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The multi-body dynamics simulation and physical iteration were carried out based on the 4-channel road simulation bench, the solution of fatigue test bench which was suitable for cab with frame and suspension was designed. Large load and displacement above the suspension can be loaded on the test bench, and the same weak position of cab exposed on the road test can be assessed well on the fatigue test bench. The effectiveness of the bench test solution was verified though comparative study. And it has important reference for the same type of cab assembly with suspension in the fatigue bench test. According to the durability specifications of cab assembly, a multi-body dynamics model with a satisfactory accuracy was built. And the fixture check and virtual iteration analysis were used to verify the effectiveness of the solution. According to the road load signal analysis and multi-body dynamics analysis results, the test bench with linear guide and spherical joint was built.

As the international community strengthens the control of carbon dioxide emissions, electric vehicles have gradually become a substitute for internal combustion engine vehicles. The battery pack is one of the most important components of electric vehicles. The strength and fatigue performance of the battery support plate not only affect the performance of the vehicle but also concern the safety of the driver. In the present study, the finite element model of a battery pack for fatigue analysis is completely established. The random vibration stress response analysis and acceleration power spectral density response analysis of the support plate for the battery pack are carried out, and the accuracy of the finite element model is verified by a random vibration test.

The performance of the rear axle plays an important role in the performance of vehicle, and its fatigue durability is an integral part in the vehicle development. Taking a SUV model as the research subject, a new methodology of multi-channel spindle coupled road simulator and fatigue simulation analysis for rear axle assembly was introduced in the paper, aiming to address the fatigue design and its verification for the rear axle in the development phase. Firstly, road loads in the proving ground was collected by arranging proper sensors. Secondly, physical iteration was performed on the multichannel spindle coupled road simulator by taking six component forces at the wheel hub as the target signals. Then, after the time waveform replication of the loads the durability test was conducted. Finally, the validated simulation model was successfully implemented to improve the fatigue life of the axle.

The cab is an essential part of a light truck, and its fatigue durability performance plays an important role in the design and development stage. Accelerated fatigue bench test has been widely applied to product development of carmakers for its low cost and short development cycle. However, in reality, interference exists generally in torsional conditions for the light truck cab when tested on the 4-post vehicle road simulation system. To solve this problem and minimize the lateral force applied on the hydraulic cylinders, the direction and size combinations of displacement release about front and rear suspensions were discussed based on multi-body dynamics simulation and fixture design theory in this paper. Through comparative study, the optimum design and layout scheme of fixtures was determined to conduct the next test procedure. The weak positions of the light truck cab were firstly predicted by utilizing finite element method (FEM) and fatigue analysis theory.