Design and experiment study of a semi-active energy-regenerative suspension system

A new kind of semi-active energy-regenerative suspension system is proposed to recover suspension vibration energy, as well as to reduce the suspension cost and demands for the motor-rated capacity. The system consists of an energy-regenerative damper and a DC-DC converter-based energy-regenerative circuit. The energy-regenerative damper is composed of an electromagnetic linear motor and an adjustable shock absorber with three regulating levels. The linear motor just works as the generator to harvest the suspension vibration energy. The circuit can be used to improve the system's energy-regenerative performance and to continuously regulate the motor's electromagnetic damping force. Therefore, although the motor works as a generator and damps the isolation without an external power source, the motor damping force is controllable. The damping characteristics of the system are studied based on a two degrees of freedom vehicle vibration model. By further analyzing the circuit operation characteristics under different working modes, the double-loop controller is designed to track the desired damping force. The external-loop is a fuzzy controller that offers the desired equivalent damping. The inner-loop controller, on one hand, is used to generate the pulse number and the frequency to control the angle and the rotational speed of the step motor; on the other hand, the inner-loop is used to offer the duty cycle of the energy-regenerative circuit. Simulations and experiments are conducted to validate such a new suspension system. The results show that the semi-active energy-regenerative suspension can improve vehicle ride comfort with the controllable damping characteristics of the linear motor. Meanwhile, it also ensures energy regeneration.