Design and Construction of a Kinetic Energy Recovery System Using Flywheel in Bicycle

Abstract

This project presents the design and construction of a Kinetic Energy Recovery System (KERS) integrated into a bicycle, utilizing a flywheel to enhance cycling efficiency. The system captures kinetic energy during pedaling or braking and releases it to assist with acceleration or uphill riding, reducing rider effort. A 3.27 kg cast iron flywheel (radius 0.075 m, moment of inertia 0.00919 kg/m²) was mounted on a bicycle frame, connected via a pulley and chain drive system. Testing on flat terrain with a 70 kg rider over 60 seconds showed the flywheel achieving 95–114 RPM at bicycle speeds of 10–12 km/h, storing 0.454–0.654 J of kinetic energy. The system improved energy efficiency and ride smoothness but added weight, impacting handling. Key advantages include reduced pedaling effort and momentum maintenance, while limitations involve increased complexity and reduced effectiveness on steep inclines. Applications include urban commuting and recreational cycling, with future enhancements proposed using lighter materials and gear integration for improved performance.