Advanced regenerative braking system for EVs: Leveraging BLDC‑supercapacitor technologies for optimized energy recovery, economic viability, and maintenance strategies

Abstract

Electric vehicles (EVs) offer a pathway to a cleaner and quieter future; however, a considerable portion of their braking energy is still dissipated as heat rather than being recuperated. To address this inefficiency, the present study proposes an advanced regenerative braking architecture that integrates high-power supercapacitors with precision-controlled Brushless DC (BLDC) motors. Employing adaptive control algorithms, the system captures up to 92.5 % of kinetic energy during deceleration, directing it first to supercapacitors for rapid storage, then gradually to the primary battery. This dual-stage energy strategy reduces thermal losses, extends battery lifespan, and ensures fast, reliable braking response. The adaptability of the proposed system is validated under various real-world conditions, including urban traffic, highway speeds, and steep inclines. Statistical validation through confidence intervals and error bars reinforces the reliability of the results. A cost-benefit analysis confirms commercial feasibility, highlighting savings in energy consumption, brake wear, and battery replacement within standard service intervals. Additionally, robust safety and maintenance strategies are outlined to ensure operational safety and long-term reliability. By converting wasted kinetic energy into a practical resource, this work lays the foundation for smarter, safer, and more sustainable electric mobility, accelerating the shift toward a truly carbon-neutral transportation future.