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April 17, 20260 citationsOpen Access

Axo Charge: A Regenerative Energy System for Commercial Electric Vehicles Using Differential Axle Bevel Gear Mechanism

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MKMahilesh kumar.S

Key Points

  • The aim is to develop a system that continuously converts mechanical energy to electrical energy in commercial electric vehicles to enhance their range.
  • Designed a regenerative energy system utilizing a bevel gear mechanism and a permanent magnet synchronous generator.
  • Analyzed system components including materials, gear specifications, and efficiency metrics.
  • Evaluated the performance of the Axo Charge system through efficiency calculations.
  • The system achieved a total efficiency of 90.25%.
  • It provides a range extension of approximately 3.8 km for each hour of operation.

Abstract

The Axo Charge system is an innovative regenerative energy solution designed to enhance the range of commercial electric vehicles (EVs) by converting mechanical energy from the differential axle into electrical energy for battery charging. Unlike regenerative braking, Axo Charge operates continuously during vehicle motion, utilizing a bevel gear mechanism coupled with a Permanent Magnet Synchronous Generator (PMSG) mounted on the backside of the differential unit. The system achieves a total efficiency of 90.25% and provides a range extension of approximately 3.8 km per hour of operation. This paper presents a comprehensive analysis of the system's design, material selection, gear specifications, and efficiency calculations

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Cite This Study

Mahilesh kumar.S (2026) studied this question.

synapsesocial.com/papers/69e1d0165cdc762e9d859300https://doi.org/10.5281/zenodo.19588781
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