Broadband Wave Energy Harvesting with a Nonlinear 3DOF Magnetic Spring-Based PTO: Design, Testing and Sustainable Design Considerations

Ocean waves constitute a vast renewable resource, yet most linear generator-based wave energy converters (WECs) rely on single-degree-of-freedom (SDOF) linear oscillators that exhibit narrow resonance bandwidths and utilise sliding components prone to wear. To address these limitations, this paper presents a nonlinear three-degree-of-freedom (3DOF) magnetic spring power-take-off (PTO) system for broadband wave energy harvesting. The device comprises three axially levitated NdFeB permanent magnets, each coupled to an independent copper coil, forming a compact, friction-free generator column. A coupled electromechanical state-space model was developed and experimentally validated on a laboratory-scale test rig. The 3DOF PTO exhibited three distinct resonance modes at approximately 35, 48, and 69 rad s−1, enabling multi-mode energy capture across a broad frequency range. Under identical excitation (6.5 N amplitude and 3.13 Hz excitation force), the 3DOF configuration achieved a 114.5% increase in RMS voltage compared with the SDOF design and a 44.10% improvement over the 2DOF benchmark, confirming the effectiveness of the coupled resonance mechanism. The levitated magnetic architecture eliminates mechanical contact and lubrication, reducing wear and maintenance while improving long-term reliability in marine environments. A preliminary life-cycle assessment estimated a cradle-to-gate carbon intensity of 40–80 g CO2-eq kWh−1, significantly lower than that of conventional hydraulic PTOs, owing to reduced steel use and recyclable magnet assemblies. The proposed 3DOF magnetic spring PTO thus offers a sustainable, low-maintenance, and high-efficiency solution for next-generation ocean-energy converters.