International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 11 | Nov 2025
p-ISSN: 2395-0072
www.irjet.net
Comparative Analysis of Regenerative Braking and Suspension-Based Energy-Harvesting Methods Arnav Kaul Independent Researcher, Mechanical & Automotive Systems, City, Country -------------------------------------------------------------------***-----------------------------------------------------------------------------ABSTRACT: Energy recovery in contemporary automobile This paper presents a comparative experimental and
analytical study of these two mechanisms and proposes a unique hybrid mechanism for energy recovery, which involves intermittent recovery of high-power braking energy and continuous recovery of energy harvested from suspension motion and road-induced vibrations.
design and development is important for improving fuel economy and overall carbon emissions. This project makes an experimental comparison between two complementary energy-recapture schemes, regenerative braking and suspension-based vibration harvesting. We developed and tested a prototype using a rackand-pinion DC motor generator, full-wave rectifier, capacitor-based voltage stabilizer and LED-load module as the regenerative suspension system under controlled vibration frequencies of 5–15 Hz. A peak power output of 150 W was recorded from a single regenerative suspension damper at a test frequency of 12 Hz, while a regenerative-braking simulator produced instantaneous peaks of approximately 2 kW. The test results showed that braking systems are delivering intermittent energy at much higher instantaneous levels, while suspension harvesting systems were operating at continuous, lowamplitude power levels appropriate only for auxiliary loads. A hybrid regenerative system can be designed that combines both suspension harvesting and regenerative braking systems that can yield energy efficiency improvements of almost 10 % in vehicle energy efficiency when combined.
2. Literature Review 2.1 Regenerative-Braking Systems Clegg [4] gave one of the first comprehensive reviews of regenerative-braking technologies, stating the operating constraints of system weight, costs, and durability for mechanical, hydraulic, and electrical architectures for heavy vehicles. Ehrhan et al. [5] proposed new hybrid and battery-electric vehicle topologies that improve energydistribution strategies using bidirectional converters. Experimental test results reported peak recovery efficiencies greater than 70 %. Fu [6] conducted an extensive review of electromagnetic regenerative braking technologies and proposed a modeling of energy transfer based on the torque–speed relation (P=Tω). Simulation results indicate effective recapture of energy from kinetic losses. Anh et al. [7] fine-tuned control algorithms for highefficiency regenerative braking systems using real-time torque feedback that can achieve smoother braking torque profiles while providing better battery charge acceptance. Li et al. [8] presented a game-theory-based adaptive braking controller that adapts to optimize the balance between driver comfort and the recuperation of energy for regenerative braking. Szumska [9] summarized two decades of evolution of regenerative braking systems, with emphasis on the push to hybridize battery storage with a supercapacitor to accommodate higher power transients. Eltaweel et al. [10] showed a flywheel energy-storage system (FESS) that can achieve short-term power spikes up to 300 kW but also indicated exacerbated gyroscopic-effect issues with compact vehicles.
Keywords—Regenerative braking, suspension harvesting, energy harvesting, DC generator, vibration energy, automotive efficiency.
1. Introduction Energy lost during braking and through suspension vibrations is still one of the largest inefficiencies in ground vehicles. According to the International Energy Agency (IEA, 2023), approximately 25–30 % of total automotive energy will be dissipated as heat energy during deceleration and structural damping [1]. Regenerative systems are being developed to recover this lost energy and convert it to usable electrical output for extending range and support auxiliary electronics. Regenerative-braking (RBS) technology is increasingly common in all-electric and hybrid vehicles, in which traction motors act as generators during deceleration [2]. RBS can recover hundreds of kilowatts for short peaking periods, but braking events are sporadic and the overall energy recovery is small. On the other hand, suspensionbased harvesters can convert vibrations induced by the road into electrical energy, converting energy into electric energy via electromagnetic or piezoelectric transducers [3]. While suspension harvesters have lower power density than regenerative braking, they can operate continuously, enabling a steady and reliable energy source.
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Research in regenerative braking has reached maturity with respect to optimization of control, lightweight energy storage devices, and hybridization of systems. The challenges that remain are in the mass of the systems, battery degradation when pulsed charged, and component costs. 2.2 Suspension-Based Energy Harvesting Xie [11] developed a dual-mass piezoelectric suspension harvester capable of generating 40 mW at 10 Hz for
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