Composition of The Intelligent Chassis

Amidst the wave of automotive intelligence and electrification, chassis systems are evolving from traditional mechanical assemblies into highly integrated digital control platforms—known as the Intelligent Chassis. The intelligent chassis is not a single technology but a systems engineering project comprised of multiple core brake-by-wire technologies working in synergy. By replacing mechanical linkages with electronic signals, it achieves precise, rapid, and integrated control of the vehicle's motion posture, forming the cornerstone of high-level autonomous driving. Its core composition primarily includes the Brake-by-Wire System, the Steer-by-Wire System, and the Suspension-by-Wire System.

I. Brake-by-Wire System: The Precise and Reliable Digital Braking Core

Brake-by-wire is crucial for the longitudinal control of the intelligent chassis, fundamentally changing how braking force is transmitted. Traditional braking relies on the mechanical-hydraulic transmission of the driver's foot force and a vacuum booster, whereas brake-by-wire centers on sensors, an Electronic Control Unit (ECU), and motor-driven actuators.

Its core composition and working principle are as follows: When the driver presses the brake pedal, a pedal travel sensor converts the displacement into an electrical signal sent to the ECU. The ECU synthesizes information such as wheel speed and vehicle attitude to calculate the optimal braking force required for each wheel, then commands a motor (in the mainstream One-box solution) to directly drive the hydraulic mechanism, achieving precise and rapid braking. This entire process "decouples" the pedal from the actuator, delivering three core advantages:

1. Ultimate Safety: Electronic signal      transmission and motor pressure buildup are far faster than traditional      hydraulics, drastically reducing emergency braking response time. The      system incorporates mechanical redundancy backup to ensure basic braking      capability even in the event of electronic failure.

2. High Efficiency and Energy Saving:      Through synergy with the electric drive system, it can seamlessly and      precisely coordinate mechanical braking force with motor braking force      (energy regeneration), maximizing kinetic energy recovery and      significantly extending the range of electric vehicles.

3. Intelligence Enablement: It      provides a directly controllable, precisely executable braking interface      for autonomous driving systems (e.g., AEB, ACC), making it an essential      prerequisite for realizing L2+ advanced driver-assistance functions.

II. Steer-by-Wire System: The Flexible and Free Steering Control Hub

The steer-by-wire system eliminates the mechanical connection (such as the steering column and gear) between the steering wheel and the steering wheels, completely relying on electronic signals for the transmission and execution of steering commands.

Its core components include: the Steering Wheel Assembly (containing a steering feel feedback motor and angle sensor), the Electronic Control Unit, and the Steering Execution Assembly (containing a steering motor). When the driver turns the steering wheel, sensors detect the angle and torque. The ECU comprehensively calculates the desired steering angle and road feel feedback based on vehicle speed, driving mode, etc., and controls the steering motor at the front wheels to execute the corresponding action.

This system brings revolutionary changes:

1. Liberates Design and Space:      Removing the mechanical connection frees up cabin layout space, enabling      possibilities like a foldable or uniquely shaped steering wheel.

2. Enhances Safety and Experience:      Software allows free customization of steering feel and steering ratio      (e.g., light at low speeds, firm at high speeds) and enables stability      interventions in synergy with the braking system under extreme conditions.

3. Supports High-Level Autonomous Driving: It provides the direct pathway for steering operations in      autonomous vehicles, allowing the system to automatically take over      steering control when activated.

III. Suspension-by-Wire System: The Dynamic Balancing Vertical Attitude Manager

The suspension-by-wire system is responsible for the dynamic control of the intelligent chassis in the vertical direction. It actively adjusts suspension stiffness and damping to optimize wheel contact and body posture in real-time.

Its core composition is typically represented by the mainstream solution of "Air Spring + CDC (Continuous Damping Control) Shock Absorbers", and includes height sensors, acceleration sensors, a control unit, and electronically controlled adjustment valves. The system continuously monitors body height, acceleration, and road vibrations via sensors. The ECU calculates and commands the air spring to adjust pressure (changing height and stiffness) and the CDC shock absorber to adjust valve opening (changing damping force) within milliseconds.

Its primary value lies in achieving dynamic balance:

1. Adaptive Comfort: Actively softens      the suspension to filter vibrations on bumpy roads and enhances support to      maintain stability on flat roads or during high-speed travel.

2. Active Handling: Actively      suppresses body roll during cornering, squat during acceleration, or dive      during braking, enhancing handling limits and stability.

3. Multi-Function Expansion: Allows      speed-dependent body height adjustment (lowering at high speed for      efficiency, raising for off-road capability) and features convenient      load-leveling functions.

IV. System Synergy: The Ultimate Value of the Intelligent Chassis

The value of the intelligent chassis far exceeds the simple sum of its subsystems. Its ultimate goal is to achieve deep synergy and unified scheduling among the various brake-by-wire subsystems through a Chassis Domain Controller, i.e., Integrated Vehicle Motion Control.

For example, during a high-speed emergency evasion maneuver, the system can coordinate the brake-by-wire system to apply precise braking to individual wheels, the steer-by-wire system to provide optimal steering compensation, and the suspension-by-wire system to strengthen support on the outer side, thereby completing the avoidance maneuver with a more stable and safer posture. This coordinated optimization of lateral, longitudinal, and vertical motions is unattainable by traditional chassis. It truly elevates the chassis from a passive execution mechanism to an "intelligent body" capable of active decision-making and coordinated optimization.

Conclusion

The intelligent chassis is composed of three core systems: brake-by-wire, steer-by-wire, and suspension-by-wire. Together, they function like the vehicle's "digital nerves" and "active skeleton," forming the foundation of the smart car's motion capabilities. Its development is progressing towards higher integration, more powerful software-defined capabilities, and more comprehensive safety redundancy. HOLS Automation deeply understands the extreme demands for precision manufacturing and reliability placed on the core components of the intelligent chassis. We are committed to providing the industry with automated, intelligent production line solutions covering these systems, empowering the reliable advancement of the smart mobility era with our advanced manufacturing technology.