ELECTRICAL POWER GENERATION THROUGH

SUSPENSION

ABSTRACT:
The suspension system is one of the most important system in
automobile, It increases driver and passenger ride quality. There are
several types of suspension system. One of them is shock ups (dampers).
The shock ups functions in such a way that when the vehicle confronts a
bump , the springs compress and the dampers return it to its original state.
Hence, we will be mainly focusing on harness electricity using this
mechanismby coupling it with rack and pinion which is ultimately
connecte dto dynamo which in turn is responsible for generating
electricity. The CAD model has been made in CAD software CATIA V5.
The project will be manufactured according to design and calculation
parameters.
INTRODUCTION:

Disturbing forces should be minimised or greatly reduced for a smooth and

comfortable ride by using some equipment.Shock absorbers are devices that isolate
vibrations from the environment.by absorbing some of the agitating
energy.Telescopic shocks are one of the most common types, shock has the
disadvantage that the flow of oil in the cylinder can be disrupted induce an oil-and-air
foam to form. These restrict the optimal flow throughout the valves.

Gas shocks are a step forward from traditional shocks. Years of rigorous study
and development with top flight shock design experts have resulted in nitrogen-filled
gas shock absorbers. They are designed to deliver shock absorbers that outperform
anything on the market today for both lowered and stock automobiles. Nitro shock
absorbers are high-quality, nitrogen-filled shocks that are custom-designed and gas-
charged for each vehicle. The application of nitrogen under pressure reduces foaming
and improves efficiency.

Working principles

The electrical armature suspensor is a key component of our project since these
armatures turn mechanical motion into electrical energy. The output voltage of this
electrical armature is 12 volts and 1 amp dc. It is powered by a 12v-100 ah
rechargeable battery. This battery may be fully charged in 36 cycling hours or less
depending on the level of discharge. Permanent magnets follow this mechanical
monument between armature coils when car shock absorber pus pulls. The magnetic
repulsion force between the armature coil and the magnet bitewing is then converted
into electrical voltage. Flexible dc wire connects these armature dynamos. The starter
ignition switch connects the battery's D.C. power supply to the engine starting. When
you turn on the starter using the start key, the engine will start, and the time starter
will function like a hefty dc motor, consuming a lot of energy.

Faraday’s Law:

Faraday's Law states that "the induced electromotive force (EMF) in any closed
circuit is equal to the time rate of change of the magnetic flux across the circuit." It is
applicable to a closed circuit consisting of thin wire. "The EMF generated is
proportionate to the rate of change of the magnetic flux," or "The EMF generated is
proportional to the rate of change of the magnetic flux."

LITERATURE REVIEW

1] “Power Generation by Using Suspension System” by Himanshu S. Rewatkar,

Vicky R. Gedekar, Kunal L. Parate
The major goal of this project is to design a controller for a car suspension system in
order to reduce passenger discomfort caused by road roughness and improve ride
handling related to pitching and rolling movements. To achieve as many control
objectives as feasible, an extremely fast and accurate controller is required.

As a result, this work uses a Neuro-Fuzzy (NF) artificial intelligence technique to

construct a robust controller that meets the control objectives. This controller has the
advantage of being able to handle nonlinearities faster than other conventional
controllers. When travelling on a bumpy road, the proposed controller's method is to
send control forces to the suspension system to reduce vibrations on each corner of
the vehicle. The NF controller is also used for vehicle modelling to eliminate body
inclinations that occur during heavy manoeuvres such as braking and cornering. A
nonlinear active suspension system for the entire vehicle is introduced and tested. The
results show that by lowering the cost function, the intelligent NF controller increased
the dynamic response.

2] “Power Generation through Rack & Pinion in Suspension System for an

Automobile” by G.P.Dhalwar , T.A.Jadhav

Attempts were made in this work to transform dissipated energy into electrical
energy. The design of a regenerative suspension system is offered in this project in
order to improve energy harvesting efficiency. The mechanical motion rectifier
converts oscillatory vibration into generator unidirectional rotation. Using software, a
modal and vibration analysis of the rack and pini on system is performed to discover
displacement and stresses at various loads. Each natural frequency's mode form is
calculated. The power is generated via a mechanical rack and pinion system with a
regenerative shock absorber. This technique can be used to generate electricity in
vehicles.

Suspension systems are used in vehicles to support the vehicle's body weight
while also isolating the chassis from road vibrations. The dampers are made to
convert vibration energy into heat, reducing the vibration conveyed by road
excitement. It is possible to capture vibration energy from the car suspension system
in order to increase the vehicle's efficiency. The term "regenerative suspension
system" refers to a suspension system that is utilised to regenerate vibration energy.
Vehicle movement consumes only 10-20% of total fuel energy. The energy
dissipation from suspension system vibration is one of the most significant losses.

A linear electromagnetic generator with a particular design that generates

power from the relative linear motion of magnets and coils. The second type involves
converting linear suspension vibrations into oscillatory rotation and harvesting energy
using rotating permanent magnetic DC or AC generators. Rack and pinion are
examples of mechanical mechanisms. The energy density of rotational shock
absorbers is higher. The bidirectional oscillation will produce a lot of impact force,
backlash, and friction in the transmission system, which will lead to wear or possibly
failure. Due to the high impact force, early prototypes of regenerative shock absorbers
based on oscillatory rotating generator rack teeth quickly wore out and snapped.

3] “Energy Generating Suspension System for Commercial Vehicles", by M. B.

Shaiju, Mukul Mitra.

In this study, a single acting positive displacement pump was used to partially exploit
the energy stored in the springs (caused by road undulations) for compressed air
generation in this paper. The system architecture and interface are based on actual
measured data from a 16T Goods Vehicle under a variety of road and traffic
circumstances, including the in-city cycle, highway cycle, and off-road cycle for both
burdened and unladen applications.

After re-sampling the data, early analysis of the data indicates that simple harmonic
displacements are available. The re-sampling was done with Microsoft Excel®
macros, and the system response was designed based on the re-sampling sequence.
The gathered data strongly suggests that this unique design has the ability to absorb
road energy and support standard commercial vehicle braking systems.

Since the dawn of transportation, fuel consumption has been a major consideration.
These are reasons that have to do with our environment as well as economics. Fuel
consumption is an essential sales argument in the competitive truck market, because
customers drive their trucks for an average of 150 000 km per year, which implies that
fuel accounts for a significant portion of a vehicle's lifespan cost.
Existing commercial vehicle braking systems are primarily air assisted, relying on
compressed air from a reservoir that is refilled based on demand by a positive
displacement compressor, which is often driven directly by the vehicle power pack.

4] “Magnetic Suspension System with Electricity Generation”, by Daspute

Sharad G. ,Deshmane Shubham M , Dhage Prashant P. , Gaikwad VaibhavJ,
Prof. Mali Pravin K

In this study, the magnetic repulsion between dipoles is used in the design of a
magnetic shock absorb shock absorption. We used to have a lot of issues riding on
her two-wheeler on the uneven roads. due to the unevenness of the road It was
discovered that the similar poles of two magnets with the same qualities and strength
repel each other, and that their magnetic fields keep them at a constant distance from
each other. This led her to believe that if the shock absorber were composed of
magnets with comparable poles facing each other, it would work better and require
less maintenance. Regenerative braking systems have grown in popularity over the
last decade, collecting energy that would otherwise be wasted.

In this project two magnets are placed in a piston. One magnet is fixed with piston.
Another one is movable, which is connected with rod. With magnets are replaced by
air. Our magnetic shock absorber works on the basic principle of magnet that
“opposite poles attract each other and same poles repels each other”. In this both
magnets are facing the same poles (both magnets are placed facing north and north or
south and south). Both magnets are same pole. When the rod moves inside the piston,
the movable magnet moves towards the fixed magnet. Since both magnets are of same
pole repulsion force is created between the magnets.

The shock absorber is a vital component of every vehicle. Different types of springs,
such as helical springs, leaf springs, and coil springs, are utilised as shock absorbers
in vehicles. Between the axles, a shock absorber is utilised. the vehicle's frame Shock
absorbers are a key component of vehicle and motorbike suspensions, as well as
aircraft suspensions.landing gear, and a variety of industrial machine supports In
addition, large shock absorbers have been utilized to limit the susceptibility of
structures to earthquake damage and resonance, structural engineering is used.
Previously,Regenerative braking systems have grown in popularity over the last
decade, collecting energy that would otherwise be wasted. lost due to braking.

PROBLEM STATEMENT:

⮚ As we see that there are several energy losses in a automobile system. To

increase ride quality ie. preventing passengers from experiencing bumps and
jerks, the suspension system is implemented. But, other than that the potential
for use of that energy is still not clarified. Hence we focus on harnessing
electricity using the shock ups .

OBJECTIVES:
● To offer a maximum efficiency of battery.
● To increase the energy conversion rate for
charging the battery.
● To reduce the shock loads (Vibrations) on the
bumpy roads.

METHODOLOGY:

Phase I

● -We started our work with a literature survey.

 ● -Search many research papers from various articles and published journal
papers.
● Then we collected all the topic related data from these research papers and
studied them in a detailed manner along with the standard reference books and
academic books.
● Reference sites:

http://explore.ijert.org/
http://www.ijetcse.com/
http://industrialscience.org/
http://www.ijist.net/

● Worked on diff. Mechanisms that can be useful for our project.

● We have done a 3D sketch of the model in CATIA V5.
● After the final analysis and material selection we go out in the market to
purchase the required components with required specifications.
● In this purchasing process we approximately estimated the cost required to
purchase the components and for machining.
● We selected standard components.
● Finally, our product will be manufactured in the second semester and results
and testing will be carried out.

PHASE II

● Actual preparation of project:

● We will complete calculations of remaining parts.
● We will purchase standard components from the market.
● -Manufacturing will be done.
● Assemble will be done.
 ● Testing of set up will be done.
● Representation of actual theoretical report.

DESIGN MODELLING:

CAD: -

Computer-aided design (CAD) is the use of computer systems (or workstations) to

aid in the creation, modification, analysis, or optimization of a design. CAD software
is used to increase the productivity of the designer, improve the quality of design,
improve communications through documentation, and to create a database for
manufacturing. CAD output is often in the form of electronic files for print,
machining, or other manufacturing operations. The term CADD (for Computer Aided
Design and Drafting) is also used.

Its use in designing electronic systems is known as electronic design

automation (EDA). In mechanical design it is known as mechanical design
automation (MDA) or computer-aided drafting (CAD), which includes the process
of creating a technical drawing with the use of computer software.

CAD software for mechanical design uses either vector-based graphics to depict the
objects of traditional drafting, or may also produce raster graphics showing the overall
appearance of designed objects. However, it involves more than just shapes. As in the
manual drafting of technical and engineering drawings, the output of CAD must
convey information, such as materials, processes, dimensions, and tolerances,
according to application-specific conventions.
CAD may be used to design curves and figures in two-dimensional (2D) space; or
curves, surfaces, and solids in three-dimensional (3D) space.

CAD is an important industrial art extensively used in many applications,

including automotive, shipbuilding, and aerospace industries, industrial
and architectural design, prosthetics, and many more. CAD is also widely used to
produce computer animation for special effects in movies, advertising and technical
manuals, often called DCC digital content creation. The modern ubiquity and power
of computers means that even perfume bottles and shampoo dispensers are designed
using techniques unheard of by engineers of the 1960s. Because of its enormous
economic importance, CAD has been a major driving force for research
in computational geometry, computer graphics (both hardware and software),
and discrete differential geometry.

The design of geometric models for object shapes, in particular, is occasionally

called computer-aided geometric design (CAGD)

USES:

Computer-aided design is one of the many tools used by engineers and designers and
is used in many ways depending on the profession of the user and the type of software
in question.

CAD is one part of the whole Digital Product Development (DPD) activity within
the Product Lifecycle Management (PLM) processes, and as such is used together
with other tools, which are either integrated modules or stand-alone products, such as:

• Computer-aided engineering (CAE) and Finite element analysis (FEA)

• Computer-aided manufacturing (CAM) including instructions to Computer

Numerical Control (CNC) machines

• Photorealistic rendering and Motion Simulation.

• Document management and revision control using Product Data

Management (PDM).

CAD is also used for the accurate creation of photo simulations that are often required
in the preparation of Environmental Impact Reports, in which computer-aided designs
of intended buildings are superimposed into photographs of existing environments to
represent what that locale will be like, where the proposed facilities are allowed to be
built. Potential blockage of view corridors and shadow studies are also frequently
analyzed through the use of CAD.

CAD has been proven to be useful to engineers as well. Using four properties which
are history, features, parameterization, and high-level constraints. The construction
history can be used to look back into the model's personal features and work on the
single area rather than the whole model. Parameters and constraints can be used to
determine the size, shape, and other properties of the different modelling elements.
The features in the CAD system can be used for the variety of tools for measurement
such as tensile strength, yield strength, electrical or electromagnetic properties. Also,
its stress, strain, timing or how the element gets affected in certain temperatures, etc.

TYPES:

There are several different types of CAD, each requiring the operator to think
differently about how to use them and design their virtual components in a different
manner for each.

There are many producers of the lower-end 2D systems, including a number of free
and open-source programs. These provide an approach to the drawing process without
all the fuss over scale and placement on the drawing sheet that accompanied hand
drafting since these can be adjusted as required during the creation of the final draft.

3D wireframe is basically an extension of 2D drafting (not often used today). Each

line has to be manually inserted into the drawing. The final product has no mass
properties associated with it and cannot have features directly added to it, such as
holes. The operator approaches these in a similar fashion to the 2D systems, although
many 3D systems allow using the wireframe model to make the final engineering
drawing views.
3D "dumb" solids are created in a way analogous to manipulations of real-world
objects (not often used today). Basic three-dimensional geometric forms (prisms,
cylinders, spheres, and so on) have solid volumes added or subtracted from them as if
assembling or cutting real-world objects. Two-dimensional projected views can easily
be generated from the models. Basic 3D solids don't usually include tools to easily
allow motion of components, set limits to their motion, or identify interference
between components.

There are two types of 3D Solid Modelling

• Parametric modelling allows the operator to use what is referred to as "design

intent". The objects and features created are modifiable. Any future
modifications can be made by changing how the original part was created. If a
feature was intended to be located from the centre of the part, the operator
should locate it from the centre of the model. The feature could be located
using any geometric object already available in the part, but this random
placement would defeat the design intent. If the operator designs the part as it
functions the parametric modeler is able to make changes to the part while
maintaining geometric and functional relationships.

• Direct or Explicit modeling provide the ability to edit geometry without a

history tree. With direct modelling, once a sketch is used to create geometry
the sketch is incorporated into the new geometry and the designer just
modifies the geometry without needing the original sketch. As with parametric
modelling, direct modelling has the ability to include relationships between
selected geometry (e.g., tangency, concentricity).

Top end systems offer the capabilities to incorporate more organic, aesthetics and
ergonomic features into designs. Freeform surface modelling is often combined with
solids to allow the designer to create products that fit the human form and visual
requirements as well as they interface with the machine.
CAD MODEL

DRAFT
REFERENCE
1] “Power Generation by Using Suspension System” by Himanshu S. Rewatkar,
Vicky R. Gedekar, Kunal L. Parate

2] “Power Generation through Rack & Pinion in Suspension System for an

Automobile” by G.P.Dhalwar , T.A.Jadhav

3] “Energy Generating Suspension System for Commercial Vehicles", by M. B.

Shaiju, Mukul Mitra.

4] “Magnetic Suspension System with Electricity Generation”, by Daspute

Sharad G. ,Deshmane Shubham M , Dhage Prashant P. , Gaikwad VaibhavJ,
Prof. Mali Pravin K