
expertise in Full / Hybrid Electric Vehicles (FEV/HEV) in terms
of the design and development of combined conventional and
regenerative braking systems which meet users’ requirements
for personal transport, legislative requirements and TML’s inhouse standards for weight, cost, and durability. Additionally the
project aimed to introduce the structured Failure Mode Avoidance
methodology (researched and developed by the University of
Bradford) to the Company through a proven ‘case study’ of new
product introduction.
The Technology Strategy Board is a business - led organisation
established by the Government. Its mission is to accelerate
research into, and development and exploitation of, technology
and innovation for the benefit of UK business- building economic
growth and quality of life.
• To develop low carbon and affordable vehicles for
sale worldwide.
• To expand the technology capability of TMETC
and its knowledge base.
• Develop an efficient regenerative braking technology
and a productive design strategy through the use of
Failure Mode Avoidance.
The KTP also contributed directly to the delivery of TML’s
strategy for the next generation of FEVs and HEVs to be
produced by Tata Motors by supporting it in achieving
affordable low carbon vehicles in high volume. The battery cost
which represents a significant part of the cost of electric vehicles
can now be reduced in terms of the battery energy capacity
required to achieve the required range performance level.
Company Benefits
About the Sponsor
FAST FACTS:
The KTP has directly contributed to the expanding capability of
TMETC by developing key technological expertise in 2 areas,
viz. braking systems and new product introduction within a
Failure Mode Avoidance (FMA) framework. This has increased
the value of TMETC in serving the strategic needs of its parent
group TML through the delivery of a design methodology for
regenerative braking for low carbon vehicles (FEVs and HEVs)
based on analysis and prediction, which is presented within a
new product development process based on the Bradford FMA
framework.
• Acquired knowledge and capabilities in regenerative braking
and new product introduction process based on the FMA
framework.
• The expertise in road vehicle braking systems has been
incorporated into the Information database and the Technical
database that have been generated as key deliverables in
the project by the Associate. These are available to TML
employees worldwide and allow, for example, the braking
design and behaviour of any Tata vehicle worldwide, under
any operational or loading condition, to be analysed.
• Methods for predicting FEV power and energy requirements
which relate especially to battery capacity and energy
recuperation through regenerative braking have been added
to TMETC’s (and thus TML’s) standard procedures.
• The new product introduction process based on the Bradford
FMA framework has been integrated into TMETC procedures.
Business Partnerships, Research and Knowledge Transfer, University of Bradford
01274 236000
www.ktp.brad.ac.uk
The KTP programme offered me an unparallel level of experience
which covered all aspects of project management in an area of
technology which is rapidly expanding in demand in the market
for future vehicles. I would like to thank all that were involved in
the project from conception through to fruition, without whom
none of its success would not have been possible.
Associate Benefits
• The KTP Associate, Joseph Hartley, moved into a senior
Engineer post at TMETC with responsibility for brakes and
braking systems focussing on regenerative braking.
• Completed and achieved a Level 5 Diploma in Management
from the Chartered Management Institute. Joseph
developed substantial knowledge and expertise in road
vehicle braking and became TMETC’s expert on the theory
and science of braking, leading in regenerative braking.
• Awarded the prize for best technical presentation by TML.
This brought great kudos to TMETC, recognised by the
Company’s senior management.
“The KTP programme has proved to be a fantastic
graduate scheme to develop my career in the
Automotive Industry. Collaborating with the industrial
strength of TMETC and TML along with the
academic expertise of the University of Bradford’s
Engineering, Design and Technology School was an
invaluable experience for me. The support of both
partners and the Technology Strategy Board allowed
me to reach a level of engineering development
that would not have been possible from any other
graduate employment scheme.”
Joseph Hartley, KTP Associate
The Academic Partner
At the start of the KTP project, the Company had identified that
knowledge and expertise to support the design, optimisation
and development of regenerative braking systems was a key
strategic need. Joseph Hartley, the KTP Associate, acquired
advanced knowledge of existing braking system technology and
system architecture and has led not just TMETC but also TML
in understanding how well these might meet the requirements
for electric vehicles. The project demonstrated a high level of
technical advance in relating to the brake actuation system and
the integration of advanced control systems for mixed-mode
braking. It showed how a combination of conventional (friction)
braking and regenerative braking could be optimised so that
range is maximised and the driver’s impression of the brakes on
a vehicle fitted with regenerative braking is exactly the same as
for a conventional powertrain vehicle.
Work on the Tata Ace EV also provided a proven ‘case study’
of new product introduction using the structured ‘Failure Mode
Avoidance’ methodology developed at the University of Bradford.
The Associate
Regenerative braking is an exciting technology in the current
development of prototype and production vehicles. Effective
implementation of such a system enables kinetic energy which
is normally wasted through friction braking to be recovered
and reused to accelerate the vehicle, increasing the capacity
of whatever storage system is used to supply energy to the
traction motor. The ability to harness this energy efficiently is
dependent on the control strategy of the braking system as well
as the motor controller, which must work in harmony to provide
the driver with a cohesive driving experience and the expected
level of performance in terms of traction and braking. Developing
the skills to implement a regenerative braking system on real
vehicles meant that the whole project served as a learning curve,
since much of the work had not been done before, especially
within the Tata group of companies.
The University of Bradford provided excellent facilities to allow
rolling-road testing to be conducted to enhance TMETC’s
knowledge of the performance of the ‘Ace’ fully electric vehicle
on standard European drive cycles. The learning gained from this
work was then used to develop a specific drive cycle aimed at
replicating the expected usage of electric vehicles in their current
format, which was disseminated within TMETC to serve as a
benchmark for vehicle usage and the envelope of performance
within which FEVs can be utilised.
“Overall this was a most enjoyable project to work
on. I was able to apply my knowledge and expertise
to the work of a cutting-edge automotive technology
company working across continents, and participate
in real-life systems design and engineering.”
Professor Andrew Day, School of Engineering,
Design and Technology, University of Bradford.
Academic Benefits
• 4 final year undergraduate projects, 3 MSc projects, 1 PhD
project supported through the KTP project by TMETC.
• Tata Ace electric vehicle donated to the University.
• 3 conference publications;
• ‘Outstanding’ grading from the KTP directorate;
• Continuing research collaboration.
Business Partnerships, Research and Knowledge Transfer, University of Bradford
01274 236000
www.ktp.brad.ac.uk