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Design and hierarchical optimization of a hybrid electromagnetic linear actuator for cab suspension systems
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DOI：10.1016/j.mechatronics.2026.103577.png)
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Abstract
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To improve ride comfort and address the limited fail-safe capability and energy utilization of electromagnetic actuators in commercial vehicle cab suspensions, a hybrid electromagnetic linear actuator (HELA) is proposed. HELA coaxially integrates a hydraulic damper and an electromagnetic linear actuator, enabling active force generation, energy regeneration, and passive fail-safe damping within the original installation space. A three-degree-of-freedom quarter-cab suspension model is established to determine the passive damping coefficient and actuator force, stroke, and velocity requirements using linear quadratic regulator (LQR) control. From the initial structure, Morris sensitivity analysis and hierarchical optimization target seven key parameters to avoid magnetic saturation, reduce radial size, and balance thrust output with detent-force suppression. The optimized actuator reduces detent force by 50.13%, increases average thrust by 8.09% to 487.75 N, and lowers the thrust ripple ratio to 7.42%. On a Class C road at 54 km/h, the hybrid mode achieves peak/average regenerative powers of 93.02/5.02 W and reduces net actuator energy consumption by 83.4%. Prototype tests confirm short-circuit damping capability and an approximately linear current-thrust relationship, with the measured thrust showing reasonable consistency with finite-element predictions.
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