ELECTROMAGNETIC ACTIVE SUSPENSION

FOR LIGHT-WEIGHT VEHICLES

A Technical Project Report

Submitted in partial fulfilment of the

requirements for the award of the degree
of
Bachelor of Technology
In
Mechanical Engineering
By

ZUBIN PARIDA Regd. No. 2111100239

JAGRUTI RATH Regd. No. 2111100301
DEBASIS KHUNTIA Regd. No. 2111100313
DINESH KU. SOREN Regd. No. 2111100340

under the guidance of

PROF. JITENDRA NAIK

SCHOOL OF MECHANICAL SCIENCES

ODISHA UNIVERSITY OF TECHNOLOGY AND RESEARCH
BHUBANESWAR
APRIL,2025

© 2025 OUTR Bhubaneswar. All rights reserved

 School Of Mechanical Sciences
Odisha University of Technology and Research
Bhubaneswar, Odisha

CERTIFICATE OF APPROVAL

Certified that the project entitled " ELECTROMAGNETIC ACTIVE

SUSPENSION FOR LIGHT-WEIGHT VEHICLES", submitted by Mr.
Zubin Parida (Registration No.2111100239), Ms. Jagruti Rath
(Registration No.2111100301), Mr. Debasis Khuntia (Registration
No.2111100313), Mr. Dinesh Ku. Soren (Registration No.2111100340) to
the School of Mechanical Sciences, Odisha University of Technology and
Research, for the partial fulfilment of the degree of Bachelor of Technology
has been accepted.

……………………………………. …………………………………….

Signature Signature
Prof. Jitendra Naik Prof. Saroj Ku. Pradhan
(Supervisor) (Head of School, SMS)
 DECLARATION

We certify that
a) The work contained in this project report is original and has been done
by us under the guidance of our supervisor.
b) The work has not been submitted to any other Institute for any degree
or diploma.
c) We have followed the guidelines provided by the Institute in preparing
the project report.
d) We have conformed to the norms and guidelines given in the ethical
code of conduct of the Institute.
e) Whenever we have used materials (data, theoretical analysis, figures,
and text) from other sources, we have given due credit to them by citing
them in the text of the project report and giving their details in the
references. Further, we have taken permission from the copyright
owners of the sources, whenever necessary.

Signature of the students

 Acknowledgement
We would like to extend our heartfelt thanks to our guide, Prof. Jitendra Naik of the
Department of Mechanical Engineering, whose expertise and insightful guidance have been
instrumental throughout the development of this project. The patience and knowledge of
our guide have also been a cornerstone of our progress.
Our sincere appreciation goes to the Head of the School of Mechanical Sciences, Dr. Saroj
Ku. Pradhan, for providing the facilities and conducive environment necessary for our
research.
We are also grateful to the faculty members and technical staff of the department, whose
assistance and advice have been crucial in the successful completion of our project.
Lastly, we would like to thank everyone who directly or indirectly contributed to the success
of this project, as every bit of support has been a step towards our goal.

Zubin Parida (2111100239)

Jagruti Rath (2111100301)
Debasis Khuntia (2111100313)
Dinesh Ku. Soren (2111100340)
OUTR Bhubaneswar
26 April 2025
 ABSTRACT

This project introduces an advanced Electromagnetic Active Suspension (EMAS) system,

designed to enhance the performance and comfort of heavy luxury vehicles such as Volvo
buses and goods carrier trucks. The EMAS system actively reduces road-induced vibrations
and noise, ensuring a smoother and quieter ride for passengers. By minimizing impact forces
transmitted to the chassis, the system enhances the durability of critical vehicle components,
including tires and suspension elements. Furthermore, dynamic load distribution across all
wheels improves vehicle balance and stability during acceleration, braking, and cornering,
significantly boosting overall performance.

The integration of EMAS with Advanced Driver Assistance Systems (ADAS) enables seamless
support for automated driving functions, such as adaptive cruise control and emergency
braking, improving safety and operational efficiency. This project highlights the potential of
electromagnetic suspension technology in transforming vehicle dynamics while promoting
sustainability through reduced wear and energy-efficient operation. By combining innovative
engineering and advanced technology, the EMAS system exemplifies the future of modern
suspension systems in heavy-duty transportation.

Keywords: electromagnetic suspension, dynamic load distribution, noise reduction, vehicle

durability, ADAS integration.
 LIST OF ABBREVIATIONS

Abbreviations Meanings

1. EMAS Electro-magnetic Active Suspension

2. ADAS Advance Driver Assistance System
3. ECU Electronic Control Unit
4. MR Magnetorheological Dampers
5. LVDT Linear Variable Displacement Transducer
6. PCB Printed Circuit Board
7. FR4 Flame Retardant 4
8. PVC Polyvinyl Chloride
9. PID Proportional-Integral-Derivative
10. M Mass of the vehicle with passenger
11. g Acceleration due to gravity
12. F Weight of the vehicle
13. µ Magnetic permeability
14. I Current in electro-magnet
15. N No. of turns in the coil
16. A Cross-section of the wire
17. x Gap between the disc and electromagnet
18. Fm Force induced by the magnet
19. P Power
20. R Resistance
21. dc Diameter of the coil
22. k Spring stiffness
23. Ꟙ Deflection
24. fn Ride frequency
25. MPC Model Predictive Control
26. MEMS Micro-Electro-Mechanical Systems
27. Lu Length of the upper cylinder
28. Du Diameter of the upper cylinder
29. Ll Length of lower cylinder
30. Dl Diameter of lower cylinder
31. d Diameter of plates
32. t Thickness of plates
33. ds Diameter of the spring
34. ls Length of the spring
35. V Voltage in Electromagnet
36. C Lifting Capacity of Electromagnet
37. H Model height
38. L Model length
39. W Model Width
 LIST OF TABLES

Chapter No. Table No. Table caption Page No.

3 3.1 Comparison of the different

vehicle suspension
4 4.1 Components used in electromagnetic
active suspension mechanism
4.2 Electrical components used in the
model
5 5.1 Values of various parameters of a
EMAS
8 8.1 Findings of the testing
9 9.1 Cost of materials and components
used in the model
 LIST OF FIGURES

Chapter No. Figure No. Figure Caption Page No.

1 1.1 General leaf spring

Suspension

1.2 Coil Spring

Shock Absorber

1.3 Pneumatic air

Suspension

1.4 Magnetic Suspension

5 6.1 3D Model of EMAS

6.2 Front isometric

6.3 Front View & back view

6.4 top & bottom view

6.5 Sectional View

6.6 Electromagnet

6.7 Exploded View

7 7.1 Circular Electromagnet

7.2 Spring used in the suspension

7.3 Sensor and circuit testing

7.4 Suspension welded

7.5 Electronic integration

7.6 Testing of the project

8 8.2 Distance between road and sensor (x)

 TABLE OF CONTENT

Title Page No.

CERTIFICATE i
DECLARATION ii
ACKNOWLEDGEMENT iii
ABSTRACT iv
LIST OF ABBREVIATIONS v
LIST OF TABLES vi
LIST OF FIGURES vii

CHAPTER 1: INTRODUCTION 1
1.1: Preamble
1.2: Overview
1.3: History
1.4: Objective
1.5: Problem statement
1.6: Scope of the report

CHAPTER 2: LITERATURE REVIEW

CHAPTER 3: THEORETICAL BACKGROUND

3.1: Basics of suspension mechanism
3.2: Fundamentals of Electro-magnetic suspension mechanisms
3.3: Key components and their functions
3.4: Mechanism and working principle of electromagnetic
active suspension

CHAPTER 4: COMPONENT SPECIFICATIONS

4.1: Materials used in model

CHAPTER 5: MATHEMATICAL FORMULATION

5.1: Design assumption
5.2: Calculation and findings for the suspension

CHAPTER 6: CAD SIMULATION AND DEVELOPMENT

CHAPTER 7: FABRICATION AND TESTING

7.1: Testing Procedure
7.2: Functioning of electro-magnetic active suspension
7.3: Fabrication process of EMAS
7.4: Advantages of Electromagnetic Active Suspension
CHAPTER 8: RESULTS & DISCUSSIONS

CHAPTER 9: COST ESTIMATION AND ANALYSIS

CHAPTER 10: FUTURE SCOPES

CHAPTER 11: CONCLUSION

REFERENCES
 CHAPTER-1
INTRODUCTION
1. INTRODUCTION

1.1 Preamble
Suspension technology has always played a pivotal role in the advancement of vehicle
dynamics and passenger comfort. With the growing demands of modern transportation,
traditional passive and semi-active suspension systems are no longer sufficient to meet
expectations in comfort, safety, and performance. Electromagnetic Active Suspension (EMAS)
emerges as a cutting-edge solution, offering a leap forward in suspension control using
electromagnetic actuators and intelligent control systems. Much like how fusion welding
revolutionized metal joining with its efficiency and versatility, EMAS is redefining vehicular
suspension by enabling real-time response to road conditions, especially in heavy-duty and
luxury vehicles. Though the system offers remarkable advantages, including enhanced ride
quality and adaptability, it also presents engineering challenges in terms of control complexity,
power management, and system integration—making it a compelling area for exploration and
innovation.

1.2 Overview

The modern transportation industry is constantly evolving to address challenges such as

passenger comfort, vehicle performance, and sustainability. In this context, Electromagnetic
Active Suspension (EMAS) systems offer transformative potential, especially for heavy luxury
vehicles like Volvo buses and goods carrier trucks. By leveraging electromagnetic forces,
EMAS delivers precise control over suspension dynamics, providing several critical
advantages over traditional suspension systems.
Vibration and Noise Reduction: One of the primary goals of EMAS is to actively cancel out
road-induced vibrations and noise. Unlike traditional passive or semi-active suspension
systems, EMAS utilizes electromagnetic actuators to adapt in real-time, creating a smoother
and quieter ride for passengers. This improvement is especially crucial for luxury buses and
long-haul goods carriers, where ride quality directly impacts passenger satisfaction and cargo
safety.

Enhanced Component Durability: By reducing the impact forces transmitted to the vehicle's
chassis and suspension components, EMAS significantly extends the lifespan of critical parts,
such as tires, shock absorbers, and linkages. This minimizes maintenance costs and ensures
long-term operational reliability.
Dynamic Load Distribution: EMAS actively manages load distribution across all wheels,
improving vehicle stability and performance during cornering, acceleration, and braking. By
maintaining optimal wheel-to-road contact, the system enhances control and safety, especially
under heavy loads or uneven terrain.

Support for Advanced Driver Assistance Systems (ADAS): The integration of EMAS with
Advanced Driver Assistance Systems (ADAS) marks a significant advancement in vehicle
automation and safety. The suspension system works in harmony with adaptive cruise control,
emergency braking, and other automated functions, ensuring a seamless driving experience
while reducing risks associated with human error.

The EMAS system replaces traditional mechanical springs and dampers with a combination of
sensors, electromagnetic actuators, and control systems. These actuators generate
electromagnetic forces to counteract road-induced vibrations and disturbances, allowing for
immediate and precise adjustments to the suspension.

EMAS is particularly suited for heavy luxury vehicles (e.g., Volvo buses) and goods carriers,
where load distribution and ride comfort are paramount. Its adaptability makes it valuable
across various industries, from transportation and logistics to high-performance sports cars.

Despite its advantages, the adoption of EMAS faces challenges such as high development costs,
energy consumption, and system complexity. However, advancements in materials, control
algorithms, and power efficiency are paving the way for broader implementation. Future
iterations of EMAS could incorporate renewable energy sources, making it even more
sustainable and cost-effective.In summary, Electromagnetic Active Suspension redefines
vehicle dynamics by combining cutting-edge technology with engineering innovation. Its
ability to deliver superior comfort, safety, and efficiency positions it as a vital component of
modern and future automotive design.

1.3 History

Electromagnetic Active Suspension (EMAS) represents a significant evolution in vehicle

suspension systems, with its origins tracing back to the ongoing quest for improved ride
comfort, stability, and handling. The development of EMAS is rooted in decades of
advancements in mechanical engineering, electronics, and control systems.
1. Early Developments in Suspension Systems
The first suspension systems, developed in the late 19th century, used mechanical springs to
absorb road shocks. These systems were purely passive, relying on fixed components like leaf
springs or coil springs to dampen vibrations. By the mid-20th century, hydraulic and pneumatic
suspensions emerged, introducing semi-active control to improve comfort and stability.
2. The Emergence of Active Suspension
In the 1970s and 1980s, automotive researchers began exploring the idea of active suspension
systems. These systems used actuators and sensors to dynamically adjust suspension
characteristics in real-time, providing better performance than passive systems. Early examples
included hydro-pneumatic and electrohydraulic systems, which demonstrated significant
improvements in ride quality and handling but were limited by high energy consumption and
mechanical complexity.
3. Transition to Electromagnetic Technology
The concept of Electromagnetic Active Suspension began gaining traction in the 1990s, as
advances in electromagnetics and microprocessor technology made the idea feasible. Unlike
hydraulic or pneumatic systems, EMAS relies on electromagnetic actuators, which are faster,
more precise, and require fewer mechanical components. These actuators use electromagnetic
forces to counteract road disturbances, providing real-time adjustments for superior ride
control.
4. Key Milestones in EMAS Development
 1990s: Initial research and development into electromagnetic suspension began, with
prototypes demonstrating the potential for improved performance and reduced noise.
 2000s: Automakers and research institutions started developing more sophisticated
EMAS prototypes. Audi and Bose Corporation played significant roles in advancing
this technology. Bose, in particular, developed an innovative electromagnetic
suspension system that showcased unparalleled ride smoothness and stability, although
it never reached mass production due to high costs.
 2010s: The automotive industry shifted its focus toward integrating active suspension
systems with electronic control units (ECUs) and sensors, including ADAS
technologies. EMAS systems were tested in high-performance and luxury vehicles to
improve handling, comfort, and safety.
 Present Day: Continued advancements in materials, energy-efficient actuators, and AI-
based control algorithms have made EMAS more viable. While still a premium
 technology, it is increasingly seen as a key component of future transportation systems,
especially for electric and autonomous vehicles.

5. Challenges and Research Areas

Throughout its development, EMAS has faced challenges, including high manufacturing costs,
energy demands, and complexity. Ongoing research focuses on addressing these issues by:
 Improving energy efficiency through regenerative braking and energy recovery
systems.
 Reducing production costs with advanced materials and simpler designs.
 Enhancing control algorithms to maximize the system's responsiveness and reliability.

Fig 1.1 General leaf spring [4] Fig 1.2 Coil Spring [5]

Fig 1.3 Pneumatic air suspension [6] Fig 1.4 Magnetic Suspension [7]
1.4 Objective

The primary objective of this project is to design an Electromagnetic Active Suspension

(EMAS) system tailored for heavy luxury vehicles, such as Volvo buses and goods carrier
trucks, to enhance ride comfort, safety, and durability through the integration of advanced
electromagnetic technologies. The system aims to achieve the following:

1. Reduce Vibrations and Noise:

 Develop an active suspension system utilizing electromagnetic actuators to
counteract road-induced vibrations in real-time.
 Enhance passenger comfort and minimize cabin noise levels, contributing to a
quieter and smoother travel experience, particularly critical for long-haul
journeys.

2. Enhance Vehicle Component Durability:

 Mitigate the transmission of impact forces to the vehicle’s chassis and
components, thereby reducing wear and tear on critical parts like tires,
suspension elements, and linkages.
 Extend the service life of vehicle components, minimizing maintenance costs
and downtime.

3. Ensure Dynamic Load Distribution:

 Design the suspension system to actively distribute loads dynamically across
all wheels, ensuring balanced performance during acceleration, braking, and
cornering.
 Improve vehicle stability and control, reducing the risk of rollovers and
enhancing overall safety.

4. Support Advanced Driver Assistance Systems (ADAS):

 Integrate the suspension system with ADAS technologies to enhance
automated driving functions such as adaptive cruise control, lane-keeping
assist, and emergency braking.
 Ensure seamless interaction between the suspension system and electronic
control systems for improved safety and driver assistance.

5. Optimize Energy Efficiency:

  Explore energy-efficient electromagnetic actuator designs to minimize power
consumption without compromising performance.
 Incorporate regenerative capabilities to harness energy from vehicle dynamics
and reduce reliance on external power sources.

6. Promote Scalability and Applicability:

 Develop a modular suspension system design that can be adapted for various
vehicle types, including heavy-duty trucks, luxury buses, and electric vehicles.
 Ensure compatibility with future advancements in electric and autonomous
vehicle technologies.

Expected Outcomes:
The successful design of the EMAS system will provide:
 A highly adaptive suspension solution capable of delivering superior ride quality and
comfort for heavy luxury vehicles.

 Increased durability of vehicle components, reducing operational costs for fleet

operators.

 Enhanced safety and performance, particularly for vehicles operating under varying
load and road conditions.

 A technological foundation for future innovations in suspension systems and

autonomous driving support.

This project embodies a forward-looking approach to modern transportation challenges,

combining mechanical ingenuity and electronic intelligence to redefine vehicle dynamics and
passenger experience.

1.5 Problem statement

Developing an electromagnetic active system would probably involve tackling the following
major obstacles:

1. High Energy Consumption: Electromagnetic actuators typically require significant energy

to generate the forces needed to control suspension dynamics, especially for heavy vehicles.
Maintaining energy efficiency is a critical concern to avoid excessive power consumption,
particularly for electric or hybrid vehicles.
2. Cost of Materials and Manufacturing: The components needed for EMAS, including
electromagnetic actuators, sensors, and control units, can be expensive to manufacture, making
the system costly to produce and implement. The high cost of raw materials (e.g.,
electromagnets) may increase the overall price of the vehicle.

3. System Complexity and Integration: Designing and integrating the complex components
of the EMAS, such as electromagnetic actuators, sensors, and real-time control systems,
requires sophisticated engineering and software development. Integrating EMAS with existing
vehicle systems, including ADAS (Advanced Driver Assistance Systems), further complicates
the development process.

4. Control System Development: The electromagnetic actuators and sensors need to be

durable and resistant to environmental factors like heat, moisture, and road debris. The
longevity of the system is vital for minimizing maintenance and ensuring a long lifecycle for
both the vehicle and the suspension system.

5. Road Condition Variability: Road conditions can vary significantly (e.g., potholes, bumps,
uneven surfaces), and the suspension system needs to respond dynamically to these conditions.
The system must be capable of reacting instantly to changes in road surface while maintaining
vehicle stability.

1.6 Scope of the report

This report offers a thorough overview of the entire project, including the design and
construction process, theoretical underpinnings, operational principles, testing protocols, and
result analysis. The development and integration of the suspension and sensor, energy
harvesting via the electro-magnets, and the addition of sustainable energy to improve the
suspension’s functionality will be the main areas of focus. It discusses the advantages of self-
adjusting levels of suspension at any hinderance on road, including improved traction, fuel
efficiency, and reduced risk of vehicle instability. It also describes how the electromagnetic
set-up with sensor and active adjusting suspension design work together to create a more
efficient and user-friendly vehicles and discuss any engineering challenges and solutions in
integrating these technologies.
The report will delve into the technical aspects of the innovative suspension propulsion system,
outlining the design specifications, materials used, methodologies employed, and the
performance metrics obtained through testing. Additionally, the report will discuss the
implications of the project's findings and explore avenues for future research and development
in the field of active suspension propulsion.

It paves the path for future developments in both suspension technology and less-power
consumption integration, highlighting the opportunities of integrating creative mechanical
design with sustainable energy practices. The seamless integration of this auto adjusting
suspension system eliminates the need for manual intervention, fostering a hassle-free and
enjoyable riding experience.

This convergence of mechanical ingenuity and electrical integration transcends the boundaries
of traditional suspension design. Beyond the realm of transportation, it encapsulates sustainable
energy capture and utilization, embodying a step towards eco-friendly commuting solutions.
 CHAPTER-2
LITERATURE REVIEW
2. LITERATURE REVIEW
2.1 Conventional Suspension systems:

Conventional suspension systems are integral components of automotive engineering, designed

to provide comfort, stability, and control for vehicles. These systems have evolved over time,
with several key types used in modern vehicles. Types of a conventional suspension system:
MacPherson Strut, L Suspension and Torsion Baon.

2.2 Limitations of conventional suspensions:

Conventional suspension systems offer a balance between comfort and handling. Systems like
the double wishbone allow for better handling, while leaf springs provide durability and load-
bearing capacity but at the cost of ride quality. The main trade-off is between comfort (smooth
ride) and performance (handling and stability). A simple systems like MacPherson struts are
less expensive and easy to maintain, more complex setups like double wishbones and leaf
springs require more frequent maintenance and are susceptible to wear. The durability of
suspension components is influenced by factors such as road conditions, vehicle load, and
driving behaviour. A suspension can struggle under extreme conditions, such as off-road terrain
or heavy payloads. Systems like air suspension or adjustable shock absorbers are introduced to
address these limitations in specific applications, such as off-road or commercial vehicles.

2.3 Emerging Trends:

Advancements in materials, such as lightweight alloys and composites, have led to the
development of stronger, more efficient suspension systems. Additionally, adjustable or semi-
active suspensions are increasingly used to provide a more adaptive solution for varying road
conditions and driving scenarios. However, despite these advancements, conventional systems
still dominate the market due to their proven reliability, simplicity, and cost-effectiveness.

The concept of Electromagnetic Active Suspension Systems (EAMS) was developed by several
scientists and engineers to address the shortcomings of traditional suspension systems,
particularly in terms of ride comfort, handling, and the ability to adapt to varying road
conditions. The principle behind EAMS lies in the use of electromagnetic forces to actively
control the suspension system's stiffness and damping, providing a more responsive and
adaptable solution than passive suspension systems. Review may highlight any challenges or
limitations associated with shaft drive systems for bicycles and discuss potential areas for
future research and improvement. The idea of using electromagnetic forces in suspension
systems emerged in the late 20th century, drawing from the field of active vibration control.
Electromagnetic actuators were already being used in other areas of engineering, such as in
active noise cancellation and vibration isolation, and the idea was adapted for suspension
systems.

One of the first and notable examples of this research comes from Smith et al. (2005)[9], who
designed an electromagnetic active suspension system aimed at improving vehicle ride quality
and handling. Their system employed electromagnetic actuators to replace traditional hydraulic
dampers and springs, which allowed for real-time, adaptive adjustments to suspension
properties based on road conditions and vehicle dynamics.

2.4 Active suspension systems integrated into heavy vehicles:

Research on active suspension systems integrated into heavy vehicles, such as buses, trucks,
and other commercial vehicles, has been a subject of considerable interest in recent years.
While most of the active suspension research has traditionally focused on passenger cars and
sports vehicles, there is growing interest in applying similar systems to heavy vehicles for
improved ride comfort, stability, and performance. The integration of active suspension in
heavy-duty vehicles offers significant advantages, especially in terms of reducing road-induced
vibrations, improving safety, and extending the life of critical vehicle components. Here are
some notable research efforts and studies related to this topic:

1. Electromagnetic Active Suspension for Heavy Vehicles:

 Research Focus: A study by Barbosa and Jang (2015) [14] explored the integration of
electromagnetic active suspension systems (EMAS) in heavy-duty trucks. Their
research demonstrated that by using electromagnetic actuators, the suspension could be
actively controlled to reduce vibration and improve load distribution, thereby
enhancing ride comfort and vehicle stability. The study showed that active suspension
systems could effectively counteract road-induced forces, reducing shock loads on
vehicle components.

Key Findings: The study indicated that electromagnetic active suspension could extend
the lifetime of truck components, reduce maintenance costs, and enhance load handling
by distributing weight more efficiently. However, they also identified significant
challenges such as power consumption and the complexity of control systems.
2. Hydraulic Active Suspension for Commercial Vehicles:

 Research Focus: Another approach to active suspension in heavy vehicles involves

hydraulic active systems. Palanisamy et al. (2007)[15] examined the use of hydraulic
actuators integrated into the suspension systems of heavy buses. Their work showed
that active suspension could be used to dynamically adjust the suspension's damping
force in real-time, improving both ride comfort and vehicle handling.

 Key Findings: The integration of hydraulic active suspension allowed for real-time
adjustment of the suspension based on road conditions. The study concluded that this
system could significantly reduce vibration levels within the cabin, improving
passenger comfort in buses and enhancing driver safety in trucks by reducing the effects
of road irregularities.

2.5 Advanced Strategies: Self adjusting suspension system:

Electromagnetic Active Suspension Systems (EMAS) represent a significant advancement in

automotive suspension technology, offering the potential for enhanced ride quality, improved
handling, and the integration of adaptive performance features. Several studies have explored
the design, implementation, and practical challenges associated with EMAS, with notable
contributions from Smith et al. (2005) [13] and Jones and Martinez (2007) [13].

Smith et al. (2005)[9] were among the pioneers in the field of electromagnetic active
suspension, presenting one of the first comprehensive designs for such a system. Their research
primarily focused on improving ride comfort and vehicle handling by actively controlling the
suspension forces in response to road irregularities. The study outlined a system that utilized
electromagnetic actuators to vary the suspension force dynamically, thereby improving the
vehicle’s ability to isolate road shocks and vibrations.

However, while the theoretical design presented significant improvements in ride quality, the
study also identified key challenges that limited the immediate practical application of the
system. One of the primary concerns raised by Smith et al. was the high energy consumption
of the electromagnetic actuators. These actuators require substantial amounts of electrical
power to generate the necessary forces, especially when the system is operating in real-time
and continuously adjusting to road conditions. The increased energy demands of EMAS
systems led to concerns about their efficiency, particularly in relation to the additional power
requirements of the vehicle's electrical system.

Additionally, the complexity of the control algorithms was another major drawback discussed
by Smith et al. The researchers highlighted the need for highly sophisticated real-time control
mechanisms to ensure the system could respond promptly and accurately to dynamic road
conditions. This added complexity not only increased the cost of implementation but also raised
concerns about the system's reliability and long-term durability, as it would require constant
adjustments and recalibration in response to changing driving conditions.

Despite these challenges, Smith et al.'s study laid the groundwork for future developments in
EMAS, showing that while significant improvements in vehicle dynamics could be achieved,
practical constraints like energy efficiency and control system complexity needed to be
addressed for broader adoption.

In 2007, Jones and Martinez [13] conducted a comprehensive study on the integration of
electromagnetic suspension systems into conventional vehicle platforms. Their research aimed
to demonstrate the potential benefits of EMAS when integrated with existing vehicle
architectures, specifically focusing on improved road handling and ride comfort. They explored
how electromagnetic actuators could be used to provide active suspension control, adjusting
the suspension force based on real-time road conditions. This would theoretically enhance the
vehicle's ability to respond to both high-frequency disturbances (such as bumps) and low-
frequency ones (such as larger road undulations).

Jones and Martinez's research confirmed that EMAS could indeed improve vehicle
performance, particularly in terms of road handling. The ability to actively adjust the
suspension force allowed for better tire-road contact, improving stability and safety during
high-speed cornering, braking, and acceleration. Additionally, the active nature of the
suspension system offered better isolation from road-induced vibrations, enhancing the overall
comfort for passengers.

However, their study also highlighted several practical challenges that impeded the widespread
adoption of EMAS. One of the main issues identified was the increased system weight.
Electromagnetic actuators, along with the necessary power supply and control systems, added
significant weight to the vehicle, which in turn affected fuel efficiency and performance. The
additional weight was a particularly notable disadvantage for vehicles that were already heavy,
such as buses and trucks.
2.6 Sustainable Energy in Suspension Propulsion:

It is an emerging concept that integrates suspension systems with renewable energy

technologies to improve vehicle performance while reducing the environmental impact. The
idea focuses on using the suspension system not only to enhance the ride quality and vehicle
handling but also to generate, store, and utilize sustainable energy for propulsion or other
vehicle functions. This can be achieved by integrating energy-harvesting mechanisms with the
vehicle’s suspension, harnessing kinetic energy from motion or environmental sources.

2.7 Summary and Insights:

The research into integrating active suspension systems into heavy vehicles has shown
promising results in terms of improving ride comfort, vehicle stability, and load handling.
However, challenges related to energy consumption, system weight, and cost still hinder their
widespread adoption. Semi-active suspension systems offer a more cost-effective alternative
while still providing significant improvements in vehicle performance and comfort. Moving
forward, advancements in materials, control algorithms, and energy efficiency will likely play
a key role in making active suspension systems more viable for heavy vehicles, especially with
the growth of electric and autonomous vehicle technologies.
 CHAPTER-3
THEORETICAL
BACKGROUND
3. THEORETICAL BACKGROUND
3.1 Basics of suspension mechanism

A suspension system is a crucial component of a vehicle designed to absorb shocks, vibrations,

and provide stability while maintaining optimal tire contact with the road. It ensures a smooth
ride, improves vehicle handling, and enhances safety by controlling the impact forces between
the vehicle and the road surface.

Here’s an overview of the basic functions and components of a suspension system:

Purpose of Suspension System
The primary functions of a suspension system include:
1. Absorbing Shocks and Impacts: The system reduces the impact of road irregularities
(such as bumps, potholes, and debris) to minimize discomfort for the passengers and
protect the vehicle.

2. Maintaining Tire Contact: Ensures the tires stay in contact with the road for optimal
traction, which is essential for vehicle control, handling, and braking efficiency.

3. Enhancing Stability: The suspension helps to maintain vehicle balance, especially

during cornering, braking, or accelerating, preventing the vehicle from rolling over.

4. Improving Ride Comfort: By minimizing the effects of road disturbances, the

suspension system provides a smoother, more comfortable ride for passengers.

5. Vehicle Weight Support: The suspension supports the weight of the vehicle and its
passengers while maintaining the correct ride height and load distribution.

Components of Suspension System

A typical suspension system consists of several key components that work together to provide
comfort, handling, and safety:

1. Springs:

 Function: Springs are the primary components of the suspension system that absorb the
shocks from the road.
 2. Shock Absorbers (Dampers):
 Function: Shock absorbers control the rebound of the springs and dissipate the energy
generated by the springs compressing and expanding. Without shock absorbers, the
springs would continue to oscillate, leading to an uncomfortable ride.

3. Struts:
 Function: A strut is a structural component of the suspension system that combines the
function of a shock absorber and a spring. Struts are often found in the front suspension
of vehicles and are integral to the vehicle's suspension geometry.

4. Control Arms:
 Function: Control arms connect the wheel hub to the vehicle’s chassis and allow the
wheels to move up and down while maintaining proper alignment. They help control
the vertical movement of the suspension.

5. Sway Bars (Anti-roll Bars):

 Function: Sway bars reduce body roll when cornering by linking the left and right
suspension systems. They help maintain stability by preventing excessive tilting or
leaning of the vehicle during turns.

6. Ball Joints:

 Function: Ball joints connect the control arms to the steering knuckles and allow for
movement of the wheels. They serve as pivot points, enabling the wheels to move up
and down and turn left and right.

7. Bushings:

 Function: Bushings are made of rubber or polyurethane and are used to cushion and
reduce friction between metal components, such as between the suspension arms and
the chassis.

Disadvantages of conventional suspension system:

i. Limited Adaptability, conventional systems (e.g., passive springs and dampers) are not
capable of adapting to changing road conditions.
ii. Conventional suspension systems cannot dynamically adjust to road irregularities They
cannot be utilized in situations requiring precise motion.
 iii. Conventional systems do not effectively manage body roll during cornering, which can
lead to stability issues, especially in heavy vehicles or during aggressive driving.
vi. As conventional systems don't actively adjust to vehicle load or road conditions,
components like tires and suspension parts experience greater wear and tear over time.

3.2 Fundamentals of active suspension mechanisms

An active suspension system continuously adjusts the forces exerted by the suspension
components (such as springs and dampers) to improve vehicle stability, handling, and comfort.
The system uses electronic or hydraulic actuators to change the suspension's stiffness, damping,
and ride height based on real-time input from various sensors that monitor vehicle dynamics,
road conditions, and driver inputs.
Active suspension systems represent a significant leap forward in vehicle suspension
technology, offering enhanced performance, improved ride comfort, and better handling
compared to conventional passive suspension systems. Though they come with challenges,
such as higher cost and complexity, their ability to adapt to varying road conditions and driving
demands makes them a valuable innovation in the automotive industry, especially for high-
performance and luxury vehicles. As technology evolves, it's likely that active suspension
systems will become more common and affordable, offering even greater benefits to both
comfort and safety.
Advantages of active suspension mechanisms:
1. Improved Ride Comfort: Active suspension can adapt to road conditions in real-time,
providing a much smoother and more comfortable ride compared to conventional
suspension systems.
2. Enhanced Handling and Stability: By actively controlling the suspension, the system
can reduce body roll, squat, or dive during acceleration, braking, or cornering, resulting
in better vehicle handling and stability.
3. Increased Safety: Active suspension systems can optimize tire contact with the road,
improving traction and reducing the risk of accidents caused by unstable suspension
responses, especially under extreme driving conditions.
4. Vehicle Load Control: Active suspension systems can maintain optimal ride height and
load distribution, improving the vehicle's performance regardless of passenger or cargo
load.

However, there are some limitations and considerations with active suspension systems:
 1. Cost: Active suspension systems are generally more expensive than conventional
suspension systems, due to the complexity of the components (sensors, actuators, control
units) and the manufacturing costs.
2. Complexity and Maintenance: These systems are more complex, requiring specialized
maintenance and repair. If any component fails (e.g., actuators), it can significantly affect
vehicle performance.
3. Energy Consumption: While fully active systems are more efficient than passive ones, they
can still consume more energy, particularly hydraulic systems, which need a continuous
supply of fluid pressure.
4. Weight: Some active suspension systems, particularly hydraulic systems, can add weight
to the vehicle, which may reduce overall fuel efficiency.
Table3.1 Comparison of the different vehicle suspension

PARAMETERS PASSIVE SEMI-ACTIVE ACTIVE SUPENSION SYSTEM

SUSPENSION SUSPENSIONS Hydraulic/ Pneumatic Electro-magnetic
Structure Simplest Complex Most Complex Simple
Weight/Volume Lowest Low High Highest
Cost Lowest Low Highest High
Ride comfort Bad Medium Good Best
Handling Bad Medium Good Best
Reliability Highest High Medium High
Dynamic Passive Passive Medium Good

3.3 Key Components and their Functions:

3.3.1 Sensors:

Sensors are critical in active suspension systems as they provide real-time data about the
vehicle's dynamics and road conditions. The primary sensors include:

 Ride Height Sensors: Measure the distance between the vehicle's body and the wheels
to ensure optimal ride height. This allows the system to adjust the suspension to keep
the vehicle level.
  Accelerometers: Measure the vehicle's acceleration, including vertical (up-and-down)
and lateral (side-to-side) movements. This helps determine the amount of suspension
damping required.

 Wheel Speed Sensors: Monitor the speed at which each wheel is rotating. This data is
crucial for detecting variations in road conditions, such as bumps or obstacles, and
adjusting the suspension accordingly.

 Load Sensors: Measure the weight distribution across the vehicle and detect changes
in the load, such as during acceleration or braking, to optimize suspension performance.

 Damper Position Sensors: Monitor the position of the shock absorbers (dampers) to
adjust their behaviour in real time for precise control of ride quality and handling.

3.3.2 Actuators:

Actuators are the devices responsible for physically changing the suspension system in
response to the control signals from the system's brain. They allow for real-time adjustments
in the suspension settings, such as stiffness, damping, or ride height.
 Hydraulic Actuators: Use fluid pressure to control suspension force. They are
commonly used in high-performance systems due to their ability to deliver significant
force with precision. The fluid in the actuator adjusts the suspension in response to
vehicle inputs.
 Electric Actuators: Use electric motors to adjust the suspension. These are more
energy-efficient and lighter than hydraulic actuators and are increasingly used in
modern active suspension systems.
 Electromagnetic Actuators: These use electromagnetic forces to adjust suspension
characteristics. They can change the suspension's stiffness and damping characteristics
quickly and precisely.

3.3.3 Control Unit (Electronic Control Unit or ECU):

The ECU acts as the "brain" of the active suspension system. It processes data from the sensors,
evaluates the vehicle's current state, and sends commands to the actuators to adjust the
suspension parameters. The control unit works in real-time, making constant adjustments to
the system based on factors like:

 Road conditions
  Vehicle dynamics (e.g., acceleration, braking, cornering)

 Driver inputs (e.g., steering, throttle, braking)

The ECU uses sophisticated algorithms and control strategies (like PID controllers, fuzzy logic,
or machine learning) to calculate the optimal suspension setting that balances comfort and
handling.

3.3.4 Damping Components:

Damping is a key function in any suspension system, and in active systems, the damping
characteristics are dynamically controlled to optimize ride comfort and handling.

 Magnetorheological Dampers (MR Dampers): These are adjustable dampers that use
a magnetic field to control the viscosity of a fluid inside the damper. By varying the
magnetic field, the damper can be adjusted to provide different levels of resistance,
improving ride comfort and vehicle handling.

 Electromagnetic Dampers: These dampers use electromagnetic forces to control the

damping characteristics of the suspension. They offer faster response times and greater
control than traditional dampers.

 Adaptive Dampers: These dampers automatically adjust their performance based on

real-time inputs, such as road conditions or driving style, without needing external
control systems.

3.3.5 Suspension Springs

In active suspension systems, the spring elements are sometimes enhanced or controlled in
conjunction with the damper and actuator systems to allow real-time adjustments to the
suspension.

 Air Springs: Often used in active suspension systems, air springs can be inflated or
deflated to change the vehicle’s ride height or stiffness, providing better ride quality
and vehicle levelling.

 Variable Stiffness Springs: These springs can change their stiffness dynamically.
Some active suspension systems use materials or technologies that allow the spring
stiffness to be adjusted based on vehicle conditions.
3.3.6 Power Supply

Active suspension systems require a reliable and consistent power source. The power supply
provides energy to the actuators, sensors, and control units to enable them to function in real-
time.

 Electrical Power: Most modern active suspensions use electric actuators and electronic
control systems, so a stable electrical power source is needed, often from the vehicle’s
battery.

 Hydraulic Power: In systems with hydraulic actuators, the suspension relies on a

hydraulic pump and reservoir to provide pressure for actuator movement.

3.3.7 Communication System

The communication system links all components of the active suspension system, allowing the
sensors, actuators, control units, and power supply to work in unison. This can involve:

 Wired Communication: Communication cables are used to link sensors,

actuators, and the control unit, providing a stable and fast data transfer system.

 Wireless Communication: In some modern systems, wireless communication

(such as Bluetooth or CAN bus) may be used to provide flexibility in sensor
placement and reduce the overall weight of the system.

3.4 Mechanism and working principle of electromagnetic active suspension

3.4.1 Working Principle-:
Electromagnetic active suspension uses electromagnetic forces to dynamically adjust the
suspension system, providing real-time control override height and damping. It responds to
road conditions by actively controlling the interaction between the vehicle's chassis and wheels.

3.4.2 Mechanism-:
• The electromagnetic active suspension consists of 4 Mild steel plates out of which 2 are
fixed by pins and 2 are freely moving arranged in series. The 2 movable plates are
mounted on a single shaft.
• The housing consists of 2 hollow cylinders which are merged with each other .It also
consists of 2 springs attached at the upper end and the lower end of the 2 cylinders
respectively .
• The electromagnet is attached on the 1st Fixed MS- Plate which is further attached with
Arduino Micro-controller and Ultrasonic sensors which will detect the obstacles on the
road.
• Now the signal from the sensors is sent to the Arduino Micro-controller and a current
is generated which will flow through the electromagnet . Hence a magnetic field will
develop .
• Now the electromagnet will attract the mild steel plate placed just below it. But as there
is a fixed MS- Plate above it , therefore it cannot move further. This will exert a force
on the upper spring . Thus, the upper spring will exert a force in the downward direction
. Now this is the case of single – acting EMAS when obstacle is small.
 CHAPTER-4
COMPONENT
SPECIFICATIONS
4. COMPONENT SPECIFICATIONS

4.1 Materials used in model:

a. Active suspension mechanism components
Table 4.1 Components used in electromagnetic active suspension mechanism
Components Material used specifications

Electromagnetic Actuators Silicon Steel(core) F=100-2000N

Copper wire(windings) V=12-48V
Response time=20ms to 100ms
Spring High-strength steel Spring rate=20–200 N/mm
Deflection(x)= 30–150 mm

Shock Absorbers aluminium alloys Fm=500–3000 N

Stroke length=50–250 mm
Response time=<10 ms for
real-time damping adjustments
Coils & Magnets coils: Copper 100–5000 turns(coils)
magnets: Rare-earth magnets
1–1.5 Tesla magnetic flux
density (Magnet)
b. Electrical Components:
Table 4.2 Electrical components used in the model
Component Material used Specifications

Sensors Accelerometers, Position MEMS-based, 0.1–10 m/s, 0–

Sensors (e.g., LVDT), 5000 N, ±250 to ±2000°/s
Velocity Sensors, Force
Sensors, Gyroscopes, Current
sensors
Control Unit/ECU PCB made of FR4 32-bit micro-controller, 1–4 GB
RAM, 16–64 GB storage, 12–48
V DC,
Battery Lithium, graphite (anode), 12V to 48V
nickel-cobalt-manganese 10–100 Ah
(cathode)
Jumper wires Copper core with PVC or 22–28 AWG
silicone insulation.
Length= 10–50 cm
 CHAPTER-5
MATHEMATICAL
FORMULATION
5. MATHEMATICAL FORMULATION

5.1 Design assumption

a. Outer Housing: 2 merged hollow cylinders, likely made of mild steel.
b. Shaft Material: High-tensile steel with a diameter of 12–20 mm, supporting movable
plates.
c. Fixed and Movable Plates: 4 mild steel plates with 2 fixed and 2 movable plates
mounted on a single shaft.
d. Electromagnet: Positioned below the upper spring to attract the adjacent mild steel
plate.

e. Ultrasonic Sensors: Detect road irregularities and obstacles in real-time.

f. Arduino Microcontroller: Processes sensor signals and dynamically controls current to
the electromagnet.
g. Response Time: Signal processing and current adjustments within 10–15 ms.
h. Shock Absorption: Upper and lower springs designed to absorb sudden loads without
exceeding 80% yield stress.

5.2 Calculation and findings for the suspension

 Let us consider the entire mass (M) of the vehicle (Volvo luxury bus) along with the
• mass of passengers = 16 tons.
• g (acceleration due to gravity) = 9.8 m/𝒔𝟐
• Weight force (F) = M×g = 16000×9.81 =156.96 KN.
 No. of suspension units -:
Let us assume vehicle has 4 suspension units (one for each wheel).
Force/suspension unit = F/4 = 156.96/4 = 39.24 KN.
 Magnetic force calculation -:
𝐴
Fm = µ × 𝐼 2 × 𝑁 2 × 2𝑥 2(MAGNETIC FORCE IN A COIL)

Where,
• µ = magnetic permeability = 𝟒 × 𝝅 × 𝟏𝟎−𝟕 T/mA
• I= current through the coil.
• N= no. of turns in the coil.
 • A= cross sectional area of coil.
• x= gap between electromagnet and disc.
 Let us assume initial values as I= 200 A , N= 1000 , A= 0.01 m2, x= 0.05m = 50 mm
0.01
Fm= 4 × 𝜋 × 10−7 × 2002 × 10002 × × 0.052
2

= 100.480 kN.
(This force is sufficient to support one suspension unit.)
 Power requirements -:
P= 𝐼 2 × 𝑅
Suppose resistance of coil is 1 ohm.
Thus P= 2002 × 1 = 40 kW.
Thus for 4 suspension units total power required = 40 × 4= 160 kW

Table 5.1 Table for the findings:

Sl.No. Parameter Symbol Value Unit
1 Force due to vehicle weight F 156.96 kN
2 Magnetic Force Fm 100.48 kN
3 Power in Unit Suspension P 40 kW
4 Current flowing I 200 A
5 Cross-sectional area A 0.01 m2
6 No. of turns in coil N 1000 -
7 Acceleration due to gravity g 9.8 ms-2
8 Magnetic Permeability µ 4π×10-7 T/mA

Design parameters of the suspension system:

Sl.No. Parameter Symbol Value Unit
1 Length of the upper cylinder Lu 304.8 mm
2 Diameter of the upper cylinder Du 38 mm
3 Length of lower cylinder Ll 228.6 mm
4 Diameter of lower cylinder Dl 40 mm
5 Diameter of plates d 36 mm
6 Thickness of plates t 8 mm
7 Diameter of the spring ds 25 mm
8 Length of the spring ls 150 mm
9 Voltage in Electromagnet V 12 V
10 Lifting Capacity of Electromagnet C 15 kg
11 Model height H 965.2 mm
12 Model length L 406.4 mm
13 Model Width W 355.6 mm
 CHAPTER-6
CAD SIMULATION
AND
DEVELOPMENT
6. CAD SIMULATION AND DEVELOPMENT

6.1 CAD model demonstration

6.1 Electro-magnetic active suspension

6.2 Front isometric View

(a) (b)
6.3 (a) and (b) are front and back view of the model respectively

(c) (d)
6.4 (c) and (d) are top and bottom view of the model respectively
 6.6 Electromagnet

6.5 Sectional View

6.7 Exploded View

 CHAPTER-7
FABRICATION
AND
TESTING
7.FABRICATION AND TESTING

7.1 Testing Procedure

Comprehensive testing is essential to ensure the Electromagnetic Active Suspension (EMAS)
system operates safely, efficiently, and reliably under real-world conditions. The testing
process is categorized into four critical areas: Safety Testing, Performance Testing, Durability
Testing, and Quality Assurance Testing.

a. Safety Testing
Safety is the foremost concern in any vehicular system, particularly for one as integrated as
EMAS. This phase ensures that no component poses a risk during installation, operation, or
failure scenarios.

1. Structural Integrity Check

All structural components, including the housing frame, movable and fixed mild steel
plates, and shafts, undergo rigorous visual inspections and non-destructive testing
(NDT) methods such as ultrasonic flaw detection and magnetic particle inspection.
These tests confirm the absence of cracks, manufacturing defects, or material
weaknesses that could compromise structural integrity.

2. Electromagnetic Component Testing

The electromagnetic coils and assemblies are tested under various operational loads to
monitor temperature rise, current draw, and magnetic field strength. Thermal imaging
and current sensors verify that overheating and short circuits do not occur during
prolonged use or high-intensity activation.

3. Sensor Verification
Ultrasonic sensors are assessed for their range, accuracy, and reliability under different
environmental conditions (dust, moisture, varying light levels). Benchmark testing with
calibrated objects ensures that obstacle detection remains within an acceptable error
margin.

4. Electrical Safety
All electrical connections are checked for proper insulation, secure soldering, and
compliance with voltage ratings. A multimeter and oscilloscope are used to identify
signal dropouts, short circuits, or power surges. Ground fault detection ensures user and
system safety.
b. Performance Testing
The true measure of EMAS lies in its functional performance across diverse terrain conditions
and vehicular scenarios.

1. Suspension Responsiveness
The system is subjected to dynamic simulations on a test track with varying surface
textures—gravel, asphalt, potholes, and speed bumps. High-speed data acquisition
systems record the time lag between obstacle detection and suspension adjustment.
Real-time responsiveness is critical for shock absorption and ride comfort.

2. Ride Comfort Analysis

Accelerometers and gyroscopes are mounted on the chassis to quantify vibration levels
and body motion. Data from the EMAS-equipped vehicle is compared to passive
suspension setups, focusing on parameters such as vertical acceleration, jerk, and cabin
noise levels. The goal is to provide a smooth, less fatiguing ride for occupants.

3. Comparison with Traditional Systems

Performance metrics from EMAS are benchmarked against conventional spring-
damper and hydraulic suspension systems. Parameters include handling performance,
body roll in cornering, pitch during acceleration or braking, and responsiveness over
sudden road disturbances.

c. Durability Testing
Durability ensures that EMAS can withstand continuous operational stresses without
degradation over time.

1. Fatigue Testing
A mechanical rig applies cyclical loads to the suspension system to simulate long-term
road impacts. This stress testing validates the system's endurance, identifying any
fatigue-prone components such as springs or weld joints after thousands of load cycles.

2. Component Wear Analysis

The system is operated over extended periods under varying loads to observe wear
patterns in mechanical and electromagnetic elements. Factors such as spring
deformation, coil degradation, and shaft play are documented for lifecycle prediction
and maintenance planning.
 3. Sensor Longevity
Ultrasonic sensors are tested in a controlled environment that mimics rain, dust, UV
exposure, and temperature fluctuations. Longevity is gauged based on retained
accuracy and functional reliability after continuous operation and harsh condition
exposure.

d. Quality Assurance Testing

Quality Assurance ensures that the final product is production-ready and adheres to defined
standards.
1. Compliance with Standards
All materials and manufacturing processes are reviewed for compliance with ISO, SAE,
or regional automotive standards. This includes dimensional tolerances, material
hardness, thermal resistance, and electromagnetic interference (EMI) limits.

2. Functional Testing
The fully assembled EMAS system undergoes operational verification through
complete test runs. All subsystems—sensor input, signal processing, magnetic
actuation, and spring damping—are monitored for synchronous operation and error-
free performance.

3. Error Resolution
Any detected performance anomalies are systematically diagnosed using debugging
tools, sensor recalibration, and mechanical readjustments. Post-correction testing
validates that all issues have been effectively resolved before final deployment.

7.2 Functioning of Electromagnetic Active Suspension

The Electromagnetic Active Suspension (EMAS) system represents a paradigm shift from
passive and semi-active suspension systems, offering real-time adaptability through
electromagnetic actuation and intelligent control.

1. Core Functional Principle

Unlike traditional suspensions that rely on mechanical resistance, EMAS actively controls
damping force and suspension height using electromagnets regulated by a microcontroller. The
system dynamically adapts to changing terrain and driving conditions, optimizing both ride
comfort and vehicle handling.
  Key Functional Components and Processes
1. Obstacle Detection
Strategically positioned ultrasonic sensors constantly emit high-frequency sound waves
that reflect off objects on the road surface. The return time of these waves helps
calculate obstacle distance, height, and shape.

2. Signal Processing
Sensor data is fed into a microcontroller (e.g., Arduino or STM32), which processes
inputs using filtering algorithms to distinguish genuine obstacles from noise. Based on
the nature and urgency of the detected anomaly, the controller computes the required
electromagnetic force.

3. Magnetic Force Generation

The electromagnet mounted on the upper fixed MS plate is activated via pulse-width
modulation (PWM) to generate a controlled magnetic field. This field attracts the lower
movable MS plate, altering the suspension geometry in real-time.

4. Spring Compression and Balancing

The upward movement of the movable MS plate compresses the upper spring. This
action balances the magnetic attraction with mechanical resistance, ensuring that the
vehicle body remains stable during force changes.

5. Real-Time Adjustment
EMAS continuously modulates magnetic intensity based on real-time inputs. The
control loop operates within milliseconds, enabling immediate adaptation to bump,
potholes, or sudden braking, thereby preventing shock transmission to the cabin.

6. Energy Efficiency
To conserve power, EMAS only engages the electromagnetic components when
necessary. During steady driving or smooth surfaces, the system reduces current flow,
switching to a passive mode where the springs manage damping.

7.3 Fabrication Process of EMAS

The fabrication of the Electromagnetic Active Suspension involves the careful integration of
mechanical, electrical, and control systems. Below is a detailed breakdown of the process:

 Materials Required
 Structural Frame: 4 mild steel (MS) plates (2 fixed, 2 movable), central shaft, and
cylindrical housing.

Electromagnetic Assembly: High-capacity electromagnets, copper coils, ferrite cores,

and optional permanent magnets.

Suspension Components: Pre-calibrated steel springs, miniature shock absorbers.

Electronic Components: Microcontroller (Arduino or STM), ultrasonic sensors, power
control modules, jumper wires, and PCB boards.

Power Supply: Rechargeable lithium-ion battery, voltage regulators, and Electronic

Control Unit (ECU).

 Step-by-Step Fabrication Process

1. Frame Construction
 Manufacture the external housing using hollow cylindrical steel structures, ensuring a
smooth internal surface for minimal friction.
 Securely mount two fixed MS plates inside the cylinder using high-tensile steel pins or
welded joints.

2. Shaft and Movable Plate Assembly

 Mount two movable MS plates onto a centrally aligned shaft, allowing vertical
displacement.
 Insert this shaft into the cylinder, ensuring free movement with linear bearings or
bushings.

3. Spring Installation
 Attach one spring to the top end and one to the bottom end of the movable MS plates.
 Springs are tensioned to predefined force constants for effective impact absorption.
4. Electromagnetic Integration
 Mount the electromagnet onto the upper fixed plate with insulation to prevent
overheating.
 Wire the electromagnet to the microcontroller and battery unit, integrating a relay or
MOSFET for current control.

5. Sensor Configuration
  Install ultrasonic sensors near the suspension interface to detect vertical road
disturbances.
 Interface them with the microcontroller via digital I/O pins.
6. Circuit and Wiring Setup
 Develop a compact control circuit using a breadboard or PCB.
 Connect power modules, coils, and sensors, ensuring signal integrity and avoiding EMI
interference.
 All wires are insulated and secured to avoid fatigue or detachment.
7. Final Assembly and System Testing
 Fit all subassemblies inside the cylindrical frame, checking alignment and functional
integration.
 Perform initial testing on flat surfaces followed by controlled terrain simulations.
 Record performance data and recalibrate force parameters and sensor logic as needed.

7.4 Advantages of Electromagnetic Active Suspension

The EMAS system offers numerous benefits over conventional suspension systems. Its
advanced control, adaptability, and efficiency make it ideal for future mobility solutions.

2. Adaptive Suspension Control

EMAS automatically detects road irregularities and adjusts damping levels in real-time,
ensuring optimal vehicle handling and passenger comfort regardless of terrain.

3. Enhanced Ride Comfort

By dynamically reducing vibrations and eliminating harsh road shocks, EMAS
significantly improves the in-cabin experience, especially on uneven or rugged roads.

4. Greater Vehicle Stability

EMAS reduces body roll, dive, and squat during acceleration, braking, or cornering,
leading to more predictable and safe vehicle behaviour.

5. Lower Maintenance Requirements

With fewer moving parts and no hydraulic fluids, EMAS requires less frequent
servicing. Electromagnets are highly durable with minimal mechanical wear.
 6. Energy Efficiency
Unlike fully active systems, EMAS conserves power by only activating during
necessary conditions, contributing to the overall energy economy of the vehicle.

Faster Response Time

Electronic control ensures immediate actuation—much faster than mechanical or hydraulic
counterparts—allowing better adaptability during emergency manoeuvres or terrain shifts.

Fig 7.1 Circular Electromagnet Fig 7.2 Springs used in the suspension

Fig 7.3 Sensors and circuit testing

Fig 7.4 Suspension welded

 Fig 7.5 Electronic Integration

(a) Fig 7.6 (a) and (b) Testing of the project (b)
 CHAPTER-8
RESULTS &
DISCUSSIONS
 Table 8. 1 The findings of the testing

Sl. No. Distance(x) (in cm) Voltage(in volts)

1 30 0.4
2 15 0.8
3 20 1.15
4 15 1.6
5 10 2.2
6 5 2.8
7 2 3.0

Fig 8.1 Plot between distance vs voltage

8.1 RESULTS AND DISCUSSIONS -:
1. Ultrasonic Sensor Output and Voltage Variation
Ultrasonic sensors operate based on the time-of-flight (TOF) principle, where an
ultrasonic pulse is emitted and the time taken for the echo to return is measured. This
time is directly proportional to the distance between the sensor and the reflecting
surface (i.e., the obstacle).
The system was designed such that the voltage induced varies with the sensor output,
which is a function of the distance measured. As the obstacle is moved further away
from the sensor, the travel time of the ultrasonic pulse increases, which in turn triggers
a higher analog or PWM voltage signal in the interfacing circuit (depending on the
design logic). This may be achieved through an analog voltage converter or by
interpreting the pulse width and converting it into a proportional voltage using signal
processing circuitry or a microcontroller algorithm.
The testing confirmed a linear or near-linear voltage increase with distance in the
calibrated range of the sensor (typically 2 cm to 400 cm for most ultrasonic modules).
Fluctuations were minimal under stable environmental conditions, indicating reliable
performance of the sensor in the setup.
2. Effect of Voltage on Spring Stiffness
The system includes a spring-based mechanical component whose stiffness is altered
by an actuator driven by the voltage induced from the sensor system. This actuator
could be a servomotor or an electromagnetic element that adjusts the spring tension or
compresses it further, depending on the voltage level.
In mechanical terms, the stiffness k of a spring determines the resistance offered against
deformation (as per Hooke's Law: F=kx). The increase in voltage leads to greater force
being applied on the spring’s preloading mechanism, thereby effectively increasing the
stiffness.
Observations during the testing phase showed that with increased sensor distance (and
thus higher voltage), the spring compressed less under the same applied manual load.
This confirmed that the system was indeed increasing the spring constant dynamically
in response to sensor input, validating the designed behaviour.
3. Manual Load Application and System Response
The load in the experiment was applied manually in a controlled environment to
eliminate interference from dynamic or unpredictable forces. Manual loading allowed
for consistent monitoring of spring compression across different voltage levels and
distances. At lower voltages (i.e., when the obstacle was closer), the spring exhibited
greater compression under the same manual force, indicative of a lower stiffness
setting. As the voltage increased, corresponding to greater obstacle distances, the
spring's compression decreased under identical loading conditions, proving the voltage-
stiffness dependency.
 While manual loading is inherently slower than automated systems, it allowed precise
and real-time control during each test iteration. It also ensured that results were not
influenced by mechanical vibrations or momentum effects that could distort sensor
readings and spring responses.
4. Overall System Behaviour and Performance Analysis
The experiment effectively demonstrates a closed-loop system where the distance
sensed by an ultrasonic sensor governs the electromechanical response of a spring
system. This integration showcases the utility of mechatronics—merging sensors,
actuators, and mechanical elements for dynamic behaviour control. The system
displayed high repeatability across trials, with consistent voltage-distance-stiffness
relationships. Minor hysteresis was observed in the spring’s response, likely due to
internal friction or lag in actuator adjustment, but remained within acceptable
tolerances.
Sensor performance was found to be slightly sensitive to environmental noise and
surface reflectivity of the obstacle, which may cause minor deviations in measured
distance. However, since the mechanical response relies on relative change rather than
absolute values, the system maintained its overall reliability.

Fig 8.2 distance between road and sensor (x)

From the above diagram, it can be inferred that the distance “x” represents the variable
gap between the sensor and the obstacle. This distance is dynamic, and changes based
on the shape and depth of the obstacle encountered. As “x” varies, the sensor detects
these fluctuations and translates them into corresponding changes in the voltage and
current supplied to the electromagnet. These electrical variations directly influence the
behaviour of the electromagnet, adjusting its magnetic force as needed. Consequently,
the suspension system is activated and modulated in real-time, ensuring that the vehicle
adapts appropriately to the terrain conditions by maintaining stability and comfort.
Programming for the ultrasonic sensor integrated in Arduino UNO controller (Done
using C language):
// Pin definitions
const int trigPin = 9;
const int echoPin = 10;
const int ledPin = 6; // PWM pin for LED

void setup () {
pinMode(trigPin, OUTPUT);
pinMode(echoPin, INPUT);
pinMode(ledPin, OUTPUT);
Serial.begin(9600);
}

void loop () {
// Trigger ultrasonic pulse
digitalWrite(trigPin, LOW);
delayMicroseconds(2);
digitalWrite(trigPin, HIGH);
delayMicroseconds(10);
digitalWrite(trigPin, LOW);

// Read echo pulse duration

long duration = pulseIn(echoPin, HIGH);

// Calculate distance (cm)

float distance = duration * 0.034 / 2;

int brightness;
 // If object is closer than 30 cm
if (distance <= 30) {
// Map distance 0–30 cm to brightness 255–0 (closer = brighter)
brightness = map(constrain (distance, 0, 30), 0, 30, 255, 0);
} else {
brightness = 0; // LED dim/off if beyond 30 cm
}

// Set LED brightness

analogWrite(ledPin, brightness);

// Print to Serial Monitor

Serial.print("Distance: ");
Serial.print(distance);
Serial.print(" cm | LED Brightness: ");
Serial.println(brightness);

delay (200); // Update every 200ms

}
 CHAPTER-9
COST ESTIMATION
AND ANALYSIS
9. COST ESTIMATION AND ANALYSIS

9.1 Cost estimation breakdown

A. Cost of materials and components

Table 9.1 Cost of materials and components used in model

Sr No Materials and components Cost
1. Electromagnetic Actuators (4 units) ₹12,000
2. Sensors (Position/Displacement, 4 units) ₹4,000
3. Control Unit/ECU ₹7,500
4. Power Supply/Battery ₹3,000
5. Mechanical Components (Springs, Shock Absorbers) ₹3,500
6. Magnetic Field Generators (Coils and Magnets) ₹4,000

7. Actuator Mounting & Assembly ₹1,500

8. Software & Control Algorithms ₹4,000
9. Prototyping & Testing ₹3,000
10. Installation & Labor Costs ₹2,500
11. Research & Development ₹3,000
Total Estimated Cost (Mass Production) ₹40,000

Total Estimated Cost Range:

Project Cost Estimation
The total estimated cost for this project is approximately ₹40,000 INR, encompassing all
essential expenses, including material procurement, fabrication, testing, and potential overhead
costs. This estimation accounts for anticipated expenditures related to prototype development,
component sourcing, labour, and analysis to ensure a comprehensive and functional suspension
system design.
 CHAPTER-10
FUTURE SCOPES
10. FUTURE SCOPES

10.1 Improvements and Breakthroughs

Recent advancements in electromagnetic and smart materials are propelling Electromagnetic
Active Suspension Systems (EAMS) into a new era of performance and efficiency. The
incorporation of high-efficiency rare-earth permanent magnets (such as neodymium-iron-
boron) and the emergence of superconducting coils have the potential to drastically reduce
power losses while increasing the force output of actuators. As highlighted in recent IEEE
research, these materials improve magnetic flux density, which translates into faster and more
accurate actuator response—an essential feature for real-time suspension control in variable
terrain conditions.

In parallel, the application of AI and machine learning in suspension control systems is a

breakthrough. Adaptive control algorithms such as model predictive control (MPC) and
reinforcement learning allow EAMS to continuously learn from vehicle dynamics and road
profiles, adjusting suspension parameters in real time. This ensures not only improved ride
quality but also optimized energy consumption by minimizing unnecessary actuator activation.

Furthermore, technological progress in miniaturization—enabled by micro-electromechanical

systems (MEMS) and compact embedded controllers—allows for a reduction in the size and
weight of system components. This integration simplifies assembly and opens the door to
broader applications in compact and electric vehicles. Combined with the potential for
integration into regenerative energy systems (harvesting kinetic energy from suspension
movements), EAMS could become not only smarter but also more self-sustaining in operation.

10.2 Research Avenues and Innovations

Future research is likely to focus on hybrid suspension systems, combining electromagnetic
systems with traditional active technologies like hydraulic or pneumatic actuators. These
hybrid models aim to balance the strengths of each system—electromagnetic systems provide
fast response and precision, while hydraulic systems offer higher force capacity. Such
integration could address performance gaps, especially in heavy-duty and off-road vehicles, by
providing adaptive stiffness and damping in extreme conditions.

An exciting innovation frontier lies in energy harvesting suspension systems, where the kinetic
energy generated by vertical wheel motion is converted into electrical energy. This concept not
only contributes to a vehicle’s power supply but also enhances overall energy efficiency,
particularly in electric vehicles. Researchers are exploring linear electromagnetic generators
embedded within suspension struts, capable of converting vibrations into usable energy without
significantly altering suspension dynamics.

Another promising avenue is the use of lightweight composite materials and 3D-printed
components. Through additive manufacturing, suspension components can be designed with
optimized topologies that reduce weight without sacrificing strength. This not only improves
performance but also reduces energy consumption and manufacturing costs. Additionally, the
use of smart materials—such as magnetorheological fluids and shape-memory alloys—can
provide adaptive characteristics, further enhancing EAMS capabilities.

10.3 Accessibility and Environmental Sustainability

For EAMS to become a mainstream solution, cost reduction and scalability are critical. Mass
production using modular and standardized designs can significantly bring down the cost per
unit, making it viable for not just luxury vehicles but also mid-range cars, electric vehicles, and
public transport systems. Companies are already exploring modular platforms that can be
adapted across different vehicle classes without compromising performance.

From an environmental perspective, EAMS aligns with the global push for greener and more
sustainable transportation solutions. By reducing dependence on hydraulic fluids and
minimizing mechanical friction, electromagnetic systems reduce operational wear and the
environmental impact of maintenance and disposal. The integration of recyclable materials and
biodegradable polymers in actuator housing and insulation further enhances the sustainability
profile of the system.

Moreover, EAMS contributes indirectly to fuel and energy savings by improving vehicle
aerodynamics and reducing vibration-induced energy losses. A smoother ride also reduces
stress on other components like tires, bearings, and frames—lowering maintenance needs and
prolonging vehicle lifespan. When integrated with renewable energy systems, particularly in
electric vehicles, EAMS offers a holistic solution toward zero-emission and energy-efficient
transportation.
CONCLUSION
CONCLUSION
The successful development and implementation of the Electromagnetic Active Suspension
System (EAMS) in this project represents a meaningful step toward the future of intelligent,
adaptive vehicle dynamics. By integrating electromagnetic actuators, sensor feedback
mechanisms, and real-time control algorithms, the system achieves precise modulation of
suspension forces to deliver an optimized balance between ride comfort, handling, and
component longevity.

Unlike traditional suspension systems that rely on passive damping elements, this innovative
EAMS actively responds to road disturbances through finely tuned electromagnetic control.
This enables the system to mitigate vibrations, absorb shocks more effectively, and adapt
dynamically to varying terrain and driving conditions. The result is a smoother and safer
driving experience, with significantly reduced wear and tear on the vehicle’s structural
components.

Moreover, the use of digitally programmable components and modular architecture provides
greater flexibility for integration with modern vehicular technologies, including electric
drivetrains and autonomous navigation systems. The system’s potential for energy-efficient
operation and even energy recovery during motion adds to its appeal in the context of
sustainable automotive design.

This project has not only demonstrated the feasibility of electromagnetic suspension but has
also laid a strong foundation for future research in advanced control strategies, such as machine
learning-driven suspension tuning, adaptive terrain recognition, and cooperative systems with
ADAS. The implications of this work suggest that electromagnetic suspensions could soon
evolve from experimental setups into real-world automotive solutions, fundamentally
transforming the way vehicles interact with the road.
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Books and Articles:

 RK Gupta; Books on vehicle suspension systems, automotive engineering, or

advanced suspension technologies. 2nd Edition.