Analysis and Enhancement of Electric Vehicle Range and Battery Life using Regenerative Braking

This paper presents the design and hardware implementation of a Regenerative Braking System (RBS) for an Electric Vehicle (EV), with a specific focus on a hybrid E-bike retrofit application. Unlike purely theoretical models, this study details the integration of a 60V,1200W,25A brushless DC (BLDC) hub motor, a Regenerative Braking controller, and a lithium-ion battery of 60V,28Ah with battery management system (BMS) onto an existing Internal Combustion (I.C.) engine motorcycle chassis. The hardware architecture utilizes a dedicated regenerative controller to manage the transition between mechanical friction braking and electromagnetic regenerative braking. By implementing a sensor-based feedback loop, the system monitors real-time parameters such as battery voltage rating, charging current and regenerative current while decelerating. Experimental results obtained from road tests demonstrate the system’s ability to reclaim kinetic energy and improve overall battery range under various load conditions and terrain gradients. This work provides a practical framework for developing affordable, sustainable transport solutions through the electrification of legacy vehicular platforms.