ZF has introduced the next generation of its Smart Chassis Sensor, just months after beginning production of the initial model for the Cadillac CELESTIQ.
The new version adds a 3-axis accelerometer to the existing wheel travel measurement system, significantly expanding the sensor’s functional scope. This includes real-time load detection, chassis health diagnostics, and support for active noise cancellation, capabilities increasingly valuable to electric vehicle (EV) platforms.
Unlike traditional ride-height sensors, the Smart Chassis Sensor is embedded directly into the ball joint of the suspension system, enabling precise measurement of suspension travel through changes in joint angle.
The new model builds on this architecture by capturing dynamic acceleration data directly at the wheel itself. By mounting the sensor at all four corners, OEMs can use this data to monitor chassis behavior, road surface characteristics, and vertical excitation across the vehicle.
Designed for seamless integration, the sensor combines low weight, robust construction, and high signal quality. It enables a range of data-driven functions, including chassis health monitoring, load detection, and active noise cancellation, and is a key enabler of ZF’s software-defined Chassis 2.0 strategy.
Real-time chassis monitoring
The integration of 3D acceleration detection allows for early identification of mechanical anomalies through spectral analysis of vibration patterns. Changes in those patterns (such as those caused by worn bushings, loose wheel fasteners, or misaligned components) can trigger diagnostic alerts before failure occurs. This approach supports emerging trends in predictive maintenance and is a foundation for digital chassis health systems.
The sensor also enables real-time load detection using embedded algorithms that estimate vehicle weight and its distribution. This function can be used to ensure compliance with gross vehicle weight limits, provide more accurate range estimation in EVs, and support weight-sensitive systems like adaptive damping or dynamic ride leveling.
Data backbone for electrified chassis
By feeding high-resolution, corner-level data into a central chassis domain controller, the sensor enhances the precision of systems like semi-active damping (e.g., Continuous Damping Control), fully active suspensions (e.g., sMOTION), and electromechanical roll control. In steer-by-wire configurations, the additional data improves road feedback modeling, helping refine the digital steering feel.
When combined with cabin microphones and sound processors, the sensor’s frequency data can also support active noise cancelation by enabling accurate identification and countering of persistent road-induced vibrations.
The Smart Chassis Sensor is designed as a drop-in replacement for standard ball joints and offers a low-weight package with high signal fidelity. By embedding measurement electronics into a part already standard in most independent suspension systems, the need for separate ride-height sensors is eliminated, reducing complexity and installation time for OEMs.
With this upgrade, the sensor now serves as a multi-functional input device for the broader vehicle ecosystem, supporting performance and reliability enhancements critical to next-generation EV architectures.
Filed Under: Sensors, Technology News