Optimization and experimental study of a multi-configuration regenerative shock absorber for energy harvesting and ride comfort

Regenerative shock absorbers (RSAs) provide a promising way of recovering and utilizing waste energy of vehicle suspension. Simultaneously minimizing vibration and optimization of energy harvesting remain major challenges. The aim of this study was to minimize the vibrations of the suspension system in order to improve ride comfort and handling of vehicles under real road conditions by using optimally designed RSAs. This study focuses on optimizing the design of the RSA to simultaneously harvest maximum energy and enhance ride comfort. Multi-configurations of the RSA are investigated through experimental and simulation studies. An RSA incorporating a barrel cam follower mechanism was developed. These RSAs are made to transform vibrational energy produced during the vehicle motion into electrical energy which can be used to power the sensors and other devices. Furthermore, to optimize the designed RSA, identification of the parameters was carried out to observe its effect on system performance. Tuning was made through various parameters to make the prototype more efficient, compact, reliable, and accurate. Several lab-tests were carried out to investigate the performance of RSA with the different barrel cams such as (lead 32, 48, and 64 mm) at sinusoidal excitation the frequency (1–3 Hz) and amplitude (2.5 – 12.5 mm) with external load (3, 4 and 5 Ω). The Experiments show that the RSA with 32 mm lead of barrel performed satisfactorily with the highest efficiency of 74.21%. Also, the behavior of RSA was analyzed with the quarter-vehicle model considering ISO-classified road profile classes A, B, and C. Results show that RSA with 32 mm cam has higher road handling and ride comfort than the other RSAs. The implementation of RSA technology transforms the transportation by offering a paradigm shift toward self-sustainability and accompanying in a new era of eco-friendly and innovative transportation solutions. Highlights.