Vertical-Longitudinal Coupling Effect Investigation and System Optimization for a Suspension-In-Wheel-Motor System in Electric Vehicle Applications

In-wheel-motor-drive electric vehicles have attracted enormous attention due to its potentials of improving vehicle performance and safety. Road surface roughness results in forced vibration of in-wheel-motor (IWM) and thus aggravates the unbalanced electric magnetic force (UEMF) between its rotor and stator. This can further compromise vertical and longitudinal vehicle dynamics. This paper presents a comprehensive study to reveal the coupled vertical–longitudinal effect on suspension-in-wheel-motor systems (SIWMS) along with a viable optimization procedure to improve ride comfort and handling performance. First, a UEMF model is established to analyze the mechanical–electrical–magnetic coupling relationship inside an IWM. Then a road–tire–ring force (RTR) model that can capture the transient tire–road contact patch and tire belt deformation is established to accurately describe the road–tire and tire–rotor forces. The UEMF and the RTRF model are incorporated into the quarter-SIWMS model to investigate the coupled vertical–longitudinal vehicle dynamics. Through simulation studies, a comprehensive evaluation system is put forward to quantitatively assess the effects during braking maneuvers under various road conditions. The key parameters of the SIWMS are optimized via a multi-optimization method to reduce the adverse impact of UEMF. Finally, the multi-optimization method is validated in a virtual prototype which contains a high-fidelity multi-body model. The results show that the longitudinal acceleration fluctuation rate and the slip ratio signal-to-noise ratio are reduced by 5.07% and 6.13%, respectively, while the UEMF in the vertical and longitudinal directions varies from 22.2% to 34.7%, respectively, and is reduced after optimization. Thus, the negative coupling effects of UEMF are minimized while improving the ride comfort and handling performance.