Key Technologies Of Vehicle Integration Development For Passenger Car

From the basis of the traditional vehicle development process, this paper highlights the overall vehicle integration development process. It descripts target setting, cascading and verification process in the form of a V Chart. The paper follows the bottleneck issues in the development process of the vehicle original design, encompasses chassis and body systems design and development and focuses on topology optimization for the twist beam rear axle and the structural safety design aspect vehicle front rails of the vehicle body. It establishes a development platform for forward thinking virtual refinement model, which includes:(1) Based on SOA (Service Oriented Architecture), a simulation database, resource library and a modeling tool, it establishes a forward thinking virtual refinement model with combination of an automated development process and the database to sets up an Engineering Performance Data Modeling System.(2) The paper performs topology optimization for the twist beam rear axle, the most important chassis member, by considering vehicle attributes of dynamics, static strength, fatigue (durability), NVH and forming (manufacturing). The final design met the targets for different operating conditions and formed the semi-rigid twist beam rear axle design method.(3) The vehicle front rail structure were optimized and validated based on high strain rate effect, and the overall vehicle front impact performance were improved with impact energy distribution and acceleration waveforms, and the vehicle body and structure intensity performance were analyzed by CAE integrated simulation.(4) The bench test and vehicle verification tests were conducted for both component and vehicle with regard to twist beam rear axle performance in terms of the frontal and offset impact and vehicle on road durability.The research results show we could achieve a lightweight body structure that meets overall requirements and performs better than the benchmark vehicle, by using the processes, the key technologies and methods we mentioned above. Keywords: Performance-oriented vehicle development process; Semi-rigid twist beam rear...