Vehicle suspension systems have been extensively explored in the past decades, contributing to ride comfort, handling and safety improvements. The new generation of powertrain and propulsion systems, as a new trend in modern vehicles, poses significant challenges to suspension system design. Consequently, novel suspension concepts are required, not only to improve the vehicle’s dynamic performance, but also to enhance the fuel economy by utilizing regeneration functions. However, the development of new-generation suspension systems necessitates advanced suspension components, such as springs and dampers. This Ph.D. thesis, on the development of hybrid electromagnetic dampers is an Ontario Centres of Excellence (OCE) collaborative project sponsored by Mechworks Systems Inc. The ultimate goal of this project is to conduct feasibility study of the development of electromagnetic dampers for automotive suspension system applications. With new improvements in power electronics and magnetic materials, electromagnetic dampers are forging the way as a new technology in vibration isolation systems such as vehicle suspension systems. The use of electromagnetic dampers in active vehicle suspension systems has drawn considerable attention in the recent years, attributed to the fact that active suspension systems have superior performance in terms of ride comfort and road-handling performances compared to their passive and semi-active counterparts in automotive applications. As a response to the expanding demand for superior vehicle suspension systems, this thesis describes the design and development of a new electromagnetic damper as a customized linear permanent magnet actuator to be used in active suspension systems. The proposed electromagnetic damper has energy harvesting capability. Unlike commercial passive/semi-active dampers that convert the vibration kinetic energy into heat, the dissipated energy in electromagnetic dampers can be regenerated as useful electrical energy. Electromagnetic dampers are used in active suspension systems, where the damping coefficient is controlled rapidly and reliably through electrical manipulations. Although demonstrating superb performance, active suspensions still have some issues that must be overcome. They have high energy consumption, weight, and cost, and are not fail-safe in case of a power break-down. Since the introduction of the electromagnetic dampers, the challenge was to address these drawbacks. Hybrid electromagnetic dampers, which are proposed in this Ph.D. thesis, are potential solutions to high weight, high cost, and fail-safety issues of an active suspension system. The hybrid electromagnetic damper utilizes the high performance of an active electromagnetic damper with the reliability of passive dampers in a single package, offering a fail-safe damper while decreasing weight and cost. Two hybrid damper designs are proposed in this thesis. The first one operates based on hydraulic damping as a source of passive damping, while the second design employs the eddy current damping effect to provide the passive damping part of the system. It is demonstrated that the introduction of the passive damping can reduce power consumption and weight in an active automotive suspension system. The ultimate objective of this thesis is to employ existing suspension system and damper design knowledge together with new ideas from electromagnetic theories to develop new electromagnetic dampers. At the same time, the development of eddy current dampers, as a potential source for passive damping element in the final hybrid design, is considered and thoroughly studied. For the very first time, the eddy current damping effect is introduced for the automotive suspension applications. The eddy current passive damper, as a stand-alone unit, is designed, modeled, fabricated and successfully tested. The feasibility of using passive eddy current dampers for automotive suspension applications is also studied. The structure of new passive eddy current dampers is straightforward, requiring no external power supply or any other electronic devices. Proposed novel eddy current dampers are oil-free and non-contact, offering high reliability and durability with their simplified design. To achieve the defined goals, analytical modeling, numerical simulations, and lab-based experiments are conducted. A number of experimental test-beds are prepared for various experimental analyses on the fabricated prototypes as well as off-the-shelf dampers. Various prototypes, such as eddy current and electromagnetic dampers, are manufactured, and tested in frequency/time domains for verification of the derived analytical and numerical models, and for proof of concept. In addition, fluid and heat transfer analyses are done during the process of the feasibility study to ensure the durability and practical viability of the proposed hybrid electromagnetic dampers. The presented study is only a small portion of the growing research in this area, and it is hoped that the results obtained here will lead to the realization of a safer and more superior automotive suspension system.

Vehicle suspension systems have been extensively explored in the past decades, contributing to ride comfort, handling and safety improvements. The new generation of powertrain and propulsion systems, as a new trend in modern vehicles, poses significant challenges to suspension system design. Consequently, novel suspension concepts are required, not only to improve the vehicle’s dynamic performance, but also to enhance the fuel economy by utilizing regeneration functions. However, the development of new-generation suspension systems necessitates advanced suspension components, such as springs and dampers. This Ph.D. thesis, on the development of hybrid electromagnetic dampers is an Ontario Centres of Excellence (OCE) collaborative project sponsored by Mechworks Systems Inc. The ultimate goal of this project is to conduct feasibility study of the development of electromagnetic dampers for automotive suspension system applications. With new improvements in power electronics and magnetic materials, electromagnetic dampers are forging the way as a new technology in vibration isolation systems such as vehicle suspension systems. The use of electromagnetic dampers in active vehicle suspension systems has drawn considerable attention in the recent years, attributed to the fact that active suspension systems have superior performance in terms of ride comfort and road-handling performances compared to their passive and semi-active counterparts in automotive applications. As a response to the expanding demand for superior vehicle suspension systems, this thesis describes the design and development of a new electromagnetic damper as a customized linear permanent magnet actuator to be used in active suspension systems. The proposed electromagnetic damper has energy harvesting capability. Unlike commercial passive/semi-active dampers that convert the vibration kinetic energy into heat, the dissipated energy in electromagnetic dampers can be regenerated as useful electrical energy. Electromagnetic dampers are used in active suspension systems, where the damping coefficient is controlled rapidly and reliably through electrical manipulations. Although demonstrating superb performance, active suspensions still have some issues that must be overcome. They have high energy consumption, weight, and cost, and are not fail-safe in case of a power break-down. Since the introduction of the electromagnetic dampers, the challenge was to address these drawbacks. Hybrid electromagnetic dampers, which are proposed in this Ph.D. thesis, are potential solutions to high weight, high cost, and fail-safety issues of an active suspension system. The hybrid electromagnetic damper utilizes the high performance of an active electromagnetic damper with the reliability of passive dampers in a single package, offering a fail-safe damper while decreasing weight and cost. Two hybrid damper designs are proposed in this thesis. The first one operates based on hydraulic damping as a source of passive damping, while the second design employs the eddy current damping effect to provide the passive damping part of the system. It is demonstrated that the introduction of the passive damping can reduce power consumption and weight in an active automotive suspension system. The ultimate objective of this thesis is to employ existing suspension system and damper design knowledge together with new ideas from electromagnetic theories to develop new electromagnetic dampers. At the same time, the development of eddy current dampers, as a potential source for passive damping element in the final hybrid design, is considered and thoroughly studied. For the very first time, the eddy current damping effect is introduced for the automotive suspension applications. The eddy current passive damper, as a stand-alone unit, is designed, modeled, fabricated and successfully tested. The feasibility of using passive eddy current dampers for automotive suspension applications is also studied. The structure of new passive eddy current dampers is straightforward, requiring no external power supply or any other electronic devices. Proposed novel eddy current dampers are oil-free and non-contact, offering high reliability and durability with their simplified design. To achieve the defined goals, analytical modeling, numerical simulations, and lab-based experiments are conducted. A number of experimental test-beds are prepared for various experimental analyses on the fabricated prototypes as well as off-the-shelf dampers. Various prototypes, such as eddy current and electromagnetic dampers, are manufactured, and tested in frequency/time domains for verification of the derived analytical and numerical models, and for proof of concept. In addition, fluid and heat transfer analyses are done during the process of the feasibility study to ensure the durability and practical viability of the proposed hybrid electromagnetic dampers. The presented study is only a small portion of the growing research in this area, and it is hoped that the results obtained here will lead to the realization of a safer and more superior automotive suspension system.

Damping in a multitude of engineering applications has a variable threshold requirement based on the input excitation given to the system. In most applications the desired system response is known but the input to the system is a time dependent function with fluctuating amplitudes and frequencies. Therefore for optimal performance the damping characteristics of a given system must be able to adapt to increase or decrease the amount of energy being absorbed by the system. In most mechanical systems (including vehicles) damping is achieved through a viscous medium; such as hydraulic oil. Although the oil is capable of absorbing the unwanted energy in the system, its passive nature limits its ability to achieve an optimal amount of damping given the excitation. To achieve the requisite functionality of variable damping; a multitude of solutions have been implemented, proposed, and evaluated at both commercial and academic research levels. These solutions have met the variable damping requirements but have significant cant drawbacks associated with them. To address the shortcomings associated with the aforementioned variable damping solutions, a hybrid design consisting of a conventional hydraulic damper and a linear motor topology was fused together to produce a hybrid variable damper. In this hybrid design, the oil in the system acts as bias and the linear motor topology allows for variability in the amount of damping being provided to the system. This hybrid design allows for the requisite variable damping requirement to be achieved. In addition to the hybrid design being able to achieve variable damping, it has the capacity to act as a generator and also provide fail-safe operation due to the viscous bias. Through analytical, FEM analysis and experimental modeling the hybrid damper has been characterized and with a high level of agreement between the various results. This work has also shown that the design is capable of achieving variable damping with the capacity to recover energy from the system.

Instead of dissipating vibration energy into heat waste via viscous damping elements, this dissertation proposes an innovative vibration control method which can simultaneously mitigate vibration and harvest the associated vibration energy using electromagnetic energy harvesters. This dissertation shows that the electromagnetic energy harvester can work as a controllable damper as well as an energy harvester. The semi-active control of a linear electromagnetic energy harvester, for improvement of suspension performance, has been experimentally implemented in a scaled-down quarter-car suspension system. While improving performance, power produced by the harvester can be harvested through energy harvesting circuits. This dissertation also proposes a mechanical-motion-rectifier(MMR)-based electromagnetic energy harvester using a ball-screw mechanism and two one-way clutches for the application of replacing the viscous damper in vehicle suspensions. Compared to commercial linear harvesters, the proposed design is able to provide large damping forces and increase power-dissipation density, making it suitable to vehicle suspensions. In addition, the proposed MMR-based harvester can convert reciprocating vibration into unidirectional rotation of the generator. This feature significantly increases energy-harvesting efficiency by enabling the generator to rotate at a relatively steady speed during irregular vibrations and improves the system reliability by reducing impact forces among transmission gears. Extensive theoretical and experimental analysis have been conducted to characterize the proposed MMR-based energy harvester. The coupled dynamics of the suspension system with the MMR-based energy harvester are also explored and optimized. Furthermore, a new control algorithm is proposed to control the MMR-based energy harvester considering its unique dynamics induced by the one-way clutches. The results show that the controlled proposed electromagnetic energy harvester can possibly improve ride comfort of vehicles over conventional oil dampers and simultaneously harvest the associated vibration energy. / Ph. D.

This study proposes various methods to harvest the mechanical energy present in railcar suspensions and railroad tracks to generate electricity that is suitable for onboard or trackside electronics, using electromagnetic generators. Compact electromagnetic energy harvesters that can be installed onboard railcars or wayside on railroad tracks are designed, fabricated, and tested. The designs integrate a mechanical motion rectifier (MMR) with embedded one-way clutches in the bevel gears in order to convert the bi-directional mechanical energy that commonly exists in the form of vibrations into a unidirectional rotation of the generator. The ball screw mechanism is configured such that it has reduced backlash and thus can more efficiently harvest energy from low-amplitude vibrations. Two prototype harvesters are fabricated and tested extensively in the laboratory using a suspension dynamometer and in the field onboard a railcar and on a test track. A power management system with an energy storage circuit has also been developed for this onboard harvester. The laboratory evaluation indicate that the harvesters are capable of harvesting power with sufficient current and voltage for successfully powering light electronics or charging a low demand battery pack. The harvested power varies widely from a few to tens of Watts, depending on the resistive load across the harvester and the amplitude and frequency of the mechanical motion. The laboratory test results are verified through field testing. One harvester is tested onboard a freight railcar, placing it across the wedge suspension, to use the small amount of relative displacement at the wedge suspension to harvest energy. A second harvester is placed on a test track to use the vertical motion that occurs due to passing wheels for wayside energy harvesting. Both onboard and wayside tests confirm the laboratory test results in terms of the success of the design concept in providing low-power electrical power. The harvester design is further integrated into a conventional railroad tie for ease of field installation and for improving the efficiency of harvesting the mechanical energy at the rail. The integrated design, referred to as the "smart tie," not only protects the energy harvester, the wiring harness, and supporting electronics from the maintenance-of-the-way equipment, but also positions the harvester in a mechanically advantageous position that can maximize the track-induced motion, and hence the harvested power. Although for testing purposes, the smart tie uses a modified composite tie, it can be integrated into other track tie arrangements that are used for revenue service track, including concrete and wooden ties. A prototype smart tie is fabricated for laboratory testing, and the results nearly surpass the results obtained earlier from the wayside harvester. The smart tie is currently being considered for revenue service field testing over an extended length of time, potentially at a railroad mega site or similarly suitable location. / Doctor of Philosophy / This dissertation proposes three different electromagnetic energy harvesters for harvesting railroad track and railcar suspension vibration energy. The concept is similar to what you may have seen in self-powering flashlights that are often advertised in late-night TV commercials. You shake the flashlight vigorously, which moves an energy harvester devoice and, Voila, the light bulb comes on. The device design in this study uses the mechanical energy that is present in a vehicle or at a railroad track to harvest the mechanical energy that is naturally present in the form of electrical energy, which can then be used for powering electronic devices and sensors of various kinds. Such sensors and electronics would help with improving the operational efficiency of railroads. The energy harvesters can be installed onboard a railcar or at the track. In either case, the movement of the train creates a small amount of vibration energy that is turned into electrical power. When onboard a train the power can be used for sensors, GPS, and similar devices to allow the operator to better monitor the condition and location of the train. Note that most railcars, especially the freight railcars, do not have any onboard electrical power. Similarly, the energy harvester can be installed at the track to convert the small amount of up and down motion that happens with the passing of each wheel into energy that could be used for integration of sensors that make the track "smarter." This means that the sensors can potentially alert the engineers who are responsible for monitoring the track of an existing or impending problem with the track. Both the railcar and track integration of the energy harvester that is designed, fabricated, and tested during this study are exciting concepts that can improve the rail industry in the U.S. This document includes the details of designing efficient energy harvesters, specifically for rail applications. A prototype of the energy harvester is fabricated and tested extensively in the lab and in the field, albeit to a more limited extent. The test results were quite successful, which is why I am telling you about them! Both the laboratory and field test results show that the device holds significant promise for rail applications.

The optical power of satellites such as the Hubble telescope is directly related to the size of the primary mirror. However, due to the limited capacity of the shuttle bay, progress towards the development of more powerful satellites using traditional construction methods has come to a standstill. Therefore, to allow larger satellites to be launched into space significant interest has been shown in the development of ultra large inflatable structures that can be packaged inside the shuttle bay and then deployed once in space. To facilitate the packaging of the inflated device in its launch configuration, most structures utilize a thin film membrane as the optical or antenna surface. Once the inflated structure is deployed in space, it is subject to vibrations induced mechanically by guidance systems and space debris as well as thermally induced vibrations from variable amounts of direct sunlight. For the optimal performance of the satellite, it is crucial that the vibration of the membrane be quickly suppressed. However, due to the extremely flexible nature of the membrane structure, few actuation methods exist that avoid local deformation and surface aberrations. One potential method of applying damping to the membrane structure is to use magnetic damping. Magnetic dampers function through the eddy currents that are generated in a conductive material that experiences a time varying magnetic field. However, following the generation of these currents, the internal resistance of the conductor causes them to dissipate into heat. Because a portion of the moving conductor's kinetic energy is used to generate the eddy currents, which are then dissipated, a damping effect occurs. This damping force can be described as a viscous force due to the dependence on the velocity of the conductor. While eddy currents form an effective method of applying damping, they have normally been used for magnetic braking applications. Furthermore, the dampers that have been designed for vibration suppression have typically been ineffective at suppressing structural vibration, incompatible with practical systems, and cumbersome to the structure resulting in significant mass loading and changes to the dynamic response. To alleviate these issues, three previously unrealized damping mechanisms that function through eddy currents have been developed, modeled and tested. The dampers do not contact the structure, thus, allowing them to add damping to the system without inducing the mass loading and added stiffness that are typically common with other forms of damping. The first damping concept is completely passive and functions solely due to the conductor's motion in a static magnetic field. The second damping system is semi-active and improves the passive damper by allowing the magnet's position to be actively controlled, thus, maximizing the magnet's velocity relative to the beam and enhancing the damping force. The final system is completely active using an electromagnet, through which the current can be actively modified to induce a time changing magnetic flux on the structure and a damping effect. The three innovative damping mechanisms that have resulted from this research apply control forces to the structure without contacting it, which cannot be done by any other passive vibration control system. Furthermore, the non-contact nature of these dampers makes them compatible with the flexible membranes needed to advance the performance of optical satellites. / Ph. D.

Este trabalho aborda a aplicação de uma máquina elétrica síncrona do tipo tubular linear de ímãs permanentes em um sistema de suspensão semiativa. O uso de amortecedores eletromagnéticos lineares em sistemas de suspensão não é uma ideia nova, mas a maioria dos trabalhos publicados sobre este assunto concebem soluções ativas e negligenciam as semiativas, sobretudo com estudos experimentais. Nesta pesquisa é discutido um modelo dinâmico eletromecânico acoplado de um sistema de suspensão semiativa, considerando um amortecedor eletromagnético linear e também apresentando dados experimentais. Leis da mecânica clássica e do eletromagnetismo são aplicadas para descrever o sistema que combina teoria de vibrações e máquinas elétricas. Um modelo virtual com vários subsistemas foi implementado no ambiente MATLABR /Simulink/Simscape para associar equações e simular o desempenho global. Para o caso passivo, os resultados numéricos e experimentais validam os parâmetros e confirmam a funcionalidade do sistema e a metodologia proposta. Simulações e testes experimentais para o caso semiativo são consistentes, mostrando uma melhoria na transmissibilidade de deslocamento, em relação ao modo passivo, e a possibilidade de regeneração de energia. / This work addresses the application of a tubular linear permanent magnet synchronous machine working as a damper for a semi-active suspension system. The use of linear electromagnetic dampers in suspension systems is not a new idea. However, most published papers on this subject outline active solutions and neglect semi-active ones, above all, with experimental studies. Here a dynamic mechanicalelectromagnetic coupled model for a semi-active suspension system is reported. This is in conjunction with a linear electromagnetic damper and also presents experimental data. Classical laws of mechanics and electromagnetics are applied to describe a dynamic model combining vibration and electrical machines theories. A multifaceted MATLABR /Simulink/Simscape model was implemented to incorporate equations and simulate global performance. For the passive case, numerical and experimental results validate the parameters and confirm system function and the proposed methodology. Simulation and practical results for the semi-active case are consistent, showing an improvement in the displacement transmissibility and the possibility of energy regeneration.

This master´s thesis is focused on obtaining electrical energy from vibration control car using electromagnetic dampers. The primary use of the electromagnetic damper is the production of electrical energy, which can then be used to power electrical appliances in your car or battery charging. The thesis is divided into six main parts: a literature review of possible ways of getting electricity from the car damping, theoretical and mathematical analysis of problems, the choice of design with computational analysis of dampers and power calculation.