A review of intelligent chassis structure design for electric vehicles with centralized drive configurations

Intelligent chassis systems for battery electric vehicles (BEVs) face unresolved challenges in structural-mechanical integration, multi-domain control coordination, and fault-tolerant safety architecture under battery-induced mass redistribution and X-by-wire decoupling requirements. This review employs a four-layer framework—Foundation (X-by-wire), Execution (suspension/lightweight structures), Control (domain strategies), and Evolution (autonomous-ready architectures)—to synthesize recent advances across structural mechanics, control theory, and materials science. Literature selection prioritized peer-reviewed studies with experimental or simulation validation on BEV-specific chassis implementations. Key contributions include: (1) identification of research gaps at the topology optimization-manufacturability intersection, particularly stress concentration in cell-to-chassis integration zones; (2) comparative evaluation of energy-regenerative suspensions, where hybrid electromagnetic systems achieve 67.8% energy reduction versus conventional linear motor configurations; and (3) establishment of future directions emphasizing hydrogen fuel cell compatibility, cybersecurity-resilient X-by-wire architectures, and AI-driven structural-control co-design. Successful implementation requires multi-objective structural optimization, advanced material strategies addressing strength-stiffness-vibration trade-offs, and fail-operational control frameworks. Future trajectories emphasize autonomous driving convergence, modular standardized platforms, and digital twin-enabled mechanical-electrical-software integration.