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Performance analysis of Regenerative Suspension System by using

Electromagnetic Induction system


J.Yasin1,A.Inigo valan2
1.
PG Scholar, Department of Manufacturing Engineering,
Government college of Technology, Coimbatore, Tamilnadu, India.
2.
PG Scholar, Department of Manufacturing Engineering,
Anna university regional office Coimbatore, Tamilnadu, India.
Email: yasinyas007@gmail.com

Abstract
Abstract
Transportation is an extremely important element for the day-to-day functioning of our life.
Vehicles play an important role around the world. Due to global energy concern, new forms
of clean energy technologies are favored. Green manufacturing is one of the most popular
topics nowadays. In a vehicle system energy is partially converted to move vehicles, the rest
of them are lost in other forms of waste such as heat, light, etc. Meanwhile, the vehicles
energy harvesting and the improvement of energy efficiency have been more concerned for
the last two decades. One of the important energy harvesting system (regenerative braking)
has become increasingly popular, recovering energy when break is applied. However, other
energy recovery mechanisms are that still in the research stages. In this paper expressed the
performance analysis of back and front type of regenerative suspension system by using
electromagnetic induction theory.
Keywords , Electromagnetic induction principle, vibration, battery

Introduction
The research about energy recovery from vehicle suspensions began more than ten
years ago, first as an auxiliary power source for active suspension control, and later also as
energy regenerating devices in their own accord. During the past ten years, energy recovery
from vehicle vibrations has achieved great commercialization success in hybrid or electric
vehicles. Some earlier efforts to recover energy from suspension are- Lei Zuo, et al. [1] have
worked on a prototype design of Electromagnetic energy harvester for vehicle suspension. In
this paper they have designed, characterized and tested a prototype retrofit regenerative shock
absorber.
Gupta et al, [2], (2003) has studied the available energy from shock absorbers as cars
and trucks are driven over various types of roads. They fabricated two prototypes of
regenerative electromagnetic shock absorber: a linear device (called as Mark 1) and a rotary
device (called as Mark 2) and installed them in vehicle to study energy recovery.
Goldner, et al. (2001) [3] have carried out a proof-of-concept - to evaluate the feasibility of
obtaining significant energy savings by using regenerative magnetic shock absorber in
vehicles. They proposed electromagnetic (EM) shock absorbers to transform the energy
dissipated in shock absorbers into electrical power.

1
P. Zhang et al. [4] have presented comprehensive assessment of the power that is
available for harvesting in the vehicle suspension system and the tradeoff among energy
harvesting, ride comfort, and road handing with analysis, simulations and experiments.
Zhen Longxin and Wei Xiaogang [5] have modeled the structure and dimensions of a
regenerative electromagnetic shock absorber in CAD software package.
S. Mirzaei.et al [6] introduced a passive suspension system for ground vehicles based
on a flexible Electromagnetic Shock Absorber (EMSA). They designed and provided a model
of passive suspension.
Bart Gysen et al., [7] have studied design aspects of an active electromagnetic
suspension system for automotive applications which combines a brushless tubular
permanent-magnet actuator with a passive spring.
N. Bianchi et al [8] have described the design criteria of a tubular linear motor, with
interior permanent magnets. They derived key equations for the analysis of the motor,
considering both slotted and slot less topologies.
Babak Ebrahimi et al., [9] presented the feasibility study of an electromagnetic
damper, as senor/actuator, for vehicle suspension application. They have optimized geometry
of shock absorber to achieve higher electromagnetic forces and magnetic flux induced in the
system.

2
ELECTROMAGNETIC TYPE SUSPENSION SYSTEM

Since 1980s permanent magnets were favored in electromagnetic suspension to


provide semi- active force. The damping force can be simply changed by tuning the shunt
resistances. In addition, electromagnetic shock absorbers utilize vibration energy and convert
it into electrical energy by linear motors or rotary motors to perform self control. We are
introducing new technology of electromagnetic suspension system that is based on the
electromagnetic induction.

4.1 ELECTROMAGNETIC INDUCTION TERMINOLOGY

Electromagnetic induction is the production of a potential difference (voltage) across


a conductor when it is exposed to a varying magnetic field. It is described mathematically by
faraday law named after Michel faraday who is generally credited with the discovery of
induction in 1831

The phenomenon by which an emf or current is induced in a conductor due to change


in the magnetic field near the conductor is known as electromagnetic induction.

menon by which an emf or current is induced in a conductor due to change in the magnetic
field near the conductor is known as electromagnetic induction.

Figure 1.2: principle of electromagnetic induction


The energy harvesting technique is based on the change of the flux linkage in the harvester
coil due to an ambient excitation of the harvester. According to the law of induction, a voltage
is induced, and energy is partly supplied to an attached load and partly dissipated due to the
coil resistance. The following parts are required to build a proto type of regenerative
suspension system as shown in Fig. 2.
1. Piston rod (Aluminum rod)
2. Rare earth magnet
3. Teflon tube
4. Copper coil
5. Clamping device
6. Fork setup
6

2 3

Fig 2. Electromagnetic suspension system


The piston rod is inserting through the rare earth magnet (neodymium). A copper coil is
wrapped by Teflon tube. The load is given to the shock absorber the rod moves towards
Teflon tube. When the piston rod is move to the Teflon tube it will produces a current due to
magnetic flux. Oil set up gives a better damping by the process of heat dissipation. Copper
wire of 32 gauges was chosen to wound coils because of its superior conductivity and low
resistivity.
According to Faradays law of induction, regenerated voltage is proportional to flux
density and the crossing velocity of the conducting wire. This project will focus on harvester
design approach.
4.2 CONSTRUCTION&WORKING (EXTERNAL PARTS SETUP)

The following parts are required to build a harvesting device in fork system.

Piston rod

Rare earth magnet

Fork setup

PVC pipe

Copper coil

Clampers

The piston rod is inserting through the rare earth magnet (neodymium). A copper coil
is wrapped by PVC pipe. The load is given to the fork the rod moves towards PVC pipe.
When the piston rod is move to the PVC pipe it will produces a current due to magnetic flux.
Figure 4.2.2 Experimental setup of energy harvesting device

4.3 CIRCUIT DIAGRAM


Figure 4.2.3 Circuit diagram

The power generated by the suspension is in AC power, and it needs to be converted


into DC to charge the battery. Sometimes, the regenerated voltage is not enough to charge the
battery, thus a DC to DC booster is required to meet the charging barrier by shunt the circuit.

CHARACTERIZATION OF MAGNETS
In electric machines technology, the following PM materials are used
Alnico (Al, Ni, Co, Fe);
Ferrites (ceramics), e.g., barium ferrite BaO 6Fe O and strontium ferrite
SrO 6Fe O;
Rare-earth materials, i.e., samarium-cobalt SmCo and neodymium-iron-boron
Nd Fe B

Table No 5.1.parametres of permanent magnet


Material (B.H) max Br Hc

[kJ/m3] [T] [kA/m]


Ceramics 27-35 0.4 240
Alnico 70-85 1.1 130
Rare earth magnets 190-385 1.0-1.4 760-980

-Nd-Fe-B

Table No 5.2.Temperature influence on permanent magnet materials


Material Temperature Max. operat. CB CC
Temp. [0C]
Curie [0C] [%/K] [%/K]
Ceramics 450 300 -0.20 +0.40
Alnico 830 500 -0.02 +0.01
Rare earth magnet 310 210-100 -0.13 -0.60

The material recommended for the model in this project is the Nd-Fe-B since it
considerably improves the performance to cost ratio. Ferrites are not used because they would
increase the size of the shock absorber.
DESIGN CALCUATION
From design perspective, the electromagnetic regenerative shock absorber
performance depending on the magnet area of the copper coil and distance travelled by piston
rod. The linear regenerative shock absorber is designed to have similar dimensions as
conventional shock absorber. It is based on the faradays law.
When a conductor of length l crossing a magnetic field B [T] at a constant velocity v,
the EMF voltage V is expressed as Bsin(90)

V =v n l B 6.1

l= magnet thickness+ copper coil thickness

Maximum current to be produced by

I=V/R=B v AW 6.2

Power , P= VI= B2v2l AW 6.3


AW- cross sectional area
Power is proportional to both flux density square and velocity square.
When a straight wire of length l(m) conducts a current, I(A), and is subject to a
magnetic field, B(T), normal to the wire, a force, F(N), is exerted on the wire of magnitude,

Damping force F = I l B . 6.4

Voltage is measured by multi meter approximately we investigate,

Voltage = 3v for (3 magnets)

From equation no... 6.1

V= v n l B 6.5

3=250x (.07+0.016) x1.4xv

v= 0.09966m/s

I=V/R=3/33 =0.0909amps

R- Resistance 33 ohms

P=VI= 3x.0909=.2727 watts.

Damping force

F = I l B=0.0909x.07x1.4=.00882N

The direction of the force is normal to the wire and field. The damping force developed on
the coil assembly of the EM shock is the sum of the forces exerted on each section.
Table No.6.1 Power generation depends on velocity variation

Velocity Voltage Current Power

(m/s) (Volts ) (Amps) (Watts)

0.01 0.301 0.007 0.002107

0.03 0.903 0.021 0.01896

0.05 1.505 0.035 0.05267

0.07 2.107 0.0490 0.10324

0.09 2.709 0.063 0.170667

0.11 3.311 0.077 0.2549447


3.5

2.5

1.5

0.5

0
1.0000000000000023E-2 5.00000000000001E-2 9.0000000000000066E-2

X axis - velocity, Y axis -voltage

Figure 6.1 voltage and velocity variation

In this project works we investigate the performance of the energy harvesting system
which working on the electromagnetic principle. By using this mechanism of suspension in
E-Bike we can calculate the following results below for 3 magnets with 1 setup.
Table No.9.1 Results
Velocity (m/s) Voltage (volts ) Power (watts)

0.01 0.301
0.002107

0.11 3.311
0.2549447

In this result shows one setup of harvesting system. In E- Bike there will be chance for
applying this mechanism in fork and rear suspension also. We can get more amount of energy
from device .However study of circuit design is also very important because it has direct
effects of charging efficiency. A battery is charged after going through AC-DC converter and
DC-DC booster. Yet there is still a blank space to explore the optimal circuit design to have
maximum power stored at high efficiency.
References

1. N. Nandakumar,J.Yasin,A.Inigo valan Performance analysis of Energy harvesting system


by Using Electromagnetic principle, International Journal of Applied Engineering Research,
ISSN 0973-4562 Vol. 10 No.88 (2015)
Lei Zuo, Brian Scully, Jurgen Shestani and Yu Zhou,Design and characterization of an
electromagnetic energy harvester for vehicle suspensions, Journal of Smart Materials and
Structures, Volume 19, Number 4.
2. Gupta A, Jendrzejczyk J A, Mulcahy T M and Hull J R, Design of electromagnetic shock
absorbers, International Journal of Mechanics & Material Design, Volume 3, Number 3.
3. Goldner R B, Zerigian P and Hull J R, A preliminary study of energy recovery in vehicles
by using regenerative magnetic shock absorbers, SAE Paper #2001-01-2071.
4. Pei-Sheng Zhang and Lei Zuo, Energy harvesting, ride comfort, and road handling of
regenerative vehicle suspensions, ASME Journal of Vibration and
Acoustics, 2012.
5. Zhen Longxin and Wei Xiaogang, Structure and Performance Analysis of Regenerative
Electromagnetic Shock Absorber, Journal of networks, vol. 5, no. 12, December 2010
6. S. Mirzaei, S.M. Saghaiannejad, V. Tahani and M. Moallem, Electromagnetic shock
absorber, Department of Electrical and Computer Engineering, IEEE 2001.
7. Bart L. J. Gysen, Jeroen L. G. Janssen, Johannes J. H. Paulides, Elena A. Lomonova,
Design aspects of an active electromagnetic suspension system for
automotive applications, IEEE transactions on industry applications, vol. 45, no. 5,
September/October 2009.
8. N. Bianchi, S.Bolognani, F. Tone1, Design criteria of a tubular linear IPM motor,
Department of Electrical Engineering, University of Padova,2001, IEEE
9. Babak Ebrahimi, Mir Behrad Khamesee, M. Farid Golnaraghi, Feasibility Study of an
Electromagnetic Shock Absorber with Position Sensing Capability, IEEE 2008, Page 2988-
91
10. Shakeel Avadhany, Zack Anderson, U S patent 260935, Regenerative shock absorber

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