Vicor, a leading provider of innovative high-density power modules, is supplying a fixed-ratio DC-DC converter module (BCM6135) that converts 800V high voltage to 48V as a core component of a compact active suspension system. It is expected to contribute to significantly improving driving safety and ride comfort by allowing active suspension functions, previously limited to luxury vehicles, to be applied to mid-level vehicles.

Bycor announced on the 9th that it recently developed an ultra-compact active suspension power system together with Xiamen Hongfa Electroacoustic Co., Ltd.

This system is a 5kW compact power supply unit with an overall size of 197×201×71mm and a weight of only 2.6kg.

This allows the vehicle to implement advanced features in real time, such as improved handling, improved ride quality, and reduced road noise in a variety of road conditions.

This latest innovation is making waves in the automotive market, where electrification and lightweighting are key.

The outstanding performance of the high-performance power module will serve as a core infrastructure for various vehicle electronic systems, including active suspension., which opens up the possibility of advanced features spreading to mid-level vehicles as well.

Hongfa, a specialist in automotive power management and distribution, offers relays that support 48V domain-based architectures and has collaborated with Vicor, a leader in innovative, high-performance power modules, to integrate a fixed-ratio 800V-48V DC-DC converter power module.

The Bycor BCM6135 module used in this product supports bidirectional operation and boasts an excellent current transient response speed of up to 8 million amperes per second.

This symmetrical power switching performance enables optimal energy recovery when the DC-DC converter is directly connected to a high-voltage battery system.

In other words, the vehicle effectively collects the kinetic energy generated during suspension operation and returns it to the battery, thereby maximizing overall power efficiency.

Bycor overcomes the limitations of conventional converters by providing symmetrical bidirectional performance that provides both buck and boost capabilities, as well as fast power conversion transient response.

Advanced planar packaging and efficient thermal management design have played a critical role in dramatically reducing the volume and weight of the system, making it nearly half the size of competing products.

The actual applied liquid cooling method can stably supply up to 100A of current with a high efficiency of 97.3%, thereby further enhancing the precision of vehicle suspension control.

In particular, Bycor's fixed-ratio 800V-48V DC-DC converter supplies the power required for each wheel simultaneously by operating four modules in parallel, realizing fast transient response.

This design not only meets the millisecond response speeds that OEM customers demand, but also maximizes energy recovery capabilities.

Unlike the limitations of past 12V systems and bulky conventional converters, Bycor’s solution effectively combines high-voltage batteries with a 48V power supply network (PDN), and is already widely used in plug-in hybrids and BEVs.

“Additional battery support was essential without a DC-DC converter that could meet the millisecond response speeds that OEM customers demand,” explains the Bycor R&D team. “Our BCM6135 module perfectly addresses this need, significantly reducing development time and system design difficulty.”

Additionally, the symmetrical switching design maximizes energy recovery efficiency, which can lead to extended battery life and overall power consumption savings.