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With the growing prosperity of the long-distance freight and urban logistics industry, the demand for cargo trucks is gradually increasing. The connecting bracket is the critical connecting part of the truck chassis, which bears the load transmitted by the road excitation and reduces the damage to the frame caused by the load. However, the occurrence of rough road conditions is inevitable in heavy-duty transportation. In this paper, road durability tests and fatigue life analysis are carried out on the original structure to ensure the safety of the vehicle. Based on the known boundary and load constraints, a lightweight and high-performance structure is obtained through size optimization, as the original structure cannot meet the performance requirements. Firstly, the road test was conducted on the truck where the original bracket structure is located.

The displacement of the shaft head fails to be accurately measured while the three-axle heavy-duty truck is driving on the reinforced pavement. In order to obtain accurate fatigue load spectrum of the suspension bracket, the acceleration signals of the shaft heads of the suspension obtained by the reinforced pavement test measurement are virtually iterated as responses. A more accurate model of the rigid-flexible coupled multi-body dynamics (MBD) of the whole vehicle is established by introducing a flexible frame based on the comprehensive modal theory. Furthermore, the vertical displacements of the shaft heads are obtained by the reverse solution of the virtual iterative method with well-pleasing precision. The accuracy of the virtual iteration is verified by comparing the simulation results with the vertical acceleration of the shaft head under the reinforced pavement in the time domain and damage domain.