Chassis Control System
A fully electric chassis control system is an advanced automotive technology that replaces traditional hydraulic or mechanical systems with electrically actuated components to enhance vehicle stability, handling, safety, and efficiency. These systems rely on sensors, electronic control units (ECUs), and electric actuators to dynamically adjust chassis behavior in real time.
Key Functions of a Fully Electric Chassis Control System:
1. Dynamic Stability Control — Prevents skidding/loss of control by selectively braking wheels and adjusting torque.
2. Adaptive Suspension Damping — Adjusts shock absorber stiffness based on road conditions and driving style.
3. Torque Vectoring — Distributes power between wheels for better cornering and traction.
4. Active Roll Stabilization — Reduces body roll during sharp turns using electric anti-roll bars.
5. Brake-by-Wire & Regenerative Braking — Enhances braking efficiency and integrates with EV regenerative braking.
6. Steer-by-Wire — Removes mechanical linkage between the steering wheel and wheels for customizable response.
7. Predictive Adjustments — Uses AI/camera data to anticipate road conditions (e.g., potholes, curves).
Main Features & Benefits:
✔ Faster Response Time — Electric actuators react quicker than hydraulic systems.
✔ Energy Efficiency — No hydraulic pumps, reducing parasitic losses (key for EVs).
✔ Customizable Driving Modes — Adjust handling characteristics (Sport, Comfort, Off-road).
✔ Weight Reduction — Eliminates heavy hydraulic components.
✔ Enhanced Safety — Works with ADAS (Autonomous Driving Assistance Systems).
✔ Over-the-Air (OTA) Updates — Software can improve performance post-purchase.
Examples in Modern Vehicles:
- Tesla’s Adaptive Suspension (with software-controlled damping)
- Mercedes-Benz eActive Body Control (fully electric suspension)
- Audi e-tron’s Electric Torque Vectoring
- BMW’s Integral Active Steering & Adaptive M Suspension
Future Trends:
- Fully Integrated Chassis Domains (combining braking, steering, suspension into one ECU).
- AI-Powered Predictive Control (using navigation and sensor fusion).
- Vehicle-to-Everything (V2X) Integration — Adjusts chassis based on traffic/road data.
This technology is especially crucial for electric and autonomous vehicles, where efficiency, precision, and adaptability are paramount.
A cutting-edge addition to fully electric chassis control systems is an electromagnetic suspension system, inspired by maglev (magnetic levitation) train technology. This would replace traditional hydraulic or even air/spring-based suspensions with electromagnetic actuators for ultra-fast, near-frictionless adjustments.
Electromagnetic Suspension (Maglev-Style) in Automotive Chassis Control
This system would use electromagnetic coils and active magnetic bearings to control wheel movement, eliminating physical springs/dampers.
Key Features & Benefits
✅ Near-Instant Response — Magnetic fields adjust damping/stiffness in milliseconds (faster than hydraulic or pneumatic systems).
✅ Ultra-Smooth Ride — No mechanical friction, reducing vibrations and road noise.
✅ Active Height & Stability Control — Can lift/lower wheels independently (useful for off-road or high-speed aerodynamics).
✅ Energy Recovery — Regenerative damping converts bumps into electricity (improving EV range).
✅ Fully Adaptive — AI adjusts stiffness per wheel based on road sensors, driver input, and even predictive mapping.
✅ Weight Savings — No heavy shock absorbers or hydraulic fluids.
How It Works (Simplified)
Electromagnetic Actuators replace traditional dampers, using controlled magnetic fields to adjust wheel position.
Sensors (LIDAR, cameras, accelerometers) detect road conditions in real time.
AI Control Unit calculates optimal magnetic force for each wheel.
Power Supply (high-voltage battery) feeds the electromagnetic system, with energy recovery during compression.
Potential Applications
High-Performance EVs (e.g., BYD U7, U8, U9, next-gen Tesla Roadster, Rimac Nevera).
Luxury Autonomous Cars (Mercedes, Audi, Lucid).
Military/Off-Road Vehicles (instant terrain adaptation).
Hyperloop & Future Mobility (scaling maglev tech for cars).
Challenges
⚠ Cost — Expensive materials (rare-earth magnets, high-power electronics).
⚠ Energy Consumption — Requires a robust electrical system (but regenerative features help).
⚠ Heat Management — Strong electromagnets generate heat, needing cooling solutions.
Eventually last year I was selected by BOSCH — Chasis Control System (Vehicle Motion BOSCH Mobility) R&D head quarter at Abstat, near Stutgart, Germany. I was there last year [2024]; however, unfortunately an unknown reason, I was rejected and did not get the final permit to continue working.
Later, though I got a few other offers from good companies in Germany, I returned to India due to personal reasons.
Bosch Chassis Systems Control (CC) is a division of the Bosch Group that develops and manufactures components and systems for vehicle chassis control, including braking, steering, and vehicle dynamics control. Their focus is on creating systems that enhance safety, comfort, and driving performance.
Key areas of focus for Bosch Chassis Systems Control:
- Braking Systems:
- They develop and produce braking systems like vacuum-based and electromechanical brake boosters, as well as electronic braking control systems like ABS, TCS, and ESP®.
- Vehicle Dynamics Control:
- Bosch Chassis Systems Control offers systems like Vehicle Dynamics Control 2.0, which uses smart control concepts to anticipate and intervene in vehicle behavior, enhancing stability and agility.
- Occupant Protection:
- They develop and manufacture airbag control units, crash sensors, and other systems to protect vehicle occupants in various types of collisions.
- Driver Assistance Systems:
- Bosch Chassis Systems Control is also heavily involved in the development of driver assistance systems, including radar-assisted adaptive cruise control (ACC), predictive emergency braking, lane-keeping systems, and parking assistants.
- Software and Services:
- They also develop software solutions, including vehicle motion management, to enhance the driving experience and enable new functions.
- Modular and Integrated Systems:
- Bosch offers modular and integrated braking systems, including the iBooster, ESP®, and integrated power brake.
Bosch’s approach to chassis control:
- Software-defined vehicles:
- Bosch is actively involved in the development of software-defined vehicles, enabling flexible and adaptive features through software solutions.
- Centralized E/E architectures:
- Bosch develops software solutions for both classic and centralized E/E architectures, enabling reliable and functionally safe data services.
- Vehicle computers:
- Bosch offers vehicle runtime environments (VRTE) and vehicle computers for various applications, including safety-critical functions.
- Motion integration platform:
- Bosch provides a high-performance computing solution for coordinating powertrain, chassis, and steering in modern E/E architectures.
- Data-driven services:
- Bosch uses data to develop and improve its chassis control systems and related services, including using the Bosch IoT Suite for data-based service development.
Now, let’s see about latest production car models from BYD and what they are delivering
the same Chasis Control System and more.
As per wikipedia, The Yangwang U7, U8 and U9 are battery electric super-coupe manufactured by BYD Auto under its luxury car brand Yangwang. The U9 is the second vehicle from the Yangwang brand after the U8 off-road SUV, and was formally introduced on Auto Shanghai in April 2023.
The interesting part is that this car design and developed by German car designer Wolfgang Egger, who previously served as a head designer for Alfa Romeo, Audi and Lamborghini and began working for BYD in 2017.[2]
It’s individual wheel drive system, which enables the vehicle to redistribute torque among the four wheels in case of traction loss or a tyre puncture at speed; and the “DiSus” (云辇) active suspension system, which allows the wheels’ ground clearance to be readjusted individually and even to perform a brief vertical jump.[5] The active suspension consists of three different systems; DiSus-C controls variable damping, DiSus-A controls the air suspension, and DiSus-P controls the hydraulic system.[6] Regarding the vertical jump, the U9 will shrink first, then bounce up, launching all four wheels off the ground at the same time.[5] BYD has not announced the specific reason for the jump function on the U9, but the function demonstrates the “DiSus-X” body control system.
It has a fully electric chassis control system.
BOSCH, BYD, Tesla and other companies name used here are their own trade marks.
