Ev Regenerative Braking Prototype

An educational desktop EV regenerative braking prototype controlled by an ESP32 DevKit V1 with power and RPM telemetry over USB.

Design Overview

Item	Details
Product Type	Ev Regenerative Braking Prototype
Key Functions	Monitor system voltage, current, and power via INA219 sensor, Measure motor and axle RPM using A3144 Hall-effect sensor and neodymium magnets, Drive two 12V 200 RPM geared DC motors with regenerative capability, Provide wired USB telemetry and monitoring through ESP32 DevKit V1
Power Source	Two 3.7V Li-ion batteries
Connectivity	USB
Size	Compact stacked PCB shield format mounted on the chassis
Environment	indoor
Difficulty	Intermediate
Est. Time	3-5 hours

System Architecture

Power Topology: USB-C 5V → MCU 3.3V LDO

Module List

Module ID	Type	Name	Function	Voltage
POWER	POWER	USB-C Power Jack	Power input	5V
MCU	MCU	ESP32-WROOM-32	Main controller	3.3V

Design Schemes

Ev Regenerative Braking Prototype ★

Key IC selection

main MCU

• Need: Wi-Fi/BLE enabled dual-core processor with ample ADC and hardware pulse counter peripherals for telemetry and sensor logging
• Class: 32-bit Wi-Fi/Bluetooth SoC module
• Shortlist: ESP32-WROOM-32, ESP32-S3-WROOM-1
• Pick: Select ESP32-WROOM-32 for established DevKit ecosystem and sufficient peripheral count for dual Hall sensors and I2C telemetry.

Current/Power Monitor

• Need: High-side current and bus voltage monitoring with I2C interface for real-time regenerative braking power calculation
• Class: I2C digital power monitor IC
• Shortlist: INA219, INA226
• Pick: Select INA219 for integrated 12-bit ADC, onboard calibration registers, and direct support for bidirectional current sensing.

Motor Driver with Regneration Support

• Need: Dual-channel H-bridge driver rated for 12V DC motors supporting PWM speed control and regenerative braking energy dumping
• Class: High-current dual H-bridge DC motor driver
• Shortlist: BTS7960, L298N, MC33926
• Pick: Select MC33926 or BTS7960 based on continuous current requirements and built-in current feedback for safe regen transient handling.

Risk register

ID	Area	Severity	Detail	Mitigation
r1	power	high	Regenerative braking events can cause sudden voltage spikes (inductive kickback) on the 12V bus, potentially exceeding the absolute maximum ratings of the ESP32 and INA219.	Add TVS diodes, a robust bulk capacitor bank, and a zener clamp / brake chopper circuit on the 12V power rail to absorb regenerated energy safely.
r2	emi	med	PWM switching of the dual 12V geared motors close to the A3144 Hall-effect sensors and ESP32 wiring can induce noise, causing false RPM trigger counts.	Use shielded twisted-pair wiring for Hall sensors, add RC low-pass filtering on digital input lines, and ensure proper star-grounding topology.

Key Components

2/2 modules matched to real parts. See the BOM tab for the full component table.

USB-C Power Jack (KH-TYPE-C-16P)

The candidate matches the primary MPN (KH-TYPE-C-16P) and manufacturer (Kinghelm) for the requested USB-C Power Jack.

ESP32-WROOM-32 (ESP32-WROOM-32)

Candidate 1 (ESP32-WROOM-32D) is a direct variant and valid ordering code from Espressif Systems matching the primary MP

Build Summary

• Difficulty: Intermediate
• Estimated time: 3-5 hours
• Tools required: Soldering Iron, Solder Wire, Wire Strippers, Multimeter, Antistatic Mat, USB-C Cable

See the Build tab for the full step-by-step assembly guide.

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Generated by YuanQi AI Design System · Query: EV regenerative car system using ESP32 DevKit V1 as main controller, INA219 current/voltage sensor for power measurement, A3144 Hall-effect sensor with two neodymium magnets for motor/axle RPM measurement, two 12V 200 RPM geared DC motors as drive motors, and two 3.7V Li-ion batteries as power source.