I have been interested in the developments in electric vehicle (EV) suspension systems. EV suspension systems are crucial not only for providing a smooth and comfortable ride but also for enhancing the performance, efficiency, and safety of EVs. In this article, I will explore some of the latest innovations and trends in EV suspension systems and how they shape mobility's future.
EV suspension systems are different from conventional suspension systems in several ways. First, EVs have a different weight distribution and center of gravity than internal combustion engine (ICE) vehicles due to the placement of batteries and motors. This affects EVs' handling and stability, requiring a different suspension design and tuning. Second, EVs have less noise and vibration than ICE vehicles, so the passengers can more easily feel any imperfection or disturbance in the road surface. This demands higher ride quality and comfort from EV suspension systems. Third, EVs have the potential to harvest energy from the suspension movement, which can be used to extend the range or power other features of the vehicle. This creates an opportunity for regenerative EV suspension systems that can recover kinetic energy from road bumps and shocks.
One of the most advanced EV suspension systems on the market is the BYD DiSus Intelligent Body Control System, which the Chinese EV maker launched in April 2023. The system is similar to the chassis suspension systems available in premium and luxury cars, such as Porsche's Dynamic Chassis Control and Mercedes Benz's Magic Body Control. The DiSus system has three variations: DiSus Comfort, DiSus Sport, and DiSus Off-road. Each variation can adjust the damping force, roll angle and pitch angle of each wheel independently, according to the road conditions, driving mode, and driver's preference. The system can also communicate with other vehicle systems, such as steering, braking and powertrain, to optimize the overall performance and efficiency of the vehicle. The DiSus system is initially used in BYD's luxury off-road SUV Yangwang U8, but will also be available in other models, such as BYD Han, Tang and Denza.
Another promising EV suspension system is the regenerative system developed by a team led by Professor Lei Zuo from the Advanced Energy Technology and Research Center at Stony Brook University. The system was unveiled in 2011 and won several awards for its innovation and potential. The system can recover 100 to 400 watts of vibration (kinetic) energy from a passenger car traveling at 100 km/h. The system works by pairing an electricity generator with a conventional suspension system with steel springs and hydraulic shock absorbers. The generator converts the vertical movement of the suspension into electrical energy, which can be stored in batteries or used to power other features of the vehicle. The system can also improve the ride quality by reducing the vibration transmitted to the cabin. The team estimated that such a system could improve the fuel efficiency of hybrid vehicles by one to five percent.
A similar concept is pursued by Intertronic Gresser GmbH, a German company that patented an "electricity-generating suspension system for hybrid and electric cars" in October 2014. The company claimed to increase the range by 50 percent in relation to the battery storage capacity. The system uses coupled linear generators that convert not only the vertical movement of the suspension but also the body acceleration into electricity. The company claimed that, assuming an average wheel suspension movement per meter traveled of +/-25 mm, the potential energy yield from the regenerative suspension would be 15 kWh over a distance of 100 km.
These are just some examples of how EV suspension systems are evolving and improving with new technologies and ideas. EV suspension systems are not only responsible for providing a smooth and comfortable ride but also for enhancing EVs' performance, efficiency, and safety. As more EVs enter the market and compete for customers' attention and satisfaction, EV suspension systems will play a key role in differentiating and improving their products. EV suspension systems are indeed shaping the future of smooth mobility.