Claims:
1. A power generation by suspension system in vehicle comprises;
atleast one magnet (30) configured to be mounted on striker cap (24) of damper body (28),
atleast one copper coil (32) wounded around dust cover (26) of said suspension, and
atleast one circuit to supply current generated by suspension assembly to charge vehicle battery (70).

2. The power generation by suspension system in vehicle as claimed in claim 1, wherein the electromagnetic field is configured to be induced by vertical movement of magnet (30) around copper coil (32) to charge vehicle battery (70).

3. The power generation by suspension system in vehicle as claimed in claim 1, wherein an auxiliary alternator is configured to be connected in the circuit to convert AC current generated by suspension system into DC current and supply to battery (70).

4. The power generation by suspension system in vehicle as claimed in claim 1, wherein a voltage regulator (60) is configured to maintain the voltage between a predetermined range during charging of the vehicle battery (70).

5. The power generation by suspension system in vehicle as claimed in claim 1, wherein the current generated is configured to charge battery (70) of electric vehicle and increase mileage.

6. The power generation by suspension system in vehicle as claimed in claim 1, wherein the current generated is configured to increase the battery life of an ageing battery of IC engine vehicle.

7. The power generation by suspension system in vehicle as claimed in claim 1, wherein said suspension is configured from a suspension damper.
8. The power generation by suspension system in vehicle as claimed in claim 1, wherein said magnet (30) is configured from a hollow cylindrical ring magnet.

9. The power generation by suspension system in vehicle as claimed in claim 1, wherein said copper coil (32) is configured to be of predetermined diameter and predetermined turn based on the size of suspension assembly.
, Description:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

Title of invention:
POWER GENERATION BY SUSPENSION SYSTEM TO CHARGE VEHICLE BATTERY

Applicant:
Tata Motors Limited
A company Incorporated in India under the Companies Act, 1956
Having address:
Bombay House, 24 Homi Mody Street,
Hutatma Chowk, Mumbai 400001,
Maharashtra, India

The following specification particularly describes the subject matter and the manner in which it is to be performed.
TECHNICAL FIELD
[001] The present invention relates to a power generating suspension system in vehicle, more specifically it is related to generating electrical energy by bump and rebound movement of damper body of vehicle suspension to charge vehicle battery.

BACKGROUND
[002] The MacPherson strut is a type of automotive suspension system that uses the top of a telescopic damper as the upper steering pivot. A MacPherson strut uses a wishbone, or a substantial compression link stabilized by a secondary link, which provides a mounting point for the hub carrier or axle of the wheel. This lower arm system provides both lateral and longitudinal location of the wheel. The upper part of the hub carrier is rigidly fixed to the bottom of the outer part of the strut proper; this slides up and down the inner part of it, which extends upwards directly to a mounting in the body shell of the vehicle.
[003] When vehicle is running over a road, all the road irregularities are taken care by the suspension system of vehicle by using spring and damper arrangement. Spring and damper are continuously moving up and down by means of road inputs. Traditional fossil fuel energy reserves are reducing day by day, and humanity is looking for clean energy sources. Therefore, use of electric vehicles is on rise but the limited infrastructure of charging stations is a concern. Vehicles currently in market have limited mileage available approx. 200-300 kilometers so there are limitations for usage of electric vehicles. With increase in battery capacity, range of vehicle can be increased but it is adding more cost to the customer. It is need of an hour to get more range (Mileage) with existing battery package by improving the battery charging by a secondary source other than the alternator.
OBJECTS OF THE INVENTION
[004] The main object of the invention is to generate power from auxiliary source to charge the vehicle battery.
[005] Another object of the invention is to generate power from auxiliary source to charge the vehicle battery to increase the mileage of electric vehicle.
[006] Yet another object of the invention is to generate power from damper / MacPherson strut to charge the vehicle battery.
[007] Yet another object of the invention is to use Faradays laws of magnetic induction to generate power by configuring magnet and coil around damper assembly.
[008] Yet another object of the invention is to provide alternate source of power to charge ageing battery of IC engine vehicle.
SUMMARY
[009] Before the present system and method are described, it is to be understood that this application is not limited to the particular machine or an apparatus, and methodologies described, as there can be multiple possible embodiments that are not expressly illustrated in the present disclosure. It is also to be understood that the terminology used in the description is for the purpose of describing the particular versions or embodiments only and is not intended to limit the scope of the present application. This summary is provided to introduce aspects related to a power generating suspension system to charge vehicle battery, and the aspects are further elaborated below in the detailed description.
[0010] In one implementation, by using existing damper of suspension system power is produced by Faraday’s law of induction without affecting any suspension performance and without giving any additional load to the operation of suspension damper. Adding magnet and copper wire in damper arrangement of damper assembly results in power generation. The up and down movement of the damper body with magnet and stationary copper wire around dust cover leads to generation of electromagnetic field. This current is converted to DC current from AC current by using auxiliary alternator and directing the current to battery for charging and storage purpose. Battery charging is done continuously when vehicle is running on the road and mileage will be increased by 18-20%.
STATEMENT OF INVENTION
[0011] Accordingly, the present invention discloses a power generation by suspension system in vehicle comprising of atleast one magnet configured to be mounted on striker cap of damper body, atleast one copper coil wounded around dust cover of said suspension and atleast one circuit to supply current generated by suspension assembly to charge vehicle battery.
[0012] The electromagnetic field is configured to be induced by vertical movement of magnet within copper coil to charge vehicle battery. An auxiliary alternator is configured to be connected in the circuit to convert AC current generated by suspension system into DC current and supply to battery. A voltage regulator is configured to maintain the voltage between a predetermined range during charging of the vehicle battery. The current generated is configured to charge battery of electric vehicle and IC engine vehicle to increase mileage and life of battery. The suspension system is configured from a damper assembly. Magnet is configured to be molded on striker cap is a hollow cylindrical ring magnet and copper coil is configured to be of predetermined diameter and predetermined turn based on the size of suspension assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The foregoing summary, as well as the following detailed description of embodiment, is better understood when read in conjunction with the appended drawing. For the purpose of illustrating the disclosure, there is shown in the present document example constructions of the disclosure, however, the disclosure is not limited to the specific methods and apparatus disclosed in the document and the drawing.
[0014] The detailed description is described with reference to the accompanying figure. In the figure, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawing to refer like features and components.
[0015] Figure 1 (Prior Art) illustrates a vehicle suspension system.
[0016] Figure 2 (Prior Art) illustrates a sectional view of existing suspension damper.
[0017] Figure 3 illustrates a sectional view of power generating suspension damper with magnet and copper coils.
[0018] Figure 4 illustrates a damper assembly with magnet and copper coils wounded around dust cover.
[0019] Figure 5 illustrates a circuit diagram of power generating suspension damper.
[0020] Figures depicts various embodiments of the present disclosure for purpose of illustration only. Only skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION
[0021] Some embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words “comprising”, “having”, and “including,” and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. Although any systems and methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the exemplary, systems and methods are now described. The disclosed embodiments are merely exemplary of the disclosure, which may be embodied in various forms. .
[0022] Various modification to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to another embodiment. However, one of ordinary skill in the art will readily recognize that the present disclosure is not intended to be limited to the embodiments illustrated but is to be accorded the widest scope consistent with the principles and features described herein..
[0023] The purpose of suspension system in vehicle is to keep vehicle on ground in all driving condition and absorb the shock which is created by road irregularities. The damper assembly suspension system consist of beam, damper, spring, top mount, bump stopper and dust cover. Springs in a suspension system helps to maintain the wheel contact with ground surface and thus supports ride and handling. Damper is an energy absorbing unit that absorbs the sudden jerks generated by a spring in a vehicle system. Top mount is a member which is getting connected in between body and suspension system and isolate the high frequency vibrations. Bump stopper is absorbing energy and which is released by spring and damper. Dust cover is preventing dust to go inside damper. When vehicle is going over a bump, wheel moves up and down in vehicle, damper is also moving up and down and there will be resistance from damper equal to damping force created by the valve and fluid inside damper arrangement. Striker cap will hit bump stopper when damper moves up in full bump condition.
[0024] The addition of two components like magnet and copper coil in suspension damper assembly is adapted to generate power for charging vehicle batteries. The bump and rebound movement of damper assembly allows vertical movement of magnet within the stationary copper coil wounded on dust cover. This movement of magnet within copper coil induces electromagnetic field according to Faradays law of induction. The current is converted to DC current from AC current by using alternator and directed to battery for charging and storage purpose. The power generating suspension damper ensures increase in mileage of electric vehicle and battery life of ageing battery of an IC engine vehicle.
[0025] A cylindrical ring magnet is molded on the plastic striker cap. Depending on magnetic strength requirements, thickness and length of magnet can be increased as packaging space is available. Accordingly, dust cover outer diameter can be increased as this dust cover is open to air without any packaging constrains. A clearance between the magnet and dust cover is optimally maintained for operation of damper system. Copper coil is wound over the dust cover through its entire surface area. Diameter of the copper coil is approximately 0.1mm. The coils are extended over the dust cover surface length of 180 to 200mm and the number of coils is with approximately 1500 turns.
[0026] Figure 1 shows a conventional vehicle suspension system comprising of wheel (10), damper (20) and spring (50). The suspension system in vehicle is to keep vehicle on ground in all driving condition and absorb the shock which is created by road irregularities. Springs in a suspension system helps to maintain the wheel contact with ground surface and thus supports ride and handling.
[0027] Figure 2 shows a conventional damper assembly comprising of bump stopper (22), striker cap (24), dust cover (26) and damper body (28). Bump stopper (22) is configured to absorb energy released by spring and damper. Dust cover (26) prevents entry of dust inside damper.
[0028] Figure 3 shows a damper assembly as per one embodiment of this invention used for power generation comprising of magnet (30), copper coil (32), top rubber mount bush (21), bump stopper (22) and damper body (28). A cylindrical ring magnet (30) is configured to be molded on the plastic striker cap (24). Depending on magnetic strength requirements and size of suspension the thickness and length of magnet (30) is varied. The clearance between the magnet and dust cover is optimally maintained for operation of damper assembly. Copper coils (32) are wounded over the dust cover through the entire surface area and diameter of the copper coil (32) is approximately 0.1mm. The coils are extended over the dust cover surface of length 180 to 200mm and number of coils is with 1500 turns. The bump and rebound movement of damper body (28) allows vertical movement of magnet (30) around the stationary copper coils wound on dust cover. Thus, the copper coils cuts the magnetic field during every single movement of the damper. By Faradays law of induced electricity, an EMF is induced in the system due to coils cutting the magnetic field at all instances. Induced EMF= N X ?F / ?? F: Magnetic Flux and T: Time. This induced EMF is used for charging the battery of vehicles.
[0029] Figure 4 shows a dust cover with copper coil (27) on a damper assembly. Copper coils are wounded over the dust cover through the entire surface area and diameter of the copper coil is approximately 0.1mm. The coils are extended over the dust cover surface of length 180 to 200mm and number of coils is with 1500 turns.
[0030] Figure 5 shows that in normal operating conditions rotor (64) rotates within stator (62) coils. Stator coils are connected to alternator for conversion of AC to DC current. This DC current passes through voltage regulator (60) and then supply to battery (70) and external voltage. In the case of voltage drop, voltage regulator signals rotor to increase RPM for producing more voltage generation and vice versa. Voltage produced by damper is connected to alternator, which is further connected to voltage regulator (60), to regulate the voltage in system and ensure constant voltage of 12V to 14V in system. After ageing of battery when there is a drop in generated voltage, the additional voltage generated from damper is used to increase battery life.
[0031] According to present subject matter, a power generation by suspension system in vehicle comprises; atleast one magnet (30) configured to be mounted on striker cap (24) of damper body (28), atleast one copper coil (32) wounded around dust cover (26) of said suspension, and atleast one circuit to supply current generated by suspension assembly to charge vehicle battery (70).
[0032] The electromagnetic field is configured to be induced by vertical movement of magnet (30) around copper coil (32) to charge vehicle battery (70).
[0033] An auxiliary alternator is configured to be connected in the circuit to convert AC current generated by suspension system into DC current and supply to battery (70).
[0034] A voltage regulator (60) is configured to maintain the voltage between a predetermined range during charging of the vehicle battery (70).
[0035] The current generated is configured to charge battery of electric vehicle and IC engine vehicle to increase mileage and life of battery.
[0036] The suspension system is configured from a suspension damper. Magnet (30) is configured to be mounted on striker cap is a hollow cylindrical ring magnet and copper coil (32) is configured to be of predetermined diameter and predetermined turn based on the size of suspension assembly.
[0037] Further, the invention can be used, but not limited to, in the following applications.
[0038] Exemplary embodiments discussed above may provide certain advantages. Though not required to practice aspects of the disclosure, these advantages may include those provided by the following features.
[0039] The power generating suspension damper system increases mileage of electric vehicle.
[0040] The power generating suspension damper system increases battery life of ageing battery of IC engine.

[0041] REFERRAL NUMERALS:

Element Description Reference Numeral
wheel 10
Damper 20
Top mount rubber bush 21
Bump stopper 22
Striker cap 24
Dust cover 26
Dust cover with copper coils 27
Damper body 28
Magnet 30
Copper coils 32
spring 50
Voltage regulator 60
Stator coils 62
rotor 64
Voltage produced by damper 66
Battery 70