A universal wheel suspension assembly for electric vehicle applications

Abstract

A suspension assembly for an electric vehicle, comprising: a pair of modules, each module comprising: a mounting frame, an electric drive unit fixed to the mounting frame, a wheel assembly, a tire assembly mounted on the wheel assembly, a suspension system connecting the wheel assembly with the mounting frame, a drive shaft connecting the wheel assembly with the electric drive unit, and a damping system connected between the mounting frame and the suspension system; wherein the mounting frame is provided with one or more mounting holes for attaching each module to a chassis of the electric vehicle.

Description

[0001] A UNIVERSAL WHEEL SUSPENSION ASSEMBLY FOR ELECTRIC VEHICLE APPLICATIONS

[0002] TECHNICAL FIELD

[0003] The present invention relates generally to vehicle suspension systems, and more particularly to a universal wheel suspension assembly applicable for use in both light-duty and heavy-duty electric vehicles (EVs).

[0004] BACKGROUND

[0005] Electric vehicles (EVs), including trucks and other utility vehicles, often require specialized suspension and drive systems due to varying load capacities, chassis configurations, and performance requirements. Traditionally, each vehicle model or series might rely on a unique suspension and powertrain design to meet its specific performance criteria. This approach demands significant design and manufacturing effort and can increase costs related to manufacturing, inventory, maintenance, and supply chain logistics.

[0006] In the truck industry, for instance, a manufacturer might produce a wide range of models for different payload capacities, body styles, or application types. Each model might require variations in suspension geometry, damping characteristics, drive unit configurations, and thermal management systems. This leads to complexity and inefficiency when managing multiple component sets, training service technicians, and maintaining spare parts.

[0007] Accordingly, there is a need for a universal, modular suspension and drive unit assembly that reduces complexity, cost, and lead times by standardizing key components. Such a system should allow easy integration with different chassis designs, handle both light-duty and heavy-duty operations, incorporate effective thermal management for high-demand scenarios, and be adaptable to evolving EV technologies such as battery systems, advanced drive units, regenerative braking, and enhanced control modules.

[0008] SUMMARY

[0009] The present invention introduces a universal wheel suspension assembly designed to simplify the design, manufacturing, and maintenance of electric vehicles, particularly battery electric trucks (BETs) that span light-duty (LD) to heavy-duty (HD) classes. By relying on a uniform geometry and a common set of attachment interfaces, the assembly can be easily adapted to different vehicle chassis configurations and payload requirements.The invention provides a common external structure, enabling different torque outputs and performance levels without altering the fundamental geometry. A thermal management system (e.g., liquid cooling circuits, passive heat dissipation features) is integrated to regulate drive unit temperatures during high-demand duty cycles. Additionally, regenerative braking functionality may be included to enhance energy recovery and overall drive efficiency.

[0010] Preferably, the assembly is designed with a low-mounted architecture, improving the overall center of gravity and thereby enhancing handling, stability, and ride comfort under both loaded and unloaded conditions.

[0011] The assembly’s modular design allows for quick-access mechanisms, enabling servicing or replacement of drive components (motors, inverters, etc.) without dismantling the entire suspension system. This reduces maintenance complexity and downtime.

[0012] Standardized electrical connectors and interfaces facilitate easy integration of the suspension and drive unit with a vehicle’s high-voltage and low-voltage systems, as well as with ADAS (Advanced Driver- Assistance Systems) or other vehicle-level control modules. Integrated sensors can monitor real-time parameters such as wheel speed, ride height, damping pressure, and drive unit temperature.

[0013] Another significant advantage is the ability to incorporate future technological updates. Manufacturers can release improvements (e.g., more efficient motors, enhanced control algorithms) without necessitating a complete redesign of the suspension / axle architecture. The same principles allow for scalability across light-duty, medium-duty, and heavy-duty trucks using a single design philosophy.

[0014] Overall, the universal suspension and drive unit assembly promotes a high degree of interoperability, more efficient use of manufacturing resources, and significantly reduced engineering costs. By scaling such assemblies across different vehicle sizes and classes, the invention supports broader adoption of electric vehicle platforms, especially in commercial and industrial applications requiring robust, reliable, and easily serviceable suspension systems.

[0015] In one aspect, the present invention provides a suspension assembly for an electric vehicle that comprises two mirror-image modules. Each module includes a mounting frame configured with fastening points for secure attachment to a vehicle chassis, an electric drive unit to supply torque, a wheel assembly and tire assembly, a suspension system for controlled wheel motion, a drive shaft transmitting power from the electric drive unit to the wheel, and a damping system to absorb road impacts. This arrangement provides a standardized architecture for easy integration across light-duty to heavy-duty EV platforms, thereby reducing design complexity and manufacturing costs.In a preferred embodiment, the damping system in the above-described suspension assembly is implemented either as an air spring or a coil spring. Such flexibility allows vehicle manufacturers to select a damping solution based on specific load, ride comfort, and handling requirements, thereby ensuring optimal performance for diverse commercial and industrial applications.

[0016] In another preferred embodiment, the mounting frame is formed with multiple bolt patterns or mounting hole arrangements, enabling compatibility with various vehicle chassis designs. This configuration provides the advantage of accommodating different chassis geometries without requiring a fundamental redesign of the suspension module, thus streamlining production and reducing inventory complexity. As a mounting frame, a part of one of rigid components can be used, for example a part of the electric drive unit, for example an outer housing of a gearbox.

[0017] In a further preferred embodiment, the suspension assembly is equipped with a modular control interface that communicates with the electric drive unit and integrates seamlessly with existing vehicle-level control systems. Therefore, it is possible to achieve consistent control logic and straightforward connectivity across different EV models, leading to simpler diagnostics and faster software updates.

[0018] In yet another preferred embodiment, the suspension assembly incorporates integrated sensors for monitoring parameters such as wheel speed, ride height, and damping pressures, transmitting this data to a central vehicle controller. Such real-time data acquisition allows immediate feedback for adaptive control strategies, improving vehicle safety, handling, and overall efficiency.

[0019] In an additional preferred embodiment, braking components are integrated with the wheel assembly. This allows for a compact and cohesive design where drivetrain, suspension, and braking elements operate in harmony, thereby facilitating maintenance and reducing the footprint of the overall assembly.

[0020] In a further preferred embodiment, the electric drive unit of the suspension assembly incorporates a regenerative braking system to capture energy during deceleration. Hence, it becomes possible to enhance vehicle efficiency by recovering otherwise lost energy, contributing to extended driving range and reduced operating costs.

[0021] In another preferred embodiment, a thermal management system is integrated into the electric drive unit, which may include liquid cooling channels or passive heat dissipation fins within or attached to the mounting frame. Such a thermal management configuration provideseffective heat regulation under demanding conditions, thereby improving performance and extending component lifespans.

[0022] In yet another preferred embodiment, integrated sensors are provided within the suspension assembly to measure parameters such as temperature or coolant flow, enabling realtime transmission of data to a central vehicle controller for thermal management. This enables proactive system monitoring and control adjustments to prevent overheating, thus improving reliability and reducing downtime.

[0023] Various types of the damping systems and suspension systems can be employed, such as a double wishbone suspension described in detail herein, depending on the type of the vehicle and required loads, for example by changing spring types and wishbone types.

[0024] Although the suspension assembly has been shown in the embodiment herein for a single axle, other embodiments within the scope of the invention can encompass multiple designs, such as dual axle.

[0025] These and other features, aspects and advantages of the invention will become better understood with reference to the following drawings, descriptions and claims.

[0026] BRIEF DESCRIPTION OF DRAWINGS

[0027] The invention will be described in detail with reference to example embodiments shown in the drawings, wherein:

[0028] Fig. 1 shows the wheel suspension assembly in a perspective view;

[0029] Fig. 2 shows the drive axle system in an exploded view from the back;

[0030] Fig. 3 shows the drive axle system in a cross-sectional view from the back;

[0031] DETAILED DESCRIPTION

[0032] The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention.

[0033] The present invention provides a universal suspension assembly 100 for electric vehicles, illustrated in FIGS. 1 to 3. This embodiment is designed to be adapted for various electric vehicle platforms, ranging from personal cars, via light-duty trucks to heavy-duty trucks, by utilizing standardized components and interfaces. In particular, the assembly may be implemented across diverse battery electric truck (BET) classes, from light-duty (LD) to heavy-duty (HD), by scaling the same architectural principles for different payload capacities.The suspension assembly comprises a pair of modules - a left module 110L and a right module 110R, to be fitted at each side of the vehicle chassis. Each module comprises a mounting frame 111 that can be fabricated from high-strength steel, aluminum alloy, or a composite material, depending on the desired weight and durability requirements. The mounting frame includes multiple bolt patterns or mounting holes 118, enabling direct attachment to different types of electric vehicle chassis. By varying the location of these mounting points, manufacturers can account for differences in chassis size and design without altering the core geometry of the suspension system. In some embodiments, this mounting frame 111 may be positioned relatively low on the chassis to improve the vehicle’s center of gravity, thereby enhancing handling and stability under both loaded and unloaded conditions.

[0034] Integrated with mounting frame 111 is an electric drive unit (EDU) 112, which converts electrical power from the vehicle’s battery into mechanical torque. This EDU may be provided in multiple power or torque variants, yet housed within the same external structure to maintain a uniform attachment interface. This EDU may also integrate a lubrication system and a thermal management system — such as liquid cooling channels or passive heat dissipation fins — to regulate operating temperature during heavy-duty cycles or sustained high-torque demands. Furthermore, a regenerative braking system can be included to recover energy during vehicle deceleration, enhancing overall efficiency.

[0035] Torque generated by the EDU 112 is transmitted to the wheel assembly 113 via a drive shaft 116. The wheel assembly supports a tire assembly 114 that can be selected according to the application’s load requirements. The interface between the drive shaft 116 and the wheel assembly 113 typically incorporates constant velocity joints, allowing the suspension to move vertically and pivot for steering without imposing undue stress on the drivetrain components. Other types of drive shafts can be used as well. In some embodiments, quick-access mechanisms allow the EDU 112 or major drivetrain parts to be serviced or replaced independently, thus reducing vehicle downtime.

[0036] Preferably, the suspension system 115 is a double wishbone design, which provides a stable, controllable geometry for wheel movement, thus offering adequate handling for various applications. Each wishbone arm is pivotally connected to the mounting frame 111, with the geometry set to manage camber and caster angles for optimized tire contact and reduced wear. In heavier-duty applications, these wishbones may be reinforced to accommodate higher loads while maintaining the same general shape and attachment points. This approach enables a single suspension architecture to be scaled for light-duty, medium-duty, and heavy-duty applications without redesigning the entire assembly.Between the mounting frame 111 and the suspension system 115, a damping system 117 is installed. Although this embodiment illustrates an air spring, the invention also contemplates alternative damper types, such as coil springs or a hybrid coil-and-air arrangement. The choice of damping system can depend on factors such as vehicle load capacity, desired ride comfort, or on-the-fly adjustability. Air springs, for instance, permit rapid modulation of ride height to accommodate heavy payloads or uneven road surfaces, while coil springs might be preferred for simpler, lighter- weight applications. In either case, the damping system 117 may include high-strength or corrosion-resistant materials to ensure long-lasting performance under varying operational conditions.

[0037] The suspension assembly may be steered or non-steered.

[0038] For vehicles requiring steering, a steering arrangement 120 couples the modules on opposite sides of the chassis. In a basic design, a mechanical tie rod links the steering knuckles attached to each wheel assembly 113, ensuring synchronized turning angles. In a more advanced approach, the steering arrangement can be implemented as a steer-by-wire system, where the driver’s steering input is relayed electronically to actuators controlling the wheel assemblies independently. The invention’s standardized geometry permits either steering configuration to be adopted without altering fundamental module mounts or suspensions, making it possible to produce both steerable and non-steerable axle configurations (both front and back) within the same product family. A single wheel actuator and drive by wire functionality can be used to steer each wheel individually.

[0039] In addition to mechanical integration, the modules may include standardized electrical connectors for power and signal lines, facilitating straightforward integration with an electric vehicle’s wiring harness. This includes high-voltage cables for the EDU 112, low-voltage sensor lines for wheel speed or ride height measurements, and communication links to the central vehicle control unit. In certain embodiments, additional sensors can measure the drive unit’s temperature or coolant flow (if liquid-cooled), enabling advanced thermal management strategies and real-time diagnostics. These electrical and data interfaces also allow for integration with advanced driver-assistance systems (ADAS) or other vehicle control modules, supporting features such as active stability control or torque vectoring.

[0040] In some embodiments, especially those intended for heavy-duty use, the mounting frame 111 and suspension system 115 may be constructed with reinforced cross-sections to support higher loads while preserving the same general shape and attachment points. Such scaling ensures that manufacturers can cover a wider range of vehicle classes by maintaining a single set of design principles, thereby reducing production and supply chain complexity. As a result,fleet operators and service technicians benefit from a standardized platform that simplifies training, spare parts management, and maintenance procedures. The modular nature of this universal suspension assembly 100 also facilitates future updates to motor technologies or control electronics without necessitating significant changes to the axle or chassis design, thus providing a robust and adaptable solution for electrified vehicle platforms.

[0041] While the invention has been described with respect to a limited number of embodiments, it will be appreciated that many variations, modifications and other applications of the invention may be made. Therefore, the claimed invention as recited in the claims that follow is not limited to the embodiments described herein.

Claims

CLAIMS1. A suspension assembly for an electric vehicle, comprising:a pair of modules, each module comprising:a mounting frame,an electric drive unit fixed to the mounting frame,a wheel assembly,a tire assembly mounted on the wheel assembly,a suspension system connecting the wheel assembly with the mounting frame, a drive shaft connecting the wheel assembly with the electric drive unit, and a damping system connected between the mounting frame and the suspension system;wherein the mounting frame is provided with one or more mounting holes for attaching each module to a chassis of the electric vehicle.

2. The suspension assembly according to claim 1, wherein the damping system is an air spring or a coil spring.

3. The suspension assembly according to claim 1 or 2, wherein the mounting frame comprises a plurality of bolt patterns or mounting hole arrangements to accommodate a plurality of vehicle chassis designs.

4. The suspension assembly according to any of claims 1 to 3, further comprising a modular control interface in communication with the electric drive unit, configured to integrate with existing vehicle-level control systems.

5. The suspension assembly according to any of claims 1 to 4, further comprising integrated sensors for monitoring wheel speed, ride height, and damping pressures, wherein data from the sensors is communicated to a central vehicle controller.

6. The suspension assembly according to any of claims 1 to 5, further comprising braking components integrated with the wheel assembly.

7. The suspension assembly according to any of claims 1 to 6, wherein the electric drive unit includes a regenerative braking system for energy recovery during vehicle deceleration.

8. The suspension assembly according to any of claims 1 to 7, further comprising a thermal management system integrated into the electric drive unit, the thermal management system including at least one of liquid cooling channels or passive heat dissipation fins formed in the mounting frame.

9. The suspension assembly according to any of claims 1 to 8, further comprising integrated sensors, wherein sensor data is transmitted to a central vehicle controller for real-time thermal management.

10. The suspension assembly according to any of claims 1 to 9, further comprising a steering arrangement.

11. The suspension assembly according to claim 10, wherein the steering arrangement couples the suspension systems of both modules.

12. The suspension assembly according to claim 10, wherein the steering arrangement steers each module individually.

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