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HomeTechElectronic TechnologyWorld’s Smallest Active Suspension Power System

World’s Smallest Active Suspension Power System

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A next-gen power solution redefines active suspension by cutting size in half, enhancing ride quality, and enabling real-time response through high-efficiency 800V-to-48V power conversion.

Smallest Active Suspension Power System

Xiamen Hongfa Electroacoustic Co., Ltd. (Hongfa) has introduced the industry’s smallest and highest-performing active suspension power system, designed to push a once high-end feature into the midrange electric vehicle market. This system successfully overcomes size, weight, and efficiency challenges that have plagued earlier designs for decades.

World’s Smallest Active Suspension Power System
Vicor-BCM6135-800V

The innovation centers around an ultra-compact 800V-to-48V DC-DC converter module developed in partnership with Vicor, a leader in high-performance power electronics. Unlike legacy systems that relied on bulky motors and underpowered 12V batteries, the Hongfa system leverages modern 48V power delivery networks (PDNs) and high-voltage (800V) batteries, enabling rapid real-time suspension adjustments with superior transient response.

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The key specifications are:

  • Weighs only 2.6 kg
  • Measures 197 x 201 x 71 mm
  • Delivers up to 5kW per actuator
  • Handles 6kW peak power bidirectionally
  • Supports 420V to 920V input
  • Achieves 97.3% power conversion efficiency

The solution integrates the company’s BCM6135 bus converters, which provide a fixed-ratio, bidirectional power path with record-fast transient performance—up to 8 million amps per second. These modules simplify the design by eliminating the need for hundreds of discrete components, while their advanced packaging streamlines thermal management and reduces footprint.Enclosed in a compact 1.8-liter volume, the system is nearly 50% smaller than comparable solutions, offering significant space savings without compromising performance. Its liquid-cooled design ensures reliable thermal management, supporting consistent operation even under demanding conditions.

“Fast response is essential in active suspension to avoid adding battery support,” said Peter Li, R&D Director at Hongfa. “Vicor’s modules met our performance targets and helped us accelerate development.”

The result is a transformative leap in automotive suspension, combining reduced weight and size with high energy recovery via regenerative damping. This platform is not only elevating ride comfort and safety but also playing a critical role in the next generation of electrified vehicles.

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