What are the main challenges and trade-offs of active suspension systems for EVs and HEVs?

1 Power consumption

One of the main challenges of active suspension systems is their high power consumption, which can reduce the driving range and efficiency of EVs and HEVs. Active suspension systems require electric actuators, sensors, controllers, and pumps to operate, which can draw significant amounts of energy from the battery. To address this problem, some active suspension systems use regenerative braking or energy harvesting techniques to recover some of the kinetic energy that is dissipated by the suspension and convert it into electrical energy that can be stored in the battery or used by other components.

2 Weight and packaging

Another challenge of active suspension systems is their weight and packaging, which can affect the performance and design of EVs and HEVs. Active suspension systems add extra mass and volume to the vehicle, which can increase the inertia and reduce the acceleration and braking capabilities of the vehicle. Moreover, active suspension systems can interfere with the optimal placement and cooling of the battery and other powertrain components, which can affect the thermal management and safety of the vehicle. To overcome this challenge, some active suspension systems use compact and lightweight actuators, sensors, and controllers that can be integrated into the existing suspension components or mounted on the chassis or body.

3 Cost and reliability

A third challenge of active suspension systems is their cost and reliability, which can influence the market acceptance and customer satisfaction of EVs and HEVs. Active suspension systems are more expensive and complex than passive or semi-active suspension systems, which can increase the initial and maintenance costs of the vehicle. Furthermore, active suspension systems are more prone to failures and malfunctions due to the increased number of components and connections, which can compromise the safety and functionality of the vehicle. To mitigate this challenge, some active suspension systems use robust and fault-tolerant control strategies, self-diagnostic and self-healing mechanisms, and modular and standardized designs that can reduce the cost and improve the reliability of the system.

4 Ride comfort and handling

One of the main benefits of active suspension systems is their ability to improve the ride comfort and handling of EVs and HEVs, which can enhance the driving experience and satisfaction of the users. Active suspension systems can adapt to the road surface and the vehicle dynamics, and provide optimal damping and stiffness levels for different driving scenarios and preferences. This can reduce the vibrations and noise transmitted to the cabin, and improve the stability and maneuverability of the vehicle. Moreover, active suspension systems can also compensate for the effects of the battery weight and location, and the torque distribution and regeneration of the electric motors, which can affect the balance and traction of the vehicle.

5 Energy efficiency and emissions

Another benefit of active suspension systems is their potential to improve the energy efficiency and emissions of EVs and HEVs, which can contribute to the environmental sustainability and social responsibility of the vehicle manufacturers and users. Active suspension systems can reduce the aerodynamic drag and rolling resistance of the vehicle, and optimize the powertrain operation and battery management, by adjusting the ride height, wheel alignment, and suspension forces according to the speed, load, and road conditions. This can reduce the energy consumption and CO2 emissions of the vehicle, and extend the driving range and battery life of the vehicle.

6 Future trends and opportunities

A final benefit of active suspension systems is their role in enabling future trends and opportunities for EVs and HEVs, which can create new markets and applications for the vehicle industry and society. Active suspension systems can support the development and integration of advanced driver assistance systems (ADAS) and autonomous driving systems (ADS), by providing active steering, braking, and lane keeping functions, and enhancing the safety and comfort of the passengers. Furthermore, active suspension systems can also facilitate the adoption and deployment of vehicle-to-vehicle (V2V) and vehicle-to-infrastructure (V2I) communication technologies, by allowing the vehicle to share and receive information about the road conditions and traffic situations, and adjusting the suspension accordingly.

7 Here’s what else to consider

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