Design, Simulation, and Experimental Validation of a Balanced Adaptive Electromagnetic Suspension for Kinetic Energy Harvesting

Abstract

This paper presents a comprehensive study on the design, simulation, and experimental validation of a novel electromagnetic regenerative suspension system. Conventional vehicular suspensions, while crucial for ride comfort and handling, dissipate a substantial amount of kinetic energy as waste heat, often amounting to 10-16% of total fuel energy in urban driving conditions. This study addresses this inefficiency by proposing a semi-active linear electromagnetic suspension system capable of converting vertical vibrational energy into usable electrical power. The core innovation lies in a \"Balanced Adaptive\" control strategy, which is designed to navigate the fundamental trade-off between maximizing energy harvesting and maintaining acceptable ride comfort. A detailed two-degree-of-freedom quarter-vehicle model was developed and simulated to evaluate the system\'s performance against conventional passive and aggressive adaptive systems. Simulation results demonstrate that the Balanced Adaptive system achieves a 92.6% increase in harvested energy over a passive system while limiting the negative impact on ride comfort to a manageable 13.8% increase in root-mean-square (RMS) acceleration. To validate the physical feasibility of the proposed architecture, a lab-scale prototype was constructed and subjected to a series of tests under varying conditions. Experimental data confirms the system\'s ability to generate meaningful power, with outputs reaching up to 0.98 mW under high-mass and high-frequency excitation. This dual-method approach, combining a robust simulation with empirical prototype validation, represents a significant step forward in developing practical and commercially viable kinetic energy harvesting solutions for modern vehicles.

Introduction

As the automotive industry shifts toward sustainable energy solutions, a key overlooked area is the energy loss in suspension systems. Traditional hydraulic shock absorbers convert road-induced kinetic energy into waste heat. A typical mid-sized vehicle can lose 100–400 W per wheel, representing a significant untapped energy source, especially in urban conditions.

2. Research Gap and Objectives

While various KEH methods—electromagnetic, piezoelectric, and hydraulic—have been explored, they all face a trade-off between energy harvesting and ride comfort:

• Electromagnetic: High output, scalable, but heavy and prone to wear.

• Piezoelectric: Compact, low power, suitable for small sensors.

• Hydraulic: Good for heavy vehicles, but complex and inefficient at low amplitudes.

Key challenges:

• Balancing energy recovery with passenger comfort.

• Lack of integrated studies combining simulation and prototyping.

Study Objectives:

1. Design and model a linear electromagnetic suspension for energy harvesting.

2. Develop a novel "Balanced Adaptive" control strategy to optimize the energy-comfort trade-off.

3. Build and test a physical prototype to validate the system’s energy generation potential.

4. Compare simulation and experimental data to validate the model and performance.

3. Novel Contribution

This study's unique approach lies in integrating theoretical modeling and physical prototyping, addressing the energy-comfort trade-off with a "Balanced Adaptive" control algorithm. It:

• Demonstrates feasibility in simulation and lab tests.

• Bridges the gap between academic concepts and real-world application.

• Lays the groundwork for commercial KEH suspension systems.

4. Literature Review Highlights

A. Transduction Mechanisms:

• Electromagnetic (EMEH): Converts motion to electricity using magnets and coils. Good for powering subsystems (10–150 W), but complex and prone to wear.

• Piezoelectric (PEH): Uses material deformation to generate electricity. Compact but limited to micro-power applications.

• Hydraulic: Converts motion to fluid pressure to drive generators. Effective in heavy vehicles but inefficient for smaller systems.

B. Suspension Architectures for KEH Integration:

1. Passive: Fixed damping; simple to integrate KEH.

2. Semi-active: Uses smart dampers; KEH can power its control systems.

3. Active: Fully powered actuators; some energy can be recovered, though these systems are power-intensive.

C. Research Comparison:

• Past work often focused on either simulation or experimentation—not both.

• Control strategies were generally simplistic (e.g., on-off methods).

• This study proposes a comprehensive solution, combining a new control algorithm, simulation, and physical testing to offer deeper insights into KEH viability.

Conclusion

This research has introduced a complete design, simulation, and experimental validation of an electromagnetic regenerative suspension system. Through the implementation of the “Balanced Adaptive” control strategy, the research addresses the well-known energy–comfort trade-off that has historically limited the adoption of KEH in automotive systems. Simulation results confirmed the effectiveness of the proposed control law, achieving a 92.6% improvement in harvested energy with only a 13.8% reduction in ride comfort, while prototype testing further validated the practicality and feasibility of the linear electromagnetic generator [45]. The dual-method framework, combining high-fidelity simulation with empirical experimentation, establishes a credible foundation for continued advancements in this technology. The demonstrated balance between efficiency and ride quality highlights the potential for regenerative suspensions to evolve from laboratory concepts into deployable automotive solutions. In the long term, the integration of such systems into production vehicles could contribute meaningfully to global energy efficiency initiatives and support the transition toward sustainable, intelligent, and self-powered mobility platforms [46,47].

References

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Copyright

Copyright © 2025 Gandhar S. Purandare, Vaibhav Shah, Shashikant Kawale, Tejas Sahare, Vinod Bodhale. This 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.