Mini Project Report on

(Power Generating Suspension System)

Submitted by

Shahbaz Chowdhury (20130051)

Rachit Chaudhary(20130735)
Utsav kumar(20130722)

In partial fulfillment of the requirement

for the 7th semester of the degree of

Bachelor of Technology
in
Mechanical Engineering

(2016)

Under the Supervision of

Dr. A.P Tiwary

Associate Professor

Mr. Santanu Chakraborty

Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING

SIKKIM MANIPAL INSTITUTE OF TECHNOLOGY

MAJHITAR, RANGPO, EAST SIKKIM-737132

 CERTIFICATE

This is to certify that the thesis titled Power Generating Suspension is a bonafide record of the

authentic work carried out by Shahbaz Chowdhury, Rachit Chaudhary and Utsav Kumar

bearing Registration No 20130051, 20130735 and 20130722 respectively under the supervision

and guidance of Dr. A.P Tiwary(Associate Professor) and Mr. Santanu Chakraborty(Assistant

Professor) in 2016 and is submitted in partial fulfillment of the requirement for the 7 th semester of

the degree of Bachelor of Technology in Mechanical Engineering during the academic year

2013-2017 under Mechanical Engineering Department, Sikkim Manipal Institute of Technology.

Project Supervisor Prof. (Dr.) B.B.Pradhan

Dr A.P Tiwari H.O.D.
Associate Professor Mechanical Engineering Department
SMIT
Mr. Santanu Chakraborty
Assistant Professor

(External Examiner)

(i)
 ACKNOWLEDGEMENT

I sincerely take this opportunity to express my thanks and deep gratitude to all who extended their
whole hearted cooperation, opinion and gracious hospitality to me in completing this work.

I am grateful to Dr. A.P Tiwary, Associate Professor and Mr. Santanu Chakraborty, Assistant
Professor Mechanical Engineering Department for their inspiration for taking up this project and
guidance throughout my project work. I am thankful to him/her for spending their valuable time
and effort to let this project to become qualitative.

I am exceptionally grateful to Prof. (Dr.) B.B.Pradhan, Head of Department, Mechanical

Engineering, Sikkim Manipal Institute of Technology for his constant support and fortitude.

I own my greatest debt to Col. (Dr.) A. Garg, Director, Sikkim Manipal Institute of Technology for
their kind co-operation to complete the project works.

Thank to my friend Pradumn Kumar for his great support in this project

And, lastly to my family for supporting my endeavours.

Place: Majhitar Shahbaz Chowdhury(20130051)

Date: 8.12.16 Rachit Chaudhary(20130735)
Utsav Kumar(20130722)

(ii)

ABSTRACT
In the past decade, regenerative braking systems have become increasingly Popular, recovering
energy that would otherwise be lost through braking. However, another energy recovery
mechanism that is still in the research stages is regenerative suspension systems. This
technology has the ability to continuously recover a vehicle's vibration energy dissipation that
occurs due to road irregularities, vehicle acceleration, and braking, and use the energy to
reduce fuel consumption.
A regenerative shock absorber is a type of shock absorber that converts parasitic intermittent
linear motion and vibration into useful energy, such as electricity. Conventional shock
absorbers simply dissipate this energy as heat. When used in an electric vehicle or hybrid
electric vehicle the electricity generated by the shock absorber can be diverted to its powertrain
to increase battery life. In non-electric vehicles the electricity can be used to power accessories
such as air conditioning. Several different systems have been developed recently, though they
are still in stages of development and not installed on production vehicles.
This could be used on electric or hybrid vehicles (or normal vehicles) to capture energy which
would otherwise be absorbed and wasted, and then convert it into electricity. The regenerative
shock absorbers can harvest the power in a continuous way. On the smooth highway road, the
regenerative shock absorbers can improve the fuel efficiency by 2%, and on bumpy roads up to
10% increase can be expected.

(iii)

LIST OF FIGURE
Figure Number Title Page Number
1 Conventional Shock Absorber 04
2 Application of Shock Absorbers 06
3 Schematic Diagram of Power Generating Shock Absorver 07
4 Power Generating Suspension 07
5 Volatage(y) vs. time(x) Graph at xo=0.06m and vo=3.5m/sec 10
6 Displacement vs Time (Blue) and Velocity vs Time (Green) 13
Graph at xo=0.03m
7 Displacement vs Time (Blue) and Velocity vs Time (Green) 13
Graph at xo=0.03m and vo=5.7m/sec
8 Displacement vs Time (Blue) and Velocity vs Time (Green) 14
Graph at xo=0.041m and vo=5.7m/sec
9 Displacement vs Time (Blue) and Velocity vs Time (Green) 14
Graph at vo=0.5m/sec

(iv)

LIST OF TABLE
Table number Title Page number

1. Potential Energy that can be harvested 08

(v)
NOMENCLATURE
 Symbols used Description of the symbols used

permeability of free space

mpm magnetic charge

D distance between magnet and coil at free state

B magnetic field strength

A area through magnetic field is paasing

B magnetic field strength

N number of turns in coil

V voltage developed in coil

PEM electromagnetic power

FEM electromagnetic damping force

cd damping coefficient of damper

cEM electromagnetic damping coefficient

R electrical resistance of coil wire

r radius of coil

K spring constant of the spring

m mass of the system

Fs spring force

FD damping force

Fine inertia force

(vi)
CONTENTS
Certificate...........i
Acknowledgement....ii
Abstract........iii
List of Figures..iv
List of Tables.....v
Nomenclature...vi

CHAPTER PAGE NO.

1. INTRODUCTION 1
2. LITERATURE REVIEW.2
2.1 Research Paper by GOLDNER....2
2.2 Research Paper by OLY PAZ..................................2
2.3 Research Paper by ABHIJEET GUPTA..........................3
2.4 Research Paper by LIE ZUO........3

3.CONVENTIONAL SHOCK ABSORBERS....................4

3.1 CONVENTIONAL SHOCK ABSORBER..5
3.2 WORKING OF SHOCK ABSORBERS .....5
3.3 APPLICATIONS OF SHOCK ABSORBER .....6

4. POWER GENERATING SHOCK ABSORBERS.7

5. PERFORMANCE OF PGSA...8
6. OBSERVATION AND CALCULATION...9

7. RESULTS AND DISCUSSIONS..15

8. CONCLUSIONS.....16

SCOPE FOR FUTURE WORK...17

REFERENCES.....................18
 CHAPTER I

INTRODUCTION

Energy saving is a very hot topic being discussed nowadays but if we see our automobiles they
only consume energy and give us the work, so why not use any component in automobile
which might bring a scope of generating power apart from performing its basic function. This
idea leads to the development of a SHOCK ABSORBER which can produce electricity apart
from performing its basic function of absorbing shocks.
 A regenerative shock absorber is a type of shock absorber that converts parasitic intermittent
linear motion and vibration into useful energy, such as electricity. Conventional shock
absorbers simply dissipate this energy as heat.

When used in an electric vehicle or hybrid electric vehicle the electricity generated by the
shock absorber can be diverted to its powertrain to increase battery life.

The energy thus produced by the shock absorber can be harnessed and stored for operating the
various power needs of vehicles components and thus adding some value to the overall
efficiency of the vehicle.

1
CHAPTER II

LITERATURE REVIEW

2.1 Research Paper by GOLDNER

Goldner did some preliminary studies on the energy recovery in vehicles by using a simple
regenerative shock absorber composed of a single magnet and coils. They estimated the recoverable
energy for a 2500lb vehicle with an average speed of 20 m/s (45 m/h) is about 20% - 70% of the
power that is needed for such a vehicle to travel on a typical highway at 45 mph. Goldner patent
for an electromagnetic linear generator and shock absorber design was able to recover energy at a
signicant efciency, however, its weight of 70 kg (154lbs) may not be appropriate for a passenger
vehicle.

2.2 Research Paper by OLY PAZ

Oly Paz conducted a study of different congurations of linear induction generators for vehicle
suspension. The author presented a design method for one conguration of a magnet and conductor
set -up, which was calculated to have a theoretical efciency of 46%: however, a prototype was not
fabricated . Finite element analysis on this design would suggest that the actual efciency would be
signicantly less than predicted as a result of its ineffective use of high magnetically permeable
materials for certain components.

2
2.3 Research Paper by ABHIJEET GUPTA

Abhijeet Gupta designed electromagnetic shock absorbers provide means for recovering the energy
dissipated in shock absorbers. Two electromagnetic shock absorbers for potential use in vehicles are
fabricated and tested them in a small all-terrain vehicle (125 kg). Their experiment indicated that
the rotary conguration regenerated power at a much higher efciency (21%) than the linear
conguration: however, its bulky des ign makes it incompatible with a passenger car. To further
magnify the motion and increase efciency, regenerative absorbers composed of ball screw and
rotational electric motors have been developed by a number of researchers.
2.4 Research Paper by LIE ZUO

Lie Zuo design characterize and test a retro t regenerative shock absorber which can efciently
recover the vibration energy in a compact space. Rare-earth permanent magnets and high permeable
magnetic loops are used to congure a four-phase linear generator with increased efciency and
reduced weight. The nite element method is used to analyze t he magnetic eld and guide the
design optimization .

3
CHAPTER III

CONVENTIONAL SHOCK ABSORBERS

In this section we will first give an overview about the conventional types of shock absorbers,
working of conventional shock absorbers and their applications.

3.1 CONVENTIONAL SHOCK ABSORBER

 Fig 3.1 Conventional Shock Absorber
A Conventional Shock Absorber is a mechanical device designed to smooth out or damp shock
impulse, and dissipate kinetic energy. You would be think that as shock absorbers dissipate energy
then where tat energy goes...?

In most dashpots, energy is converted to heat inside the viscous fluid. In hydraulic cylinders,
the hydraulic fluid heats up.
In air cylinders, the hot air is usually exhausted to the atmosphere.
In electromagnetic types dashpots, the dissipated energy can be stored and used later. The
amount of resistance a shock absorber develops depends on the speed of the suspension and
the number and size of the holes of the piston. All modern shock absorbers are velocity
sensitive hydraulic damping devices. This means that the faster the suspension moves the
more resistance the shock absorber provides. Because of this feature, shock absorbers adjust
themselves to road conditions.
4
As a result, shock absorbers reduce the rate of:
Bounce, Roll or sway
Brake dive and acceleration squat

3.2 WORKING OF SHOCK ABSORBERS

A conventional automotive shock absorber dampens suspension movement to produce a controlled

action that keeps the tire firmly on the road. Shocks absorbers are used to damp oscillations by
absorbing the energy contained in the springs or torsion bars when the wheels of an automobile
move up and down. Conventional shock absorbers do not support vehicle weight. They reduce the
dynamic wheel-load variations and prevent the wheels from lifting off the road surface except on
extremely rough surfaces and making possible much more precise steering and braking. The shock
absorbers turn the kinetic energy of suspension motion into thermal energy, or heat energy, to be
dissipated through the hydraulic fluid.

5
3.3 APPLICATIONS OF SHOCK ABSORBER
 Fig 3.2 Application of Shock Absorbers

Shock absorbers are an important part of automobile and motorcycle suspensions, aircraft
landing gear, and the supports for many industrial machines.
Large shock absorbers have also been used in structural engineering to reduce the
susceptibility of structures to earthquake damage and resonance.
Inrail cars and rapid transit systems because they prevent railcars from damaging station
platforms.

6
CHAPTER IV
4. POWER GENERATING SHOCK ABSORBERS
Power Generating Shock Absorber utilizes the Faradays law of electromagnetic induction and
Lenzs law to generate electrical power and simultaneously providing controlable damping to the
system. It converts this kinetic energy into electricity instead of heat waste through the use of a
Linear Motion Electromagnetic System (LMES). The LMES uses a dense permanent magnet stack
embedded in the main piston, a switchable series of stator coil windings, a rectifier, and an
electronic control system to manage the varying electrical output and dampening load.
The bottom shaft of the PGSA mounts to the moving suspension member and forces the magnet
stack to reciprocate within the annular array of stator windings, producing alternating current
electricity. That electricity is then converted into direct current through a full-wave rectifier and
stored in the vehicles batteries. The PGSA is the same basic size and shape, and mounts in the
same way, as a standard shock absorber or strut cartridge.

Figure 4.1: Schematic Diagram of Power Generating Shock Absorver

7
CHAPTER V
PERFORMANCRE OF PGSA
 The system performs best on heavy, off-road vehicles moving quickly over rough terrain.
Currently, only 10-16% of a vehicles fuel energy is used to drive the vehicle, i.e. to
overcome the resistance from road friction and air drag. The rest is lost due to braking,
vibrational energy dissipation, and other forms of loss.
Prof. Lie Zuo estimated that for a middle-size vehicle, 100W, 400W, and 1600W of average
power is available for harvesting from the regenerative shock absorbers while driving on
Class B (good), C (average), and D (poor) highways at 60 mph, which is comparable with
car alternators (500-600W). And the energy potential for trucks, rail cars, and off-road
vehicles is on the order of 1kW-10kW.
This represents a potential of 2-3% fuel efficiency increase in conventional cars, up to 6% in
military vehicles and up to 8% for hybrid vehicles.
The power regeneration is proportional to the square of the magnetic flux across the coils,
Lie Zuo said.

Figure 4.2 Power Generating Suspension

8
CHAPTER VI
5.OBSERVATIONS AND CALCULATIONS
The model chosen to use is a simple spring based model in which the energy present in the vertical
motion of a car can be observed in the compressin and extension of its springs.The energy in the
compressed spring spring is given by the equation

Table no.1: Potential Energy that can be harvested

Displacement of Energy Sum of all four

spring(cm) Harvested(J) wheels(energy4)(J)

1 9.4310-3 0.037

3 0.084 0.336
6 0.339 1.356

9 0.765 3.060

9
This energy can be transformed to equivalent electrical energy.
 Figure 5.1: Volatage(y) vs. time(x) Graph at xo=0.06m and vo=3.5m/sec

The electromagnetic damping force due to e.m.f in the coils is calculated as follows:

(i)
(ii)

(iii)

(iv)
(v)

(vi)

Equation (vi) gives the electromagnetic damping force.

The damping force of damper will be given by:

 (viii)
10

The De-alemberts equation for the mass-spring-damper-magnet-coil system is given by

equation(ix) :

(ix)

Replacing all the values in equation (ix) we will find out the equation of motion of the system.

(x)

The electromagnetic dampiong coefficient is given as:

(xi)

(xii)

(xiii)

The final expression for electromagnetic damping coefficient will be given by equation (ix):

(ix)

Therefore, electromagnetic power can be given as equation(x)

(x)

Now, if the system is at critically damped condition then we can write:

(xi)

Therefore, From eqution (xi), Electromagnetic damping coefficient is:

 (xii)

And, damping coefficient of damper is:

(xiii)

If , There is no electromagnetic damper in the system that happens in conventional shock absorvers,
then , as a result:

11
If, There is no damper in the system, Then , as a result:

Now, From Equation(x) and Equation(xii) we get:

(xiv)

Now, Net power can be calculated as:

(xv)

In conventional shock absorver, all the shock power is wasted by damper in form of heat, That is:

(xvi)

In, PGSA system, all the shock power is parted into two form i.e. electrical power in
electromagnetic damper part of system and in heat form in convetional damper part of system.
Therefore, Electrical power generated in this system is regeneratively saved. This power saved is
given as:

(xvii)

Now, percentage of power saved will be:

(xviii)
 12

Figure 5.2: Displacement vs Time (Blue) and Velocity vs Time (Green) Graph at xo=0.03m
Figure 5.3: Displacement vs Time (Blue) and Velocity vs Time (Green) at xo=0.03m and
vo=5.7m/sec

13

Figure 5.4: Displacement vs Time (Blue) and Velocity vs Time (Green) at xo=0.041m and
vo=5.7m/sec
 Figure 5.5: Displacement vs Time (Blue) and Velocity vs Time (Green) at vo=0.5m/sec

14
CHAPTER VI
6.RESULTS AND DISSCUSSIONS

A fair amount of electricity is generated by the regenerative shock absorbers. Previously, the
amount of energy which was wasted as heat energy is now converted to electrical energy which can
be stored in batteries.
Although, the amount of electricity generated in highways is comparatively lesser but on rough
terrains the recovery of energy can be of fairer amount.
The project we did was a small prototype with a small magnet and few no. of turns of coil
approximately 80 turns but it was able to give a maximum of around 8mV so if the same concept is
applied to actual shock absosbers then we can expect a good amount of electricity.

As and
Therefore we can see that :

Power is directly proportional to the square of no. of turns of coil and the magnetic strength.

15
CHAPTER VII
7. CONCLUSION

1. A larger magnetic field will be necessary if more power needs to be generated.

2. Conversion of energy produced by a vehicle shock absorbers movements into electrical
energy, allows a significant fuel savings.
3. It is possible to obtain a fuel saving between 1.5 and 6%, depending on the vehicle and on
the driving conditions. Moreover, the researchers say that this system can improve the
stability of the vehicle.
4. The system performs best on heavy, offroad vehicles moving quickly over rough terrain, so
the company is targeting military applications.
5. It also is sensible that having onboard power generation could be a real advantage in
military situations where troops are moving in remote areas without readily available fuel
sources. Conserving fuel in those scenarios, especially during combat, could be the
difference between life and death.

16
 7. SCOPE FOR FUTURE WORK

1. In the future, the researchers are planning to increase the energy density and efficiency of
the system by further increasing the magnetic field intensity and improving the harvesting
electrical circuit.
2. Wireless sensors and actuators will be used in future. For example, if the sensors detect the
car starting a turn, the power controller can increase the resistance from the shock absorbers
on the outer wheels, improving cornering.
3. There is still room for improvement in the overall design of the regenerative system, and
researchers are working on such improvement.
4. Stony Brook University, Tufts University and General motors are developing systems of
their own that use no fluids, only electromagnetic resistance. They says one of the biggest
challenges in designing such systems is making them small enough to fit into existing
vehicles, yet ensuring they are still capable of converting a useful amount of electricity.
5. There is some discussion taking place about the potential of adding their technology to the
Humvees replacement, the Joint Light Tactical Vehicle and military vehicles.Conversion of
energy produced by a vehicle shock absorbers movements into electrical energy, allows a
significant fuel savings.

17
 REFERENCES:

[01] Goldner R B, Zerigian P and Hull J R 2001 [A preliminary study of energy recovery in
vehicles by using regenerative magnetic shock absorbers] SAE Paper #2001-01-2071

[02] Oly D. Paz A thesis submitted at Lousiana State University [Design and performance of
electromagnetic shock absorber] December 2004

[03] Gupta A, Jendrzejczyk J A, Mulcahy T M and Hull J R 2006 [Design of electromagnetic shock
absorbers] Int. J. Mech. Mater. [04]Lei Zuo, Brian Scully, Jurgen Shestani and Yu Zhou [Design
and characterization of an electromagnetic energy harvester for vehicle suspensions]

[05] www.peswiki.com/electric shock absorbers

18