Regenerative electromagnetic shock

absorbers for independent suspension

system
Cite as: AIP Conference Proceedings 2148, 030053 (2019); https://doi.org/10.1063/1.5123975
Published Online: 03 September 2019

Bhavya Bhatia, and Anurag Joshi

AIP Conference Proceedings 2148, 030053 (2019); https://doi.org/10.1063/1.5123975 2148, 030053

© 2019 Author(s).
 Regenerative Electromagnetic Shock Absorbers for
Independent Suspension System

Bhavya Bhatia1a), Anurag Joshi2b),

1,2
Department of Mechanical Engineering, Manipal University Jaipur, Rajasthan, India
a
[email protected]
b
[email protected]

Abstract. Suspension systems are an integral part of an automobile. They enhance the driving experience by isolating the vibrations
and providing ride comfort to the passenger. The shock absorbers play a crucial role in this system. A shock absorber is a mechanical
or hydraulic assembly used to absorb the vibrations and smoothen out any sudden shocks. This paper deals with the design of a
shock absorbing system with a rack and pinion mechanism of a suitable gear ratio which harvests electric energy from the shocks
and impulses generated during the driving. The integration of this system with hybrid or electric vehicles will result in the vehicle
having a better range.

Keywords. Suspension System, Viscous Fluid, Damper, Magneto-rheological Fluid, Rack and Pinion, Gear Ratio, Commutator,
Fleming’s Right Hand Rule.

INTRODUCTION
Suspension systems are mainly used to absorb any kind of road shocks due to improper roads, holes and bumps thereby
imparting stability to the car. They provide with consistent contact, comfort and control and hence maximizing friction
between tires and surface of the road during any type of motion [1]. Suspension systems also provide steering stability
and improves the handling of the vehicle. A basic suspension system takes into use of the tires, tire air, springs, shock
absorbers and auxiliaries which act in unison to absorb the energy of vertically accelerated wheel allowing the frame
and body of a vehicle to be undisturbed whilst holding the road, thus isolating the vibrations. Suspension Systems are
sub-categorized into the following:

x Conventional (Dependent) Suspension System

x Independent Suspension System
x Air Suspension System
x Hydro Elastic Suspension System

Independent Suspension Systems are widely used due to one major advantage, that is, the vertical motion of one
wheel is independent of the other wheel. Both, front and rear wheels are utilized actively for providing suspension,
and this imparts more stability, better control and handling to the driver. A simplified Independent Suspension System
is shown in Fig. 1, where in the bump that causes the suspension to compress attached with one wheel, does not affect
the other wheel. This suspension system also provides us with electric power regenerated from motion of individual
wheels [2]. Further design is done taking into consideration that Independent Suspension System is used.

A shock absorber is a mechanical or hydraulic device which is designed in a manner which smoothens out or damps
out any sudden shock or impulse by converting the Kinetic Energy in the form of Heat Energy and then dissipating it.
This energy is usually wasted in the form of heat [3].

1st International Conference on Advances in Mechanical Engineering and Nanotechnology (ICAMEN 2019)
AIP Conf. Proc. 2148, 030053-1–030053-6; https://doi.org/10.1063/1.5123975
Published by AIP Publishing. 978-0-7354-1893-6/$30.00

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 FIGURE 1. Independent Suspension System

Springs have an innate property of oscillating harmonically, which is, they oscillate for a long time period with smaller
reductions in amplitude. Ideally there are no reductions in the amplitude (Fig. 2(a)). Shock absorbers reduce the
amplitude and time taken for the oscillation, and eventually damps the vibrations completely. The amplitude of
oscillation decreases with time, eventually becoming zero, and the profile of the wave is an exponentially decreasing
sinusoidal wave (Fig. 2(b)). A better understanding can be obtained from the figures below. 8
Most shock absorbers that are widely used in automobiles, contain a piston, piston rod, viscous fluid, and casing. They
work on the principle that viscous fluids resist motion of the piston, due to viscous friction. The piston has slots for
the viscous fluid to pass through and are known as piston valves. Fluid in the shock absorber casing is forced to flow
through restricted valves, thus generating hydraulic resistance. This resistance is needed and provides for the damping
effect [5].

FIGURE 2(a). Free Oscillation FIGURE 2(b). Damped Oscillations

Electro Magnetic Ride Suspensions are basically used to actively control the damping force of suspension system.
They differ from the conventional hydraulic shock absorber which have a viscous fluid only. In Magnetic Ride Shock
Absorbers, the viscous medium consists of a myriad metallic / iron particles that are suspended within it. This medium
offers desired resistance to the motion of the piston. These particles can be magnetically attracted in the presence of a
magnetic field. The piston mounts an electromagnet or an electromagnetic coil which can be activated with the help
of the connection made through the piston shaft [6]. This connection is made with the Electronic Control Unit (ECU)
which controls the suspension system for the whole vehicle. This current is supplied with the help of a battery source.
In this case, resistance to motion is provided as soon as the electromagnetic field is generated. This is done by the
aligning action of the metallic particles with the electromagnetic field line in the piston valves. The Shock Absorbers
at every hub are connected individually. Importantly, the casing and linkages of this system must exhibit non-magnetic
properties [7].
The main advantage of using an Electro Magnetic Ride Suspension is that just by altering the current passing through
the electro magnet, we can change the type of suspension according to the desired need. This suspension system is
highly customizable and can loosen for comfort, and become rigid for higher control and stability. This level of
customizability is achieved by using an Electronic Control Unit (ECU). A Magneto-rheological Fluid can be used
and essentially functions in the same way a viscous fluid with magnetic metallic particles does. A detailed view of the
cross section of the Electro Magnetic Shock Absorbers in Fig. 3 [9].

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 FIGURE 3. Cross Section of Electro Magnetic Ride Shock Absorber (with Magneto-
rheological Fluid)

Electromagnetic Shock Absorbers are used because of the following advantages:

x This suspension system provides for a faster response time as it can be controlled locally with the help of an
Electronic Control Unit (ECU).
x It is a completely flexible system as damping coefficient of the system can be changed with time and speed,
by changing the current passing through the electromagnetic coil, hence can be used as per function of the
vehicle (Example: Luxury, Sports, Heavy Duty).
x Independent control at each wheel and fully adjustable variable damping.
x Lesser wear, therefore increasing the reliability.
x Increases control by reducing Bounce, Sway, Brake Dive, and Accelerating Squat.

REGENERATIVE ELECTRMAGNETIC SHOCK ABSORBERS

Major concept of Regenerative Electromagnetic Shock Absorbers lies within the conversion of the kinetic energy
obtained from the linear motion of the casings of the Magnetic Shock Absorber, to useful energy. The conversion of
this linear motion to a rotational motion, and then harnessing this rotational energy with the help of an electrical
generator is the main objective. To obtain rotational motion from linear motion, a system of gears known as the rack
and pinion is used. This rotational motion is then given to the electrical generator and the electricity obtained is stored
in a battery reservoir. This electricity can then be channelized and be used for multiple purposes discussed later.

Electromagnetic Suspension System works on the concept of generation of a magnetic field when current is passed
through the coil. The strength of the magnetic field depends solely on the number if turns in the coil, and the amount
of current passed through. Details of this type of suspension system is explained earlier. Importantly, it is the Dampers
linear motion that plays a major role in the process of electricity regeneration. The initiation of the process is done by
the linear up and down motion of the shock absorber. This linear up and down motion is converted to rotational motion
with the help of a rack and pinion gear system.

Rack and Pinion are a set of gears which help in changing the vertical linear motion of the casing of the shock
absorber to rotational motion. The linear gear bar is known as the rack and it engages teeth with a circular gear known
as the Pinion.

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It is very important to note that the rack and pinion system will be externally attached to the moving case of the shock
absorber.

This is done because of two reasons. Firstly, in the case of wear and tear of the moving rack and pinion, easy
replacement of the unit can be arranged without disturbing the suspension system. And secondly, the lubrication will
be provided separately. And it is important that this lubrication does not interfere with the workings of the shock
absorber. If Rack and pinion would be internally installed, and breakdown in component were to occur, repair would
be a problem and damage to the whole suspension system would irreversibly occur. The Gear ratio the rack and pinion
must be low in order to get more rotations for even small linear changes in the rack. The cross section of designed
system is shown in Fig. 4.

FIGURE 4. Longitudinal cross-section of Regenerative Electromagnetic Shock

Absorber

The Connecting Shaft is a rod which will transmit the rotation obtained from the pinion to the generator. Electric
generator or Dynamo works on the principle of electromagnetic induction to convert mechanical energy to electrical
energy. We use Fleming’s Right Hand rule to understand the conversion of rotational motion to electricity. The shaft
connected to the pinion provides the required rotational motion necessary. Inside the generator there is magnetic field
set up. There is a rectangular armature coil which is rotated by this shaft. The axis of rotation of armature coil and
magnetic field are perpendicular to each other. The shaft and rectangular coil is united with the help of commutator
rings and carbon brushes. Due to rotation of shaft, a force on the armature coil is exerted which is in the presence of
a magnetic field. Due to this direct current is induced in the coil. This current is then fed into the reservoir battery, and
is ready for use. A block diagram describing the working of this Regenerative Electromagnetic Suspension System is
shown in Fig. 5.

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 FIGURE 5. Work flow of Regenerative Electromagnetic Susoension System

POSSIBLE ENHANCEMENTS
x Polymer gears can be used for rack and pinion arrangement to make the system lightweight.
x The number of rack and pinion gear arrangements can be increased for bulkier suspension systems.
x The defined device is capable of high power generation and has energy conversion efficiency with minimal
weight penalty, for improved battery efficiency.
x This system can be integrated along with the Kinetic Energy Restoration System (KERS) to boost
acceleration.

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 x The generated electrical energy can be used as a source for powering vehicle sub systems, accessories and
recharging batteries in conventional fossil fuel powered vehicles.

CONCLUSIONS
Incorporation of the proposed design into the engine based automotive vehicles can greatly reduce the load on the
battery, which arises due to the usage of electric accessories. In upcoming electric vehicles, this system can increase
the life cycle of the primary battery by providing regenerated electric power to replenish the battery while absorbing
the terrain borne shocks. Practical aspects of the defined design, is to be considered in the future scope of this paper.

REFERENCES
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