Optimal design of an integrated electromagnetic linear energy regenerative suspension system based on a hybrid optimization objective

The regenerative suspension plays an important role in reducing the energy consumption of vehicle. This paper proposes an optimized design of an Integrated Electromagnetic Linear Energy Regenerative Suspension System (IELERS) to capture the energy dissipated by traditional vehicle suspension systems. The IELERS employs a moving-coil electromagnetic linear actuator instead of conventional dampers. This actuator provides damping force to reduce vibration while also recovering kinetic energy generated by the suspension’s reciprocating motion. The IELERS features two operational modes: energy regeneration and Linear Quadratic Regulator (LQR) controlled active damping. Suspension system models were developed for each mode. In the energy regeneration mode, structural parameters of the IELERS were optimized by establishing a dimensionless hybrid optimization objective. This objective balances comfort and safety probabilities, resolving conflicts in suspension performance indicators and inconsistencies in dimensional scales. The integration of the Taguchi method with the neighborhood particle swarm algorithm improved optimization efficiency, while multi-condition optimization ensured adaptability across various driving scenarios. Finally, the dynamic performance changes of the IELERS before and after optimization were analyzed, and a prototype was developed for bench experiments. The results indicate that the optimized IELERS improves ride comfort without compromising handling stability. Compared with the energy regeneration mode, the body acceleration and suspension working space in active damping mode decreased by 22.5% and 33.8%, respectively, while tire dynamic deformation increased by 25%. Under Class B road, the vehicle suspension system generates average energy regeneration powers of approximately 63 W at a driving speed of 72 km/h.