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Development and production of Electric Vehicles is now becoming a necessity for
automakers across globe due to energy crisis and global warming. This study presents a design
concept for vibrational energy harvesting from coil springs of a vehicle using electromagnetic
induction. A novel helical magnet spring design is presented that is cost-effective yet
sophisticated to fit in any on-going production setup with minimal cost addition per vehicle yet
adds to the electrical output. For this purpose an application for Lenz Law is devised using a
variance approach in modeling design. 3 design models are simulated in SolidWorks 2017 to
analyze the relative motion required for application of N42 series magnets according Lenz Law.
A set of USN 12600 winding copper coil sleeves are placed as an outer shell to induce current
w.r.t. relative motion of magnets. Design is developed with target of low weight i.e. 10 kg.
Various models are developed to meet the targets and evaluated, in EMworks simulation tool for
SolidWorks, before any modeling is done. After re-design & evaluation iterations, a final model
is selected on ease of assembling and output. Each model is simulated and total current output is
measured for a single coil spring. Further, design is optimized for minimal weight of 3.68 kg
with an output of 10.843 kW for a total of 1500 oscillations. The practical application for this
model is mainly heavy transport vehicles due to their continuous vibrational behavior even on
smooth roads in addition to rough traction. Further research avenues for proposed design include
simulation on stress analysis, thermal analysis and fatigue cycles.