Adaptive Terrain Morphing Chassis for Off-Highway Vehicles: Enhancing Fuel Efficiency through Dynamic Structural Adaptation

Off-highway vehicles (OHVs) routinely navigate unstable and varied terrains—mud, sand, loose gravel, or uneven rock beds—causing increased rolling resistance, reduced traction, and high energy expenditure. Traditional rigid chassis systems lack the flexibility to adapt dynamically to changing surface conditions, leading to inefficiencies in vehicle stability, maneuverability, and fuel economy. This paper proposes an adaptive terrain morphing chassis (ATMC) that can actively modify its structural geometry in real-time using embedded sensors, hydraulic actuators, and soft robotic elements. Drawing inspiration from nature and recent advances in adaptive materials, the ATMC adjusts vehicle ground clearance, track width, and load distribution in response to terrain profile data, thereby optimizing fuel efficiency and performance. Key contributions include: A multi-sensor fusion system for real-time terrain classification Hydraulic actuators and morphing polymers for variable chassis configurations Simulated fuel savings of 8–14% across diverse terrains compared to fixed-geometry systems The design also contributes to sustainability by reducing energy waste and material wear, and by enabling smart, terrain-responsive behavior that can extend the lifespan of vehicle components. This innovation holds significant potential for deployment in resource-heavy industries where OHVs operate in unpredictable and efficiency-critical environments.