Just months after launching its original Smart Chassis Sensor, ZF is introducing a next-generation version that brings even more capabilities to the table. The upgraded sensor now not only measures wheel height but also tracks acceleration in all three dimensions.
This enhanced data stream unlocks a range of advanced features, including real-time chassis health monitoring, load/force detection, and active noise cancellation. The sensor also integrates effortlessly with other ZF technologies, supporting the company’s “Chassis 2.0” initiative. For instance, it can significantly improve the feedback in steer-by-wire systems, making it more accurate and lifelike.
As the automotive industry embraces digital transformation and the shift towards software-defined vehicles grows, ZF is leading the charge with its forward-looking Chassis 2.0 strategy. This approach focuses on providing intelligent, networked actuators that can be applied effectively at both the vehicle and system levels, integrated through ZF’s in-house software. The Smart Chassis Sensor plays a crucial role in this vision, enabling more precise control and better data utilization through the connection of multiple sensors.
The next chapter for the Smart Chassis Sensor has already begun. The basic model is now in mass production, and ZF is rolling out the new, advanced version with an integrated accelerometer, capable of capturing data directly in the ball joint.
With its ability to measure vertical movement and acceleration, the Smart Chassis Sensor provides valuable data that helps manufacturers develop innovative vehicle features. By analyzing patterns in acceleration and their frequency changes, the system can detect potential issues or damage to the chassis. ZF refers to this as the “Chassis Health” system — a continuous, real-time digital monitoring tool that keeps track of the chassis’ condition. If any irregularities, like loose wheel nuts after a tire change, are detected, the sensor sends maintenance alerts to the vehicle’s display, helping prevent accidents and improving overall safety.
Another standout feature is load detection. Using a specialized algorithm, the sensor can estimate the vehicle’s weight, making it easier for drivers to ensure they aren’t exceeding weight limits. This functionality helps avoid problems during roadside inspections and ensures compliance with legal weight restrictions. Additionally, it improves range estimation for electric vehicles by providing more accurate predictions of battery consumption before the journey begins.
The Smart Chassis Sensor is designed to integrate smoothly with other ZF systems. It already supports semi-active Continuous Damping Control (CDC), active sMOTION damping, and Electromechanical Roll Control (ERC) by providing sensor data. This upgraded version plays an essential role in enhancing force feedback in steer-by-wire applications.
Another useful feature is its ability to capture road surface stimuli frequencies, such as those caused by different types of pavement. This data can be used to implement active noise cancellation, reducing unwanted sound inside the cabin by generating opposing sound waves through multiple speakers.
Like its predecessor, the new Smart Chassis Sensor is housed within a ball joint — a key component in independent suspension systems that ensures stable damping and precise wheel guidance. This setup allows for accurate measurement of the relative motion between the wheel and vehicle body.
ZF has integrated the measurement electronics directly into the ball joint, making the Smart Chassis Sensor a built-in feature of the suspension system. The new sensor stands out for its low weight, rugged design, excellent signal quality, and straightforward installation. By embedding the accelerometer within the sensor, ZF has reduced the need for multiple sensors, lowering costs and streamlining the assembly process for OEMs.
ZF Group, a leading global supplier of mobility solutions, supports a range of transportation sectors, from passenger cars and commercial vehicles to construction machinery and renewable energy. Focused on reducing emissions and improving safety, ZF operates in 30 countries with over 161,600 employees and recorded revenues of €41.4 billion in 2024.
