EcoMaglev: A Hybrid PM-Assisted Active-Gap Magnetic Levitation System with Regenerative Energy Recovery — A Model-Based Feasibility Study

Abstract Magnetic levitation transport can reduce mechanical wheel-rail contact, wear, vibration, and maintenance overhead, but levitation alone does not guarantee ecological performance. Energy demand shifts to electromagnetic control, propulsion-chain losses, aerodynamic drag, thermal management, and grid interaction. This paper presents EcoMaglev - a hybrid permanent-magnet-assisted, active-gap magnetic levitation demonstrator architecture with regenerative braking energy recovery - and evaluates its performance through analytical modeling, a simulation-supported dynamic response model, Monte Carlo sensitivity analysis, and corridor-level environmental screening. The architecture couples permanent magnets for base lift with active electromagnetic coils for disturbance rejection, a closed-loop controller fed by Hall-effect and time-of-flight gap sensors, segmented linear coils for propulsion and braking, and protected power electronics that route recovered energy to a supercapacitor bank. The paper addresses common weaknesses in prototype-scale maglev proposals by separating EMS, EDS, and hybrid PM-EMS definitions; distinguishing circuit-level conversion efficiency from system-level usable recovery; and normalizing energy claims with reproducible units. Analytical results show that a 0.30 kg demonstrator moving at 2.0 m/s contains 0.60 J of kinetic energy per braking event. At a central model-based circuit efficiency of 0.74, approximately 0.44 J can be stored, corresponding to a measurable supercapacitor voltage rise of about 0.35 V. Magnetic force sizing shows that pure electromagnetic support is thermally demanding at a 10 mm gap, supporting a hybrid design in which permanent magnets supply most static lift while active coils reject disturbances. Corridor-level screening shows that full-scale environmental performance is dominated by tunnel share, load factor, and electricity carbon intensity rather than levitation technology alone.