Design and Retrofit of Regenerative Braking System for Electric Two-Wheelers

Objective: To develop and integrate a cost-effective regenerative braking retrofit kit for existing electric two-wheelers to improve energy efficiency and range.

Electric two-wheelers are rapidly growing in popularity in India, particularly for urban mobility, but their limited range and energy efficiency remain concerns for both individual users and fleet operators. Most low- and mid-range models lack advanced regenerative braking, leading to wasted kinetic energy during frequent stop-and-go traffic situations.

This project proposes the engineering and implementation of a modular regenerative braking system that can be retrofitted onto commercially available electric scooters and motorcycles. The approach includes designing a compatible power electronics interface, integrating with existing BLDC hub motors, and developing a microcontroller-based control strategy for energy recovery during braking events.

Key deliverables include a working prototype retrofit kit (including power electronics, sensors, and embedded controller), installation on a popular Indian electric two-wheeler model (e.g., Hero Electric Optima), bench and limited road testing, and a demonstrable increase in battery SOC after regenerative events. The system will feature CAN/LIN communication compatibility, safety interlocks, and user feedback via an LCD/phone dashboard.

Scalability lies in deploying this retrofit kit across the rapidly expanding electric two-wheeler market, reducing operational costs for users, extending vehicle range, and contributing to India's EV adoption and sustainability goals.