Design of a Regenerative Suspension Damper System Using Real-Road Vehicle Test Data and Analysis of Vehicle Responses

This study develops a design procedure for electromechanical regenerative dampers using recorded damper stroke, velocity, and force from city, highway, country, and rough-road driving. The signals are converted into directional force, mechanical-power, energy-coverage, and operating-duty requirements. Motor size, gear ratio, lever ratio, power-network limits, packaging, and reflected inertia are screened, and 12 V and 48 V configurations are selected separately. Force tracking is checked with a prescribed-motion actuator model, and the selected designs are compared with a hydraulic reference in a quarter-car model under paired ISO Class B/80, C/60, and D/40 km/h inputs. The design points include 0.4 kW at 0.30 m/s, 0.6 kW for continuous-load screening, and 2.3 kW for 95% mechanical-energy coverage per damper. On the selected Class D/40 km/h input, the interface-force NRMSE is 52.3% for the 12 V configuration and 23.5% for the 48 V configuration. This is a comparison of two complete system designs, and prototype validation remains necessary.