Trystan Casey
The vehicle chassis is a crucial component of any car, encompassing the entire undercarriage and serving as the main support structure for all other parts. The electrical function of a modern vehicle chassis is twofold: firstly, it acts as a platform to disperse impact forces, minimising stress on individual components and protecting occupants in a collision; secondly, it provides a stable structure to house the electrical system, which generates, stores and supplies power to various vehicle systems and components. This includes power windows, central locking mechanisms, and digital gadgets. The chassis also supports the vehicle's electrical steering system, which may be hydraulic or electric depending on the car's make. The electrical function of a modern vehicle chassis is, therefore, integral to the overall performance, safety and stability of the vehicle.
| Characteristics | Values |
|---|---|
| Chassis function | Distribution and absorption of forces, providing a platform that disperses impact forces during acceleration, braking and maneuvering. |
| Support structure for all other vehicle components. | |
| Maintains vehicle stability, safety and performance. | |
| Houses essential components like the engine, suspension system, etc. | |
| Provides rigidity and crash resistance. | |
| Electrical function | Generating, regulating, storing and supplying electric current to vehicle systems. |
| Operating electrical components like gauges, digital gadgets, power windows, etc. | |
| Powering advanced steering systems like EPAS. | |
| Electric vehicles (EVs) use Lithium-Ion batteries, offering higher energy density and faster charging. |
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What You'll Learn
Electric vehicle (EV) subsystems
The body design is the first group of EV subsystems. It refers to the structural framework of the vehicle, encompassing key aspects such as bumpers, suspension, chassis, and the overall structural framework. Engineers carefully configure these elements to ensure they work together seamlessly. While the vehicular design of EVs may not deviate drastically from conventional vehicles, there can be slight modifications in the placement of certain parts to accommodate electric powertrains, batteries, and associated electronics.
The propulsion system is the second group of EV subsystems. This is where electric energy is converted into kinetic energy to propel the vehicle. The propulsion subsystems consist of the electric motor, transmission, driveline, wheels, and motor controller (inverter), along with other electronic control units (ECUs). The electric motor is a critical component, and it can also function as a generator during regenerative braking.
The energy storage system is another crucial group of EV subsystems. These subsystems centre on the components that enable vehicles to store the energy required for overall operability. In EVs, this typically includes high-voltage batteries, fuel cells, ultra-capacitors, battery management systems (BMS), energy charger units, and contactors. The battery is particularly important as it is very heavy, and the frame and materials used must be designed to accommodate its size and weight.
Additionally, accessory subsystems in EVs include stereo systems, AC units, and lighting. These subsystems require special consideration for energy conservation as they can impact the EV's overall range by increasing power consumption.
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Electrical energy storage
The electrical functions of a modern vehicle chassis are evolving with the advent of electric vehicles (EVs). The chassis and body technology, propulsion technology, and energy source technology are the core technologies of an EV. The electrical energy storage systems in an EV chassis are critical to the vehicle's performance and functionality.
The desirable characteristics of an energy storage system (ESS) in an EV include high specific energy, significant storage capacity, longer life cycles, high operating efficiency, and low cost. The specific energy (Wh/kg) and specific power (W/kg) of the ESS are crucial factors, as they determine the vehicle's range and the charging time required. The development of efficient ESS is essential to the advancement of electric transportation.
There are various types of ESS topologies available for EVs, including hybrid combinations such as hybrid electric vehicles (HEV) and plug-in HEV (PHEV). These systems combine different energy storage methods, such as batteries, ultracapacitors, and fuel cells. The hybrid combination offers flexibility and may be a promising technology to support the wider adoption of EVs in modern transportation.
The choice of ESS technology depends on several factors, including the vehicle's performance requirements, charging infrastructure, and cost considerations. Batteries, as a key component of ESS, have received significant attention due to their potential to make EVs more environmentally friendly, cost-effective, and suitable for daily use. Lithium-ion batteries, for instance, have been studied extensively for their application in EVs.
The integration of ESS into the EV chassis presents design challenges. The chassis must accommodate the ESS while optimizing space and weight distribution. This often involves modifying the traditional chassis layout to lower the center of gravity and improve handling and stability. Modular chassis designs are emerging as a flexible and cost-effective solution, allowing manufacturers to adapt different powertrains, including electric systems, and develop multiple vehicle models from a single chassis architecture.
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Electric steering systems
Power steering, which uses a power source to assist with steering, is a common feature in modern vehicles. Electric power steering systems (EPS) use electric motors to assist the driver in turning the wheels, instead of hydraulic systems. The steering system is attached to the chassis and works with the suspension and wheels to steer and control the direction of the car.
The first power steering system was installed in 1876, but little is known about it. In 1903, a separate electric motor was used to assist the driver in turning the front wheels of a Columbia 5-ton truck. In 1926, Francis W. Davis invented and demonstrated the first practical power steering system, which was hydraulic-assisted. Over time, electric power steering has become more commonplace.
EPS uses an electric motor to control and assist with vehicle steering, providing an optimal and enjoyable steering feel. The torque sensor, along with vehicle speed and steering angle sensors, sends information to a control module, which specifies how much assistance the electric motor requires to turn the wheels, as well as how far and in which direction. Some EPS can alter the amount of resistance the driver feels when turning the wheel, providing more assistance at low speeds and less assistance at high speeds. This makes manoeuvring in tight spaces, like parking lots, easier, while also allowing for a more precise and responsive feeling on highways.
The EPS supports all driver assistance functions and autonomous driving. It enables highly-automated driving with maximum security and protection against cyber-attacks. The modular design of the steering control unit allows for flexibility in using different steering control unit variants within a vehicle series.
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Unibody chassis design
The electrical function of a modern vehicle chassis is closely tied to the integration of electric powertrains and subsystems. The chassis, as a structural component, must accommodate battery packs, electric motors, and associated electronics while optimising space and weight distribution. This requires modifications to the traditional chassis layout to lower the centre of gravity and enhance handling and stability.
Now, when it comes to Unibody chassis design, also known as monocoque chassis design, it is the standard chassis type in most modern vehicles, including sedans, hatchbacks, and SUVs. Unibody construction fuses the car frame and chassis into a single unit, providing exceptional strength, rigidity, and crash resistance. This design approach offers several advantages over traditional body-on-frame construction.
Firstly, the unibody design improves handling and stability by lowering the centre of gravity. By integrating the body, floorboards, and structural elements into one large structure, the unibody platform becomes more rigid and lightweight. This weight reduction can lead to improved fuel economy, as seen with the Ford Explorer SUV, which gained an additional four miles per gallon when switched to a unibody design.
Secondly, the unibody construction enhances safety features. The design's inherent strength and rigidity provide superior crash resistance by effectively absorbing and distributing crash energy. This improves occupant protection and can be further enhanced by incorporating crumple zones and advanced driver-assistance systems (ADAS).
Lastly, unibody construction offers greater design flexibility and interior space. By eliminating the need for a separate structural frame, automakers have more freedom in designing vehicle bodies, optimising interior space, and engineering advanced safety features. This construction method is particularly suitable for vehicles that do not require high towing capabilities or off-road capabilities, as the focus shifts towards improved fuel economy and safety.
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Safety features
Safety is a crucial aspect of modern vehicle chassis design. The chassis plays a vital role in ensuring vehicle stability, safety, and overall performance. Here are some key safety features and considerations related to the chassis:
Crashworthiness and Occupant Protection
The monocoque or unibody chassis design, commonly found in modern vehicles, offers improved safety in the event of a collision. By integrating the body and chassis into a single unit, this design provides exceptional strength, rigidity, and crash resistance. It effectively absorbs and distributes crash energy, redirecting impact forces away from the passenger compartment, thus safeguarding occupants. Additionally, the monocoque chassis lowers the vehicle's center of gravity, improving handling and stability, which further contributes to overall safety.
Advanced Driver-Assistance Systems (ADAS)
Modern chassis designs incorporate advanced technologies such as ADAS, which includes features like automatic emergency braking, lane-keeping assistance, and collision avoidance systems. These systems rely on integrated sensors and electronic control units that communicate with the chassis and other vehicle components to enhance safety actively.
Electric Vehicle (EV) Safety
The growing popularity of electric vehicles brings unique safety considerations. The integration of electric powertrains, battery packs, and associated electronics into the chassis design requires careful consideration of weight distribution and space optimization. Safety standards for EVs focus on ensuring the proper functioning of these electrical subsystems, including the battery, motor, and associated electronics, to prevent electrical faults and fires.
Chassis as a Safety Platform
The chassis serves as a platform that disperses impact forces generated during acceleration, braking, and maneuvering. By evenly distributing these forces, the chassis minimizes stress on individual components, reducing the likelihood of premature wear and tear. This distribution of forces also contributes to overall vehicle safety by maintaining structural integrity and protecting occupants in the event of a collision.
Modular Chassis and Safety Innovations
The emergence of modular chassis platforms allows for flexible and cost-effective design adaptations. This modularity enables manufacturers to integrate various safety features more easily, such as crumple zones and advanced structural designs that enhance crash performance and occupant protection.
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Frequently asked questions
A vehicle chassis encompasses the entire undercarriage of a vehicle, including the frame, engine, drivetrain, suspension, and wheels. It serves as the main support structure for all other vehicle components.
The electrical function of a modern vehicle chassis is to generate, regulate, store, and supply electric current to various vehicle systems. The vehicle electrical system comprises many components, including generators, electric wiring harnesses, and connectors. The primary purpose of the battery is to store electrical energy for future use.
Electric vehicle chassis designs must accommodate battery packs, electric motors, and associated electronics while optimizing space and weight distribution. This often involves lowering the center of gravity and improving handling and stability. Modular chassis platforms are becoming popular as they are flexible and cost-effective, allowing manufacturers to develop multiple vehicle models from a single chassis architecture.
