Innovative design steps towards a safe active lightweight chassis for an electric vehicle

Abstract

Lightweight design is still very important for an all-electric vehicle especially when used in urban areas. A new active chassis suspension designed for such an urban car is in development at the DLR. The first main component is a composite transverse leaf spring, where a new (partly) automated design and dimensioning process is in development. The second component is an orbital wheel bearing with an optional integrated electrical drive. The third component is an innovative wheel independent two axis steering actuator changing the toe and camber angle. This enables an increase of the active and passive safety of the occupants. First simulations proved the benefits of the concept regarding enhanced crashworthiness. The modular concept of the system allows to use the same wheel at each corner of the vehicle without changing a single part, thus reducing vehicle part variants and costs.