DC regen braking

[serialk11r]

Originally Posted by oil pan 4

GM tired this already and it was garbage.
Bolting a motor onto the engine to drive the crank lowered MPG on the cars they put it on.

Uh that's not true...

Between engine and transmission is best, but that's extremely hard to DIY.

Anyways, OP, since you have a 4500rpm limit diesel that gives you way more motor choices, and as you say you might want more torque for starting. Maybe a 5kW Golden Motor? For brushed, I'm having trouble finding it again but there was a Etek or something that seems to be pretty suitable.

I'm 100% sure Kelly makes regen capable BLDC controllers. Some guy even used one with an ultracapacitor pack and it did fine. If it can handle a "battery" voltage that's 40% lower than what it started with just fine, I would feel pretty confident about the converter in it.

I don't think hobby aircraft motors would be any worse for regen, good magnetic circuit, thin laminations for low eddy current losses, and high copper fill are all good for generating electricity as well. That said, you're not using a gas engine with a higher rev limit so the high speeds they can turn at are kind of overkill.