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Prototype Design for Suspension Power Generation

Authors:

Mr. V. P. Mule¹, Chetan Koli², Suraj Panad³, Abhishek Waghmare⁴

¹Assistant Professor, Department of Electrical Engineering, Sinhgad Institute of Technology

²Student, Department of Electrical Engineering, Sinhgad Institute of Technology

³student, Department of Electrical Engineering, Sinhgad Institute of Technology

⁴student, Department of Electrical Engineering, Sinhgad Institute of Technology

Abstract - The project "Generating Electricity from Vehicle Suspension Using an Alternator" introduces an innovative system for capturing energy from the vertical motion of a vehicle's suspension. Conventional shock absorbers dissipate energy generated by road-induced vibrations as heat, resulting in energy loss. This project aims to recover this wasted energy by converting it into electrical power that can support on-board vehicle systems, such as battery charging, lighting, and auxiliary electronics.

Our design canters around a specialized mechanical setup that converts two-way linear motion from the vehicle suspension into one-way rotary motion. This is achieved using a crank and one-way bearing mechanism that transmits rotational energy in a single direction, regardless of the suspension's bidirectional movement. The rotary output is then directed into a 1:50 planetary gearbox to increase the rotation speed, enabling the alternator to operate efficiently within its optimal RPM range. The car alternator, rated at 14V and 90A, utilizes this stepped-up rotational speed to generate electrical power, which can be used to charge the battery and power auxiliary systems.

By converting mechanical suspension motion into a continuous, usable power source, this project demonstrates a practical and sustainable approach to energy recovery in automotive applications. The energy harvested can reduce vehicle reliance on external charging and improve overall energy efficiency, especially in electric and hybrid vehicles

Key Words:  regenerative suspension, energy harvesting, vehicle suspension system, car alternator, planetary gearbox, bidirectional to unidirectional conversion, automotive energy recovery, sustainable power generation, auxiliary system charging, crank mechanism