INTEGRATED KINETIC ENERGY RECOVERY AND ADAPTIVE DIFFERENTIAL LOCKING FOR ENHANCED EFFICIENCY IN ELECTRIC VEHICLES

Abstract

The growing demand for sustainable transportation has intensified the need for electric vehicles (EVs) with highly efficient drivetrains that ensure optimal torque management and energy recovery. This study introduces an Integrated Kinetic Energy Recovery and Adaptive Differential Locking Mechanism designed to enhance mechanical efficiency and torque distribution while reducing drivetrain energy losses. The system integrates a semi-automatic differential locking assembly with a kinetic energy recovery configuration to achieve stable torque transfer without relying on complex electronic control. Analytical modelling was performed to establish the relationships among torque, stress, and deformation in the locking components, followed by finite-element analysis (FEA) using ANSYS Workbench 14.5 to validate mechanical integrity under a torque load of 1.19 × 10³ N.mm. Experimental testing under variable loading conditions was conducted to evaluate torque, speed, power, and overall efficiency. Results revealed minimal structural deformation (< 0.005 mm) and maximum stresses well below material limits, confirming the robustness of the design. The experimental data indicated a significant increase in mechanical efficiency from 45.2 % at light load to 90.4 % at 3 kg, closely matching analytical predictions. The findings demonstrate that the proposed mechanism provides a cost-effective and energy-efficient alternative to electronically controlled differentials, offering strong potential for integration into small- and mid-scale electric vehicle architectures.