How should chassis protection be implemented for new energy vehicles?

 　　How should chassis protection be implemented for new energy vehicles? Chassis protection for new energy vehicles is a core component in ensuring vehicle safety, extending battery life, and enhancing overall reliability. As the part of the vehicle that comes into contact with the road surface most frequently, the chassis must not only withstand the impact of stones and bumps during daily driving but also cope with risks such as corrosion from rain and snow, and short circuits caused by water ingress.

　　Physical protection forms the foundational layer of chassis protection, with the core focus on creating a ‘rigid barrier’ through structural design and material upgrades. Battery packs are typically integrated into the mid or rear section of the chassis, forming a low-centre-of-gravity layout to enhance handling stability. However, this positioning also makes them more susceptible to scratches from road obstacles.

　　Chassis guards have become critical protective components, typically made from high-strength aluminium alloy or composite materials. These materials combine lightweight properties with impact resistance, effectively dispersing impact forces during stone impacts or minor bottoming out to prevent battery casing deformation or internal cell damage. The surface of the guards is treated with an anti-scratch coating to extend their service life.

　　The chassis of new energy vehicles must meet higher sealing standards, especially at the interfaces between the battery pack and the electrical control system. Components such as silicone seals and waterproof breathable valves are used to ensure that internal components remain dry and free from short circuits during water immersion or heavy rain. The battery pack housing is typically manufactured using an integrated casting process to minimise the number of seams.

　　To address long-term threats such as salt spray and chemical corrosion, metal components of the chassis undergo electrophoretic coating or zinc-nickel alloy plating to form a corrosion-resistant protective layer, extending the chassis’ service life in humid or coastal environments. The layout of chassis wiring harnesses must also be optimised, with corrugated tubes used to wrap and secure them to the vehicle structure, while allowing sufficient slack to accommodate vehicle vibrations.

　　The battery management system continuously monitors the battery pack’s temperature, voltage, and physical deformation. If any abnormalities are detected, it immediately triggers speed limiting or power cutoff protection to prevent the spread of thermal runaway risks. Chassis vibration sensors can identify abnormal bumps or bottoming-out events, sending warnings to the owner via the in-vehicle screen or mobile app to prompt a check for chassis damage.

　　How should chassis protection be implemented for new energy vehicles? Chassis protection should combine regular inspections with optimised driving habits. Owners should avoid frequently traversing uneven roads or speeding over speed bumps to reduce chassis impact and further lower the risk of chassis damage.


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