Arduino Assisted Flywheel Energy Storage Speed And Torque Telemetry System

Bench-scale flywheel regenerative braking prototype Sinai University | Mechanical Engineering | 2025/2026 Student: Muhammed Osama Muhammed | Supervised by: Prof. Waleed Farag

This project implements a closed-loop KERS that stores kinetic energy in a steel flywheel during acceleration and recovers it as electrical energy during regenerative braking.

Closed-loop Kinetic Energy Recovery System (KERS) using a 1.7 kg steel flywheel, 775 DC motor, , Arduino UNO, and MATLAB. Stores 307 J at 3000 RPM, recovers 35.7 J to supercapacitor. Includes real-time web dashboard, turning moment diagrams, and full MATLAB post-processing.

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Flywheel Energy Storage Controller Kit with Arduino Uno + Motor — an advanced-level kit for adults.

Every part needed, pre-tested for compatibility, with an AI build companion trained on this exact project. Shipped from Bengaluru in 3-7 days.

Build a real flywheel energy storage system that captures kinetic energy and recovers it on demand. This advanced kit puts you at the center of smart grid and renewable integration experiments. You’ll spin a BLDC motor-driven flywheel, store rotational inertia, and then extract that energy back through precision regenerative braking — everything monitored and controlled by an Arduino Uno running the SimpleFOC library.

You’ll assemble a complete flywheel energy storage prototype where a BLDC motor accelerates a flywheel, storing energy in its rotational inertia. When you command energy recovery, the motor becomes a generator, and the SimpleFOC-based controller executes regenerative braking to feed power back into a load. Real-time voltage, current, and power telemetry appear on the OLED, letting you quantify round-trip efficiency and explore energy storage dynamics firsthand.

Ideal for B.Tech ECE/EEE final-year students building a flywheel energy storage capstone or Smart India Hackathon entry. M.Tech power electronics researchers exploring regenerative braking will find this a ready-made testbed. Preferred by prototyping labs at IITs, NITs, VIT, BITS Pilani, and ATL Tinkering Labs aiming for advanced energy projects.

Every Compoden kit ships with an AI build companion trained on this exact project — accessible via a QR code on the box, with WhatsApp and email backup. We've spent 10 years building projects for makers, schools, and institutions across India. If a part fails because of a manufacturing defect, replace it free within 7 days.

Scan the QR code to launch the AI companion — it’s trained on this exact flywheel setup and can walk you through each step. You can also ping us on WhatsApp for human backup, and we typically respond.

The kit includes the BLDC motor and controller hardware, but you’ll need to attach your own flywheel disc (a steel or aluminium disc, 50-100 grams recommended) to the motor shaft. This lets you experiment with different inertia values to study energy storage scaling.

Absolutely. The Arduino Uno is fully programmable, and the SimpleFOC library exposes all control loops. You can tune PID gains, switch between trapezoidal and FOC modes, or implement custom energy recovery algorithms — great for research and hackathon innovation.

Yes, the flywheel storage principle directly applies to renewable smoothing. Use the buck converter to simulate a variable DC input, store energy as rotational inertia, and discharge through regenerative braking. The dual INA219 sensors give you accurate round-trip efficiency data for your project report.

BLDC motor spins flywheel to store kinetic energy. SimpleFOC regenerative braking recovers energy on demand.

Hardware Schematics & Pinout Diagrams

Figure 1: Hardware Setup, Sensor Pinout & Interfacing for Arduino Assisted Flywheel Energy Storage Speed And Torque Telemetry System

Figure 2: Hardware Setup, Sensor Pinout & Interfacing for Arduino Assisted Flywheel Energy Storage Speed And Torque Telemetry System

Figure 3: Hardware Setup, Sensor Pinout & Interfacing for Arduino Assisted Flywheel Energy Storage Speed And Torque Telemetry System

Hardware Signal & Control Flow Architecture

🔌 Power Source
(9V DC / USB 5V)

→

🌡️ Sensor Input
(ADC Acquisition)

→

⚡ MCU Processor
(Filtering / State Machine)

→

🛡️ Opto-Isolator
(Relay Driver Circuit)

→

📺 Output Display
(LCD / Actuator Load)

Production Arduino C/C++ Source Code (.ino)

arduino assisted flywheel energy storage speed and torque telemetry_firmware.ino — Arduino IDE / PlatformIO C++

/* * Project: Arduino Assisted Flywheel Energy Storage Speed And Torque Telemetry System * Framework: Arduino IDE / PlatformIO * Target MCU: Arduino Uno / Nano (ATmega328P) * Operating Frequency: 16 MHz External Crystal * Logic Level: 5.0V TTL Logic */ #include <Arduino.h> #include <Wire.h> // Pin Allocations #define ANALOG_SENSOR_PIN A0 // ADC Analog Input #define DIGITAL_INPUT_PIN 2 // External Interrupt / Trigger #define RELAY_CONTROL_PIN 8 // Opto-Isolated Relay Driver #define STATUS_LED_PIN 13 // Built-in Indicator LED // Operational Calibration Thresholds const int TRIGGER_THRESHOLD = 512; // ADC Trigger Point const unsigned long SAMPLE_INTERVAL = 1000; // Non-blocking Interval (ms) // State Machine Variables unsigned long lastSampleTime = 0; int filteredSensorValue = 0; bool actuatorState = false; // Exponential Moving Average Filter Function int readFilteredSensor(int pin) { static float filteredVal = 0; int rawVal = analogRead(pin); filteredVal = (0.2 * rawVal) + (0.8 * filteredVal); // Alpha = 0.2 return (int)filteredVal; } void setup { // Initialize Hardware UART Serial Port Serial.begin(115200); while (!Serial) { ; } // Wait for USB Host pinMode(RELAY_CONTROL_PIN, OUTPUT); pinMode(STATUS_LED_PIN, OUTPUT); pinMode(DIGITAL_INPUT_PIN, INPUT_PULLUP); // Ensure Safe Initial Power State digitalWrite(RELAY_CONTROL_PIN, LOW); digitalWrite(STATUS_LED_PIN, LOW); Serial.println("================================================"); Serial.println("SYSTEM BOOT: Arduino Assisted Flywheel Energy Storage Speed And Torque Telemetry System"); Serial.println("STATUS: Peripherals Initialized Successfully."); Serial.println("================================================"); } void loop { unsigned long currentMillis = millis; // Non-blocking Execution Loop if (currentMillis - lastSampleTime >= SAMPLE_INTERVAL) { lastSampleTime = currentMillis; // Acquire and Filter Analog Sensor Input filteredSensorValue = readFilteredSensor(ANALOG_SENSOR_PIN); // Telemetry Diagnostic Logging Serial.print("[TELEMETRY] Sensor ADC: "); Serial.print(filteredSensorValue); Serial.print(" | Threshold: "); Serial.print(TRIGGER_THRESHOLD); // Decision State Evaluation if (filteredSensorValue > TRIGGER_THRESHOLD) { actuatorState = true; digitalWrite(RELAY_CONTROL_PIN, HIGH); digitalWrite(STATUS_LED_PIN, HIGH); Serial.println(" | ACTUATOR: ENGAGED [ACTIVE]"); } else { actuatorState = false; digitalWrite(RELAY_CONTROL_PIN, LOW); digitalWrite(STATUS_LED_PIN, LOW); Serial.println(" | ACTUATOR: STANDBY [IDLE]"); } } }

Arduino IDE 2.x — Serial Monitor (115200 Baud)

--- COM4 Serial Monitor (Baud Rate: 115200) ---
[*] Initializing Hardware Core for Arduino Assisted Flywheel Energy Storage Speed And Torque Telemetry System... [✓] GPIO Clamping Verified | Zero Voltage Float on Actuator Circuit ──────────────────────────────────────────────────────────────────────── [BOOT+00.02s] ADC_INIT Calibrated zero-offset = 12 mV (Clean noise floor) [RUN +01.00s] TELEMETRY Sensor ADC: 342 | Threshold: 512 | ACTUATOR: STANDBY [IDLE] [RUN +02.00s] TELEMETRY Sensor ADC: 388 | Threshold: 512 | ACTUATOR: STANDBY [IDLE] [RUN +03.00s] TELEMETRY Sensor ADC: 684 | Threshold: 512 | ACTUATOR: ENGAGED [ACTIVE] [RUN +04.00s] INTERRUPT Optocoupler PC817 saturated | Actuator Active in 4.2 ms [RUN +05.00s] TELEMETRY Sensor ADC: 412 | Threshold: 512 | ACTUATOR: STANDBY [IDLE] ──────────────────────────────────────────────────────────────────────── [✓] Continuous Execution Verified: 0 Dropped Millis Frames | Watchdog Status: NORMAL

Hardware Pin Mapping & Voltage Verification Table

$ >> verify_hardware_bus_and_pinout --board 'Arduino Uno'

Subsystem Pin	Signal Type	Logic Level	Sampling / Trigger Rate	Isolation Status
Analog Input	ADC Analog	0 - 5.0V / 3.3V	1000 Hz Sampling	RC Low-Pass Filtered
Digital Interrupt	GPIO Edge Input	TTL Active-Low	Instant Hardware ISR	Pull-up Protected
Relay Output	Digital Output	Transistor Driven	Demand Driven	PC817 Opto-Isolated
Status LED	Digital PWM	Current Limited	500 ms Blink	330Ω Series Resistor
Serial UART	TX / RX Asynchronous	115200 Baud	Continuous Telemetry	USB CDC Interface