Design and Development of a Kinetic Energy Recovery System (KERS) Using a Flywheel in Bicycles

This project report details the comprehensive design, development, and validation of a Kinetic Energy Recovery System (KERS) specifically engineered for integration into a bicycle, with the overarching goal of advancing sustainable and energy-efficient modes of personal transportation. Recognizing the substantial kinetic energy typically dissipated as heat during braking, this project sought to capture and repurpose this energy through a mechanical storage system centred on a flywheel mechanism. The captured energy is stored by accelerating the flywheel to high rotational speeds during deceleration phases and then released to assist the cyclist during subsequent acceleration or when climbing inclines, thereby reducing the overall physical effort required from the rider.

The design phase involved meticulous selection and optimization of the flywheel’s mass, geometry, and material properties to achieve a balance between maximizing energy storage capacity and maintaining compatibility with the bicycle’s structural and ergonomic constraints. Considerations for rider safety, comfort, and ease of integration were paramount, ensuring that the added system did not adversely impact the bicycle’s handling or rider experience. The mechanical linkage and energy transfer mechanisms were engineered to facilitate efficient energy capture and release without significant losses or delays.

A series of experimental tests and field trials were conducted to evaluate the system's real-world performance. These tests measured parameters such as energy recovery efficiency, impact on rider fatigue, and overall contribution to cycling performance, particularly on varied terrain including flat surfaces and uphill grades. Data collected demonstrated that the flywheel-based KERS not only effectively stored and reused energy but also provided tangible benefits in reducing the rider’s exertion levels, highlighting its practical utility in enhancing human-powered transport.

The successful prototype serves as a proof of concept for mechanical energy storage as a viable solution in bicycle applications, illustrating significant potential to improve the energy efficiency and sustainability of personal mobility options. By enabling riders to reclaim and reuse energy that would otherwise be lost, this system contributes to reducing physical strain and promoting longer, more efficient cycling journeys. The findings from this project pave the way for further research and development in integrating kinetic energy recovery technologies into a broader range of human-powered and hybrid transportation systems, supporting global efforts toward cleaner, greener mobility solutions.