Efficient energy use is key to continuous improvement, especially in the automotive industry. Extending vehicle range is critically important. This study investigates the innovative implementation of a four-bar mechanism, which was designed to harvest energy within automotive suspension systems. Unlike classic solutions that use gearboxes, adding complexity, more components, slacking, and more wear, this method uses a four-bar mechanism. Although four-bar mechanisms can change the speed ratio in a non-linear way which could negatively affect system performance if not managed well, they offer great advantages. This mechanism serves a dual purpose: transforming the angular motion of a rigid shaft within the suspension of a city car, as well as amplifying vibrations caused by the pavement. This amplification increases the speed ratio of the generator, which increases energy-capture efficiency thanks to the nonlinearity of the mechanism as it approaches singular positions. The ideal geometric configuration was determined by considering the spatial, kinematic, and safety limitations of the car. In this context, the genetic algorithm optimization technique was employed, resulting in a favorable speed ratio achieved in a simpler, compact, and durable design compared to traditional gearboxes.
