DESIGN, ANALYSIS AND FABRICATION OF REGENERATIVE AUTOMOTIVE

SUSPENSION SYSTEM TEST RIG MODULE

RAZLAN BIN RAZALI

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

SUPERVISOR DECLARATION

“I hereby declare that I have read this thesis and in my opinion, this report is

sufficient in terms of scope and quality for the award of the degree of

Bachelor of Mechanical Engineering (Automotive)”

Signature : ...................................

Supervisor : DR MOHD AZMAN BIN ABDULLAH

Date : ...................................

DESIGN, ANALYSIS AND FABRICATION OF REGENERATIVE AUTOMOTIVE SUSPENSION SYSTEM TEST RIG MODULE

RAZLAN BIN RAZALI

This report is submitted in partial

fulfillment of the requirements for the award

Bachelor of Mechanical Engineering (Automotive)

Faculty of Mechanical Engineering

Universiti Teknikal Malaysia Melaka

JUNE 2015

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DECLARATION

“I hereby declare that the work in this thesis is my own except for summaries and

quotations which have been duly acknowledged.”

Signature : ...................................

Author : RAZLAN BIN RAZALI

Date : ...................................

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Special to

Beloved Mom and Dad

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ACKNOWLEDGEMENT

First of all, I am so thankful and grateful to my Allah The Almighty God for giving

me this life and health in order to complete my final year project. I have had help every

time I encounter many problems and difficulties before and during the completion of the

project. Another essential part of my gratitude and respect goes to my supervisor which is

Dr. Mohd Azman bin Abdullah and my co-supervisor, En. Herdy bin Rusnandi. They had

shown exemplary guidance, monitoring, and encouraging me to complete the project

successfully. Their good value will be my essential key to go through the working

experience after this. I also would like to thank to Mr. Muhammad Afiq Arfan bin Kamal,

the one who helped to open up the Perodua Myvi car and getting the data that I needed.

Not to forget, all the fourth year students of Bachelor of Mechanical Engineering

(Automotive) for giving me moral support and help when I need their opinion regarding

to my project. Besides that, my family whom have supported me in financial and moral

support throughout the year. Furthermore, to my housemate, Thaqif bin Hat, Aizat Hazraf,

and Mohd Junaidi bin Yusof for their help. Last but not least, to those who have

contributed directly or indirectly to the success of this thesis whom I have not mentioned

their name specifically. Without all of them, there will be no success to this thesis. I really

appreciate them all.

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ABSTRACT

The quantity of vehicle nowadays is increasing rapidly from year to year, the

automotive sector has undergone a new era by producing hybrid vehicle. The definition

of a hybrid is a vehicle utilizes more than one form of on-board energy to achieve

propulsion. This means that a hybrid will have an internal combustion engine and fuel

tank as usual car, but also will have one or more electric motors and a battery pack. This

project is about the energy regenerative suspension system (EReSS). As we know when

the car is moving, it would produce waste energy in the suspension system which will be

wasted. Normally, this waste energy is dumped in a form of thermal energy in

conventional of mechanical shock absorber. This project is about harnessing the energy

and convert it to useful energy such as electrical energy to charge the battery pack by

using the electromagnet concept. Every time vehicle move on the broken or cracked

profile road, then the suspension system will move upward and downwards in vertical

motion. The motion will cause the magnet to move together with the absorber. As the

result of the process, magnetic flux occurs due to the presence of coil copper wire around

the housing which will produce electricity through the copper wires. The main target of

this project is to draw EReSS using CATIA V5R20 software and do deformation analysis

of the model. Then, fabricate the test rig module was fabricated so that it can be used in

the future.

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ABSTRAK

Jumlah kenderaan pada masa kini meningkat dengan pesat dari tahun ke tahun.

Sektor automotif telah memasuki era baru dengan menghasilkan kenderaan hibrid.

Definisi hibrid adalah sesebuah kenderaan yang mempunyai lebih daripada satu tenaga

untuk menggerakan kenderaan tersebut. Ini bermakna sebuah kenderaan hibrid akan

mempunyai enjin pembakaran dalaman dan tangki minyak seperti mana kenderaan biasa

yang lain tetapi akan juga mempunyai satu atau lebih motor elektrik dan pek bateri. Projek

ini adalah mengenai sistem tenaga penyerap hentakan regeneratif. Seperti mana yang kita

ketahui, apabila kereta bergerak, kereta tersebut akan menghasilkan sisa tenaga yang

terbuang dalam penyerap hentakan. Kebiasaannya, sisa tenaga ini akan berbentuk sebagai

tenaga haba dalam penyerap hentakan mekanikal. Projek ini akan menggunakan tenaga

tersebut dan menukarkannya kepada tenaga yang boleh diguna pakai seperti tenaga

elektrik untuk mengecas pek beteri dengan mengguakan konsep electromagnet. Apabila

kenderaan bergerak di atas jalan yang rosak atau retak, sistem penggantungan akan

bergerak dari atas ke bawah dalam keadaan menegak. Gerakan ini akan mengakibatkan

magnet tersebut untuk bergerak bersama dengan penyerap hentakan. Hasil daripada

gerakan tersebut, fluk magnet akan terhasil disebabkan oleh kehadiran gegelung wayar

tembaga disekeliling perumahan yang akan menghasilkan tenaga elektrik melalui wayar

tembaga. Tujuan utama projek ini adalah untuk melukis seluruh sistem penggantungan

EReSS menggunakan perisian CATIA V5R20 dan mengkaji perubahan bentuk selepas

meletakkan daya ke atas model tersebut menggunakan perisian yang sama. Selepas itu,

membuat fabrikasi ke atas model tersebut akan dibuat.

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TABLE OF CONTENTS

CHAPTER TITLE PAGES

DECLARATION ii

DEDICATION iii

ACKNOWLEDGEMENT iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENT vii

LIST OF TABLE x

LIST OF FIGURE xi

LIST OF SYMBOLS xiv

LIST OF ABBREVIATION xv

LIST OF APPENDICES xvi

CHAPTER 1 INTRODUCTION 1

1.0 Introduction 1

1.1 Problem Statement 2

1.3 Objective 2

1.4 Scope of Project 3

1.6 Summary 3

CHAPTER 2 LITERATURE REVIEW 4

2.0 Introduction 4

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2.1 Vehicle Suspension System 4

2.1.1 Background of suspension 4

2.1.2 Purpose of the Suspension System 6

2.1.3 Component of Suspension System 6

2.1.4 Spring 7

2.1.5 Shock Absorber 9

2.1.6 Types of Suspension System 11

2.2 Magnet 15

2.3 Electromagnet 16

2.3.1 Introduction of Faraday’s Law 17

2.3.2 Faraday’s Law Concept 17

2.4 Resistivity of Conductor 18

2.5 Past Research on Energy

Regenerative System 19

2.6 Previous Research Result 21

2.7 Test Rig 22

2.8 Stress Analysis 22

2.9 CATIA Software 23

CHAPTER 3 METHODOLOGY 24

3.1 Background Study 24

3.2 Flowchart 25

3.3 Gantt Chart 27

3.4 CATIA Drawing 29

3.4.1 Sketch 29

3.4.2 Dimension 30

3.4.3 Installation of EReSS to Perodua Myvi

Suspension System 31

3.4.4 Part by Part of the Design 32

3.4.5 Spring 32

3.4.6 Energy Regenerative Suspension System

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(EReSS) 34

3.4.7 Shock Absorber 39

3.4.8 Initial Design 40

3.4.9 Final Design 41

3.5 Perodua Myvi Specification 43

3.6 Fabrication of Test Rig Module 44

CHAPTER 4 FABRICATION AND ANALYSIS 45

4.1 Introduction 45

4.2 Fabrication 45

4.2.1 Material 46

4.2.2 Shearing Machine 46

4.2.3 Bending Machine 47

4.2.4 Welding Machine 48

4.2.5 The Drill Machine 50

4.2.6 Grinder Machine 52

4.2.7 The Assemble of Product 53

4.3 Analysis 55

4.3.1 Calculation Value of C1 and C2 55

4.3.2 Calculation of Force 57

4.3.3 Deformation Analysis and Safety Factor 58

CHAPTER 5 DISCUSSION 61

CHAPTER 6 CONCLUSION 64

6.1 Conclusion 64

6.2 Recommendation 65

REFERENCES 66

APPENDICES 69

x

LIST OF TABLE

NO TITLE PAGES

3.1 Gantt Chart for The First Semester 27

3.2 Gantt Chart for The Second Semester 28

3.3 Perodua Myvi Specification 43

4.1 Mass of Vehicle Without Driver 56

4.2 Safety Factor 58

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LIST OF FIGURE

NO TITLE PAGES

2.1 The Basic Component of The Suspension System 5

2.2 Coil Spring Made From Tapered Rod 7

2.3 The Leaf Spring 8

2.4 The Torsion Bar 8

2.5 The Air Spring 9

2.6 Construction of a Simple Shock Absorber 9

2.7 Shock Absorber Mounted and Assembly With The Coil

Spring

10

2.8 Double Wishbone Suspensions 11

2.9 McPherson Strut Suspensions 12

2.10 Bags and Strut 13

2.11 Multi-Link Suspensions 14

2.12 Trailing-Arm Suspensions 15

2.13 Electromagnetic Induction 16

2.14 The Resistivity of Material 18

2.15 The Regenerative Brakes 21

2.16 Diameter coil = 0.8 mm at 40 Hz 21

2.17 Diameter coil = 0.5 mm at 40 Hz 21

2.18 Test Rig 22

3.1 CATIA Software V5R20 24

3.2 The Flow Chart 25

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NO TITLE PAGES

3.3 The Dimension of Each Component in The Perodua

Myvi Car

29

3.4 Taking The Dimension 30

3.5 Jack Up The Perodua Myvi Car and Remove The Tire 30

3.6 Installation of EReSS at Suspension System of Perodua

Myvi

31

3.7 Exploded View 32

3.8 Assembly of Spring 32

3.9 Top Cap 33

3.10 Bottom Cap 33

3.11 Spring 33

3.12 Assembly of EReSS 34

3.13 Exploded View of EReSS 34

3.14 Housing 35

3.15 Magnet Configuration 35

3.16 Aluminium Main Shaft 36

3.17 Aluminium Barer Shaft 36

3.18 Magnet Holder 37

3.19 Top Cap 37

3.20 Bottom Cap 37

3.21 Inner Block 38

3.22 Holder Bracket 38

3.23 Shock Absorber 39

3.24 Assembly of Initial Design 40

3.25 Exploded View of Initial Design 41

3.26 Assembly of Last Design 42

3.27 Exploded View of Last Design 42

3.28 Side View of Perodua Myvi 44

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NO TITLE PAGES

3.29 Mild Steel 46

4.1 Mild Steel (Thickness 3mm) 46

4.2 (a) The Front Side Shearing Machine (b) The Back Side

Shearing Machine

46

4.3 Cutting The Mild Steel 47

4.4 The Steering if Bending Machine 47

4.5 (a) Bending Process (b) The Work Piece of Bottom

Mounting

48

4.6 The MIG Welding Machine 48

4.7 (a) Spring Weld Top and Bottom Cape (b) Cape is

Being Weld With Screw

49

4.8 Top Mounting Being Weld 49

4.9 Drill Machine and its Component 50

4.10 (a) Smaller Screw Being Drill (b) Larger Screw 50

4.11 Oil to Cold The Area and Extend Lifespan of Screw 51

4.12 Spring Attach to The Bottom Mounting 51

4.13 (a) The Grinder Machine (b) The Cylinder Rod is Being

Cut to Four Similar

52

4.14 (a) Bottom Mounting Assemble (b) Top and Bottom

Mounting

53

4.15 Complete Assemble of The Test Rig Module 54

4.16 (a) The Side from EReSS (b) The Side From Spring 54

4.17 Perodua Myvi Wheelbase 54

4.18 Data of Vehicle Mass With Drive 56

4.19 Lower Mounting (Displacement) 59

4.20 Lower Mounting (Von Misses) 59

4.21 Upper Mounting (Displacement) 60

4.22 Upper Mounting (Von Misses) 60

xiv

LIST OF SYMBOLS

N = Newton

˚C = Degree Celsius

Hz = Frequency

V = Volt

% = Percentage

kg = Kilogram

mm = Millimeters

W = Weight

F = Force

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LIST OF ABBREVIATION

EReSS = Energy Regenerative Suspension System

KERS = Kinetic Energy Recovery System

CATIA = Computer Aided Three-dimensional Interactive Application

EMF = Electromotive Force

DASYLab = Data Acquisition System Laboratory

MATLab = Matrix Laboratory

COG = Centre of Gravity

xvi

LIST OF APPENDICES

NO. TITLE PAGE

A Different Angle View of Complete Fabrication 70

B Drafting Drawing Test Rig Module

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CHAPTER 1

INTRODUCTION

1.0 INTRODUCTION

Today’s world is full of technologies and commitment, the need of a person to

be at one place after another is a must. Therefore, a vehicle is a necessity for a person

to do such thing.

Harvesting energy from vibration is one of the most promising technologies.

There were researches to figure out where energy is being wasted in a moving vehicle.

Some hybrid cars are already recovering the energy from breaking. Therefore, the

research interest had been searching elsewhere and narrowed down on the suspension

system. There were different types of car models, which had been attached sensors to

the suspension, to determine energy potential and then recorded the sensor data from

laptop computers. The test revealed that a significant amount of energy was being

wasted in conventional suspension system (Zuo & Tang, 2013).

The waste energy will be used for good, this Energy Regenerative Suspension

System (EReSS) is designed to change the waste energy to form another type of energy

which is electrical energy. The energy then can be used by attempted system. For this

project, we can use the electrical energy to recharge the battery pack. The energy

conversion that will take place is from kinetic energy to electrical energy. In order to

convert this energy, electromagnetic concept is implemented. The magnet will be used

to generate electricity by moving the magnet inside the coil for the regenerative

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system. This project is to make sure that the test rig module will be used in the future

to compare the data and increase the voltage by research.

1.1 PROBLEM STATEMENT

There was waste energy produced in suspension system while travelling. This

project is to ensure that the waste energy produced from the vibration of suspension

system can be used for something useful. This Energy Regenerative Suspension

System (EReSS) can change the waste energy which is kinetic energy created by the

movement of suspension due to the condition of the road surface to electrical energy

using the theory of electromagnet. This voltage from EReSS can be used to recharge

the battery pack. Unfortunately the voltage produced is in small scale. Therefore,

mathematical models should be developed in order to make a simulation so that the

parameter can be changed and run easily. Therefore, this test rig module is essential

to be used in comparison to EReSS being put at Perodua Myvi to find ways to increase

the voltage in the future.

1.2 OBJECTIVE

The objective of this project are to design, to do analyze and fabricate the

EReSS test rig module.

1.3 SCOPE OF PROJECT The scope of this project is to do the drawing of suspension system with the

three main components which are spring, absorber and EReSS using CATIA V5R20

software. After that, deformation analysis will be done using the CATIA V5R20

software. Then, fabrication will be done using mild steel to produce the top and lower

mounting of the suspension system for test rig module.

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1.4 SUMMARY In this chapter, the introduction, background, problem statement, objective and

scope of the project are being described. The EReSS should be implanted to the future

vehicles. This is to ensure that we can use the waste energy for good purposes. This

one invention would leads to the development of the green technologies that the world

needed right now.

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CHAPTER 2

LITERATURE REVIEW

2.0 INTRODUCTION

The regenerative energy from the suspension is the method that uses energy

resulting from the vibration of the vehicle while driving on the road. The kinetic energy

can be converted into useful energy such as electrical energy. The electrical energy

can be used to recharge the battery pack. The product that's being designed in this

project is called as “Energy Regenerative Suspension System” (EReSS). Based on the

study that had been done, the profile of the road surface in this country, mostly bumpy,

uneven and cracked which will help to produce vibration in the vehicle while driving.

Therefore, the energy regenerative vibration can be produced. This chapter will discuss

the vehicle suspension system, the use of magnets and coil to produce regenerative

energy.

2.1 VEHICLE SUSPENSION SYSTEM

2.1.1 Background of Suspension

The suspension of the vehicle has been traditionally designed to have a

compromise between the three factors of conflicting criteria. The three factors are

passenger comfort, load carrying and road holding. The suspension system needs to

support the vehicle, provide the effective isolation of passenger or payload from the

road disturbance and give the proper directional control during handling maneuvers.

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The thing needed to give good ride comfort is soft suspension, while insensitivity to

applied loads requires stiff suspension. So to give good handling of the vehicle, it

would require a suspension setting between the soft and stiff. The ability to store

energy via a spring and to dissipate the energy via a damper is called as passive

suspension system. While the ability to store, dissipate and to introduce energy to the

system is called as an active suspension system. So due to the demands of consumers,

the suspension need to be designed as something of a compromise. Usually, it will be

determined by the type of use for which the vehicle was designed. Figure 2.1 shows

an example of the vehicle suspension system.

Figure 2.1: The basic component of the suspension system (Source: Hdabob, 2009)

In the early 19th century, British horse carriage has a spring suspension system

installed in their design. Made of low-carbon steel, the spring suspension system took

the form of multi-layer leaf spring. However, the British spring suspension system is

not suitable for American carriage design due to the rough road condition. In 1820’s,

an antique suspension system, the coaches were supported on a leather strap that give

a swinging motion instead of up and down movement caused by the spring suspension

system (Uniquecar, 1999).

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As the innovation of auto development, the steed drawn enhancing vehicles

into fueled by interior burning motor, the suspension framework utilized for the

carriage was esteemed out of date because of the distinction in velocity since the

suspension framework for the carriage is inadmissible for motor controlled vehicle.

The suspension framework was later modify by Mors of Paris in 1901, when the car

organization fitted a safeguard to their vehicle. Henri Fournier won the prestigious

Paris-to-Berlin race on the twentieth of June 1901 because of this change.

Torsion bar was presented as a component of the suspension framework in

1921 via Leyland Motors. In 1922, independent front suspension was utilized as part

of the outline of Lancia Lambda and get to be regular in mass business sector vehicle

since 1932.

2.1.2 Purpose of the Suspension System

The suspension system is located between the wheel axles and the vehicle body

or frame. The purpose of suspension system are to support the weight of the vehicle,

to maintain the traction between the tires and the road, cushion bumps and hole in the

road and hold the wheels in alignment.

The suspension system allows the vehicle to travel over rough surfaces with a

minimum of up and down body movement. Besides that, it will also allow the vehicle

to corner with minimum roll to lose the traction between the road surfaces and the

tires. This provides a cushioning action so road shocks have a minimal effect on the

occupants and load in the vehicle. Road shock is the result of action from tires moving

up and down as they meet bumps or holes in the road.

2.1.3 Component of Suspension System

The component of suspension system includes the spring and all the related

parts that support the weight of the vehicle body on the wheels and axles. The main

part of suspension system is the shock absorber and springs. The shock absorber will

help to control the spring action, while the spring will support the weight of the vehicle