ZF and Levant Power Develop Regenerative Active Suspension

TTAC Staff
by TTAC Staff

ZF Friedrichshafen AG and Levant Power Corp., a Woburn, Massachusetts technology company spun off from MIT, have announced what they call the first fully active suspension system that includes a regenerative function that recovers energy from the motion of the suspension. The system is branded GenShock. Active suspensions are not new, General Motors experimented with an actively suspended ZR-1 Corvette when the automaker owned Lotus, which had worked with active suspensions before the technology was banned in Formula One. Going back even farther, there were the hydropneumatic Citroens and the last true Packards’ “torsion level” suspension. With road cars the goal in using such a system would be to combine good ride with good handling, soft sometimes and stiff sometimes, depending on the driving circumstances. Early tries at developing what chassis engineers call a “high bandwidth active suspension”, capable of dealing with those varying circumstances, have run into cost, complexity and power consumption issues. The GenShock system is claimed to be affordable, simple to integrate in existing suspension designs, and not only have modest power consumption but also be able to recover energy from the suspension.

The heart of the system is what Levant Power calls the Activalve TM, a device that combines electric and hydraulic motors (the companies are calling that an “electrohydraulic gear pump”) and can be adapting to standard mono, twin, and tri-tube damper configurations. Hydraulic fluid in the shock absorber is routed from the damper body through the valve, where the electric motor can be used to control the flow of fluid through the gear pump, or alternatively, the pump can be used to drive the electric motor as a generator, recovering electricity. The poorer the road quality, the more bumps there are, the more energy is recovered. Electronic controls adapt the damping characteristics to the driving situation, reducing body pitch and roll during cornering and braking. While the system adds a little bit of weight, compared to a passive suspension, it also eliminates the need to carry a jack, since the system is capable of raising or lowering each wheel independently.

Note that this is not a perpetual motion machine, like putting a wind generator on a car. It creates no new load on the powertrain, it merely recovers energy that would normally be turned into heat. ZF and Levant Power haven’t released any figures on just how much energy is recovered and whether that exceeds the power required to run the system. Like Innowatech‘s piezoelectric roadways, BMW’s Turbosteamer concept, or Purdue professor Xianfan Xu’s work recovering electricity from engine exhaust using large scale Peltier devices, the GenShock is harvesting energy that would otherwise go to waste.

TTAC Staff
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  • Charliej Charliej on Aug 31, 2013

    I read all the negativity, and I remember my friends who would not buy a car with an automatic transmission because "it would break". Also, a friend that would not buy a car with electronic ignition because "it would break". You can be sure that if this active suspension system is put into mass production, it will be OK. If not the first iteration, by the time it works down to mass market vehicles, it will be OK. The same with electric cars. The first generation cars are not practical. The early adopters pay the price for buying early. People who wait, get the perfected product. But, without the early adopters, there would be no perfected product. Just because you would not buy it, does not mean that it should not be produced.

    • Porschespeed Porschespeed on Sep 01, 2013

      A CD burner cost north of $100K less than 20 years ago. A 1-gig hard-drive was something only the gov could afford in the mid/late70s, and had 5 platters the size of LPs.

  • Parkwood60 Parkwood60 on Sep 01, 2013

    Now I'm no electrical engineer, but couldn't you make the bumps in the road produce electricity with just some sort of piezo electrical material between the spring and the perch on all 4 corners? Sure it wouldn't produce as much power as something like this, but it would cause no problems when/if it failed and could be implemented for a few bucks on any car.

  • ToolGuy "Honey, someone is trying to cross the moat again"
  • Rochester "better than Vinfast" is a pretty low bar.
  • TheMrFreeze That new Ferrari looks nice but other than that, nothing.And VW having to put an air-cooled Beetle in its display to try and make the ID.Buzz look cool makes this classic VW owner sad 😢
  • Wolfwagen Is it me or have auto shows just turned to meh? To me, there isn't much excitement anymore. it's like we have hit a second malaise era. Every new vehicle is some cookie-cutter CUV. No cutting-edge designs. No talk of any great powertrains, or technological achievements. It's sort of expected with the push to EVs but there is no news on that front either. No new battery tech, no new charging tech. Nothing.
  • CanadaCraig You can just imagine how quickly the tires are going to wear out on a 5,800 lbs AWD 2024 Dodge Charger.
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