Vicor high-density power modules are used in the Hongfa solution to produce a small (197 x 201 x 71mm) 5kW power supply for every actuator. Up to 6kW of peak power can be processed quickly by the system in either direction. A pair of Vicor BCM6135 modules working in simultaneously, rather than several hundred separate parts, significantly simplifies the converter’s design.
High-density power modules and 48V power delivery network enable midrange vehicles to adopt luxury feature
To bring what has long been a premium feature into the midrange vehicle class, Hongfa has developed the smallest and most effective active suspension power system in the industry.
Hongfa achieved a balance between the necessity to control the size, weight, and transient performance of active suspension systems and the need for increased efficiency, better EMI, and symmetrical regenerative power capacity, overcoming decades of failed starts by leading automotive technology providers.
Hongfa, an expert in automotive power management and distribution, teamed up with Vicor to integrate a fixed-ratio 800V-48V DC-DC converter power module.
This power module sits alongside a network of sensors, electromechanical actuators, and advanced software to enable real-time suspension adjustments for vehicles. Hongfa’s relays are enabling new 48V zonal architectures.
The partnership produced the fastest power conversion transient response in the industry and the smallest active suspension system, nearly half the size of the closest rival.
High-voltage batteries and a 48V PDN trigger a revolution for the Hongfa active suspension vision
Active suspension improves handling, creates a smoother, safer ride, and lowers road noise whether a car is traversing potholes in the suburbs, on a remote dirt lane, or on a worn highway.
A complicated electromagnetic solution that tested the limits of 12V battery power supplies and necessitated four 200-pound motors was part of early industrial attempts in the 1970s.
Historically, 12VDC has proven to be inadequate for powering active suspension motors without adding size, weight and cost.
Additionally, some conventional DC-DC converters can deliver power without the need for an intermediate battery, but the tradeoff is that they are bulky and lack the fast transient response time required to meet the regenerative demands to recoup and store power.
Active suspension systems can profit from the industry’s acceptance of 48V power delivery networks (PDNs) and today’s higher voltage (400V or 800V) primary batteries, despite a history of power-hungry, heavy loads. Plug-in hybrids and BEVs are already powered by this combination.
Of all DC-DC converter topologies, Vicor fixed-ratio 800V to 48V DC-DC BCM® bus converters offer the fastest transient response (8 million amps/second) and are naturally bidirectional.
Additionally, symmetrical bidirectional performance is provided by BCMs, which can boost or buck at the same power level. Their sophisticated planar packaging significantly minimizes total weight and footprint by streamlining the construction of thermal management systems.
Linking active suspension directly to the main battery with a bidirectional power converter enables optimal energy recuperation. Similar to how a spring absorbs and releases energy, active suspension uses regenerative shock absorbers to collect kinetic energy that is returned to the battery.
Hongfa introduces smallest active suspension system using power modules and 48V
Vicor high-density power modules are used in the Hongfa solution to produce a small (197 x 201 x 71mm) 5kW power supply for every actuator.
Up to 6kW of peak power can be processed quickly by the system in either direction. A pair of Vicor BCM6135 modules working in simultaneously, rather than several hundred separate parts, significantly simplifies the converter’s design.
The converter is optimized to work with 800V battery systems and has an operating range between 420V to 920V. With liquid cooling it can deliver up to 100A of current with 97.3% efficiency. The system housing volume is under 1.8l and weighs 2.6kg, providing a major reduction over other systems.
“When it comes to active suspension, our OEM customers require a DC-DC converter with a response rate measured in milliseconds, otherwise, additional battery support is needed,” said Peter Li, Director of Research and Development at Hongfa. “Vicor’s BCM6135 power modules not only delivered the performance we need, they also significantly shortened our development time and have made designing this system much easier for us.”
By lowering weight and space while delivering better performance, 48V and high-density power modules are opening up new possibilities for automotive electrification innovation. Together, Hongfa and Vicor are using their knowledge of the automotive industry to create cutting-edge technologies and aid in the advancement of highly efficient electric cars.
Learn more about how Hongfa and Vicor are working together to transform today’s driving experience.
