Design and development of a novel Four-Links rotational hybrid Energy-Harvesting suspension system compatible with conventional suspension technologies

[Display omitted] •A novel Four-Links Rotational Energy-Harvesting Shock Absorber (FL-EHSA) is presented.•Efficiency by transforming energy from shocks into electrical power is shown.•The system is Bench-tested for validating its energy recovery potential.•The FL-EHSA is designed for adaptable integration approach for existing vehicles.•Mathematic Equations for FL-EHSA design and dynamic modeling are provided. This study introduces a novel rotational Energy Harvesting Shock Absorber (EHSA), specifically designed for use alongside existing vehicle suspension systems. Addressing issues faced by standalone EHSAs, this design incorporates a four-bar mechanism coupled to a rotary energy recovery system. The proposed EHSA system, dubbed the FL-EHSA (Four Links Energy Harvesting Shock Absorber), is based on link connections and is highly versatile. It has the potential to significantly improve vehicle efficiency by harnessing energy usually wasted by traditional shock absorbers. Using a geometric definition process influenced by various factors such as vehicle suspension type and commercial availability of components, the FL-EHSA system was modeled, and bench-tested to validate the system’s energy recovery potential and performance. The movement of the mechanism was analyzed to achieve the target damping value matching the value of a conventional suspension and to maximize efficiency through DOE analysis and to avoid mechanical locking (singular positions). It explains the effect of backlash in mechanical components through simulation and highlights the importance of using dedicated gearboxes for energy recovery. In addition, this work highlights the untapped potential of four-bar mechanisms in automotive energy recovery applications. Moreover, the proposed design is easily integrated into any vehicle, making it a promising solution for EHSA systems.