| With the rapid development of China's automobile industry, automobile manufacturers are facing fierce competition. The core of the competition is product cost control and product renewal rate, the product serialization is one of some effective methods. Product serialization includes two concepts, one is product diversification, and another one is components generalization. Product diversification is the target of the product serialization; it is to be satisfied to the different requirement of different custom based on using the existing components. Components generalization is the key solution and the requirement. Components generalization not only uses of existing components to realize the mass production and few types of the components, and also reduces the production costs, saving cost, testing cost and human resources, finally cut down the cost of whole vehicle and shorten product development cycle and reduce the costs of human training, saving cost, whole vehicle maintenance after-sales servicing. This will improve the competition ability in product and service for the manufacturer.This article is based on actual results of minibus serialization design, testing, production process involved on a domestic automobile enterprise. The overall mission of the work is to develop extended models based on existing mature minibus, for example widen model, extended heightening widen model.This work involves many items, for example, a minimum change of boy in white , interior parts , chassis parts, body strength, stiffness to ensure that regulations, application requirements, vehicle structure to meet regulatory requirements CMVDR294 (including the front crash, offset collision, rear collisions), and the pedestrian protection legislation, but also to consider how to facilitate customers to use and maintenance the vehicle, reducing the using cost . Based on doctoral dissertation researching, this paper is focusing the item on the generalization of components for different models, the results in other areas is not here involved.The author constructs the front suspension system simulation model, the rear suspension system simulation model and the moving simulation model of whole vehicle for the standard models, widening and lengthening broadening model vehicle under the existing model's basic design parameters, structure and the overall parameters constraints of the whole vehicle layout.The vehicle performance comparative analysis is made between the real vehicle tests and the simulation results.The article includes the following three aspects:1)The application of suspension virtual prototype and bench test for the vehicle design.Suspension K & C is including geometric kinematics and flexibility, both are inseparable. This article specifically addressed the research content, tools and the parameters of suspension K & C and established the virtual suspension for the typical minibus and simulated. By the comparison between the simulation results and bench test results, the validity of the suspension model is determined. The suspension hard points, spring stiffness, articulated parts'stiffness and other mechanical properties had been set. The article also provides an effective basis and support for the structure design of the body panel and chassis parts.2)The application of the virtual simulation and road test in vehicle handling & stability researchThe vehicle handling & Stability contains two interrelated parts, one is handling that means the ability of vehicle exactly responding to driver's steering commands; another one is the stability that means the ability of vehicle recovering the original state of motion after external disturbance. The two are inseparable.The writer established the simulation model of the front suspension, the rear suspension, steering system and tire subsystem for the typical minibus by using the constraints libraries in ADAMS software and also established the whole vehicle simulation model by the introduction of road conditions and other external constraints. The models are used in simulation analysis for the handling and stability of the whole vehicle. By the comparison between the vehicle road test results and the simulation results, the effectiveness of the model is determined3)The application of the virtual simulation and road test in vehicle riding & braking researchthrough the front and rear suspension Biased design, impact strength and vibration attenuation of the simulation and comparative analysis of the road test results, the validity of the model is determined; through the comparative analysis between loaded with all-wheel brake calculation and the real test result, it is clear that the change of the vehicle parameters effect the performance of braking.The innovation of this paper lies in the following areas:1, first time in the country proposed a combining vehicle dynamics development approach, that is, simulation analysis, objective testing and subjective evaluation.2, the article take the lead in the development of research systems from the Suspension system kinematic characteristics of K (Kinemics), then to study flexible kinematics C (Compliance) of the system, then to study the dynamic characteristics D (Dynamics)of suspension system, subjective evaluation and debugging on the shock absorber of front and rear suspension in vehicle series.3, found the general principle in front and rear suspension biased design, and the ratio of them.4, study riding from impact strength and vibration attenuation, and established a set of test methods and post-processing, to optimize the design of the riding, and to improve suspension buffer block design, to achieve good results.With the improvement on computer simulation technology, and improvement of the suspension rubber bushing model, tire model and even the structure of the suspension, I believe that virtual simulation of vehicle performance results will be closer to the actual performance of vehicles, cost reduction of new products and shortening the development cycle will be more benefit from the computer simulation technology.
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