A review of the lightweight and smart McPherson suspension for new-energy vehicles

The rapid proliferation of new energy vehicles (NEVs), including battery electric vehicles (BEVs) and hybrid electric vehicles (HEVs), has fundamentally transformed automotive chassis design paradigms. The McPherson strut suspension, renowned for its compact architecture and cost-effectiveness, has emerged as a predominant configuration for NEV front axles. This review systematically examines the adaptation, optimization, and challenges of McPherson suspension systems in the context of electrified powertrains. We analyze the unique requirements imposed by NEV weight distributions, battery integration, and noise vibration harshness (NVH) characteristics, synthesizing recent advances in lightweight design, multi objective optimization algorithms, and active control integration. Key discussion areas include kinematic performance optimization through genetic algorithms and AI-driven methods, material innovations enabling mass reduction, NVH mitigation strategies, and the evolution toward semi active and energy-regenerative variants. Through critical analysis of over 30 representative studies and industrial applications, this review identifies that while McPherson suspension remains viable for NEVs, its successful implementation necessitates sophisticated parameter optimization, advanced materials, and intelligent control systems to address inherent limitations in roll stiffness and camber control. Future trajectories emphasize synergy with autonomous driving architectures and electromagnetic energy-harvesting technologies, positioning McPherson-derived systems as foundational components of next-generation intelligent electric chassis.