03 / Mechanical Engineer

Mechatronics — LET

The LET (Linear Electromagnetic Transducer) was a research program asking a simple question: can the motion a mountain-bike suspension already dissipates be turned into useful electrical power? Two prototype generations took it from proof of concept to a trail-instrumented answer.

HALLBACH ARRAY0.61 T PEAKFEMM + MATLABTRAIL-VALIDATED

The transducer is a coreless linear generator. LET 2.0 uses a cylindrical Halbach magnet array on an aluminum mover, which directs the magnetic flux radially across the coils and removes the need for a steel core. A 1,500-point FEMM magnetics model fed a MATLAB model of the device; peak radial flux climbed from roughly 0.4 T on the first prototype to 0.577 T, and 0.61 T on the refined LET 2.2 magnet arrangement.

Architecture & Model
LET 2.0 — coil and magnet geometry (CAD).
FIG 01LET 2.0 — coil and magnet geometry (CAD).
Theoretical model: radial magnetic flux from the Halbach array.
FIG 02Theoretical model: radial magnetic flux from the Halbach array.
Comparing LET architectures against the magnetics target.
FIG 03Comparing LET architectures against the magnetics target.
Coil wiring scheme and the physical build.
FIG 04Coil wiring scheme and the physical build.
Build & Test

Beyond the generator itself, the program meant building the supporting hardware: two-phase rectified coil sets, voltage-divider circuits to keep velocity-dependent voltage spikes inside a logging window, and enclosures for the battery and logger. The device was characterized on a dynamometer and then run on the trail in multiple orientations and locations.

Hand-built: coils, soldering, and bench checks.
FIG 05Hand-built: coils, soldering, and bench checks.
Dynamometer sine-sweep testing, model correlation.
FIG 06Dynamometer sine-sweep testing, model correlation.
Trail testing — fork-lower vertical mount on the bike.
FIG 07Trail testing — fork-lower vertical mount on the bike.
Ride-session data: LET voltage tracked against fork position.
FIG 08Ride-session data: LET voltage tracked against fork position.
The Honest Answer

The most useful result was a limit. By treating the maximum harvestable energy as the energy the damper already dissipates, the study put a ceiling on the whole idea. A free-to-oscillate tuned-mass-damper LET generated several times more energy than a fork-position-dependent one — but even at that, charging a small Live Neo battery would take many descents, and a real device (generator, one-way clutch, gearbox, power electronics) would add roughly 600 grams. For an industry that fights for 50 grams on a crown, the conclusion was that the weight and feel cost outweighs the energy generation benefits.

Upper bound: energy the damper already dissipates over a run.
FIG 09Upper bound: energy the damper already dissipates over a run.
Theoretical vs. measured energy across configurations.
FIG 10Theoretical vs. measured energy across configurations.
Slow-Motion Tests
FIG 11LET 1 on the dyno — slow-motion.
FIG 12LET 2 on the dyno — slow-motion.