An Integrated Approach to Regenerative Braking with Adaptive Brake Pad Wear Monitoring for Electric and Hybrid Vehicles

  • Unique Paper ID: 201260
  • Volume: 12
  • Issue: 12
  • PageNo: 3123-3129
  • Abstract:
  • Energy recovery during vehicle deceleration is central to extending the operating range of electric and hybrid powertrains. Regenerative braking achieves this by directing wheel torque through the traction motor, which operates as a generator, delivering electrical energy to the on-board battery. While the technology is well-established, a significant control gap exists: most deployed systems calibrate the torque distribution between regenerative and friction braking based on new-pad characteristics and do not adjust as pad material diminishes. This paper proposes a sensor-augmented architecture in which a MEMS Hall-effect Brake Pad Thickness Sensor (BPTS) continuously supplies pad-wear data to the braking controller, enabling real-time adjustment of the regenerative fraction. A three-regime torque-blending law is derived and its behaviour characterised analytically across the full pad service life. A supplementary wear-rate estimator generates remaining-life predictions that drive a graded maintenance alert system. Analysis shows that the proposed approach preserves roughly 20 percentage points more energy recovery at 75% pad wear relative to a conventional fixed-calibration system, and maintains a braking safety index above 0.93 throughout the pad lifecycle compared with a hazardous 0.65 when wear compensation is absent.

Copyright & License

Copyright © 2026 Authors retain the copyright of this article. This article is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

BibTeX

@article{201260,
        author = {Piyush Rajendra Mahajan},
        title = {An Integrated Approach to Regenerative Braking with Adaptive Brake Pad Wear Monitoring for Electric and Hybrid Vehicles},
        journal = {International Journal of Innovative Research in Technology},
        year = {2026},
        volume = {12},
        number = {12},
        pages = {3123-3129},
        issn = {2349-6002},
        url = {https://ijirt.org/article?manuscript=201260},
        abstract = {Energy recovery during vehicle deceleration is central to extending the operating range of electric and hybrid powertrains. Regenerative braking achieves this by directing wheel torque through the traction motor, which operates as a generator, delivering electrical energy to the on-board battery. While the technology is well-established, a significant control gap exists: most deployed systems calibrate the torque distribution between regenerative and friction braking based on new-pad characteristics and do not adjust as pad material diminishes. This paper proposes a sensor-augmented architecture in which a MEMS Hall-effect Brake Pad Thickness Sensor (BPTS) continuously supplies pad-wear data to the braking controller, enabling real-time adjustment of the regenerative fraction. A three-regime torque-blending law is derived and its behaviour characterised analytically across the full pad service life. A supplementary wear-rate estimator generates remaining-life predictions that drive a graded maintenance alert system. Analysis shows that the proposed approach preserves roughly 20 percentage points more energy recovery at 75% pad wear relative to a conventional fixed-calibration system, and maintains a braking safety index above 0.93 throughout the pad lifecycle compared with a hazardous 0.65 when wear compensation is absent.},
        keywords = {Regenerative braking, brake pad wear, Hall-effect sensor, blended braking control, torque split, electric vehicle, predictive maintenance, brake-by-wire.},
        month = {May},
        }

Cite This Article

Mahajan, P. R. (2026). An Integrated Approach to Regenerative Braking with Adaptive Brake Pad Wear Monitoring for Electric and Hybrid Vehicles. International Journal of Innovative Research in Technology (IJIRT), 12(12), 3123–3129.

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