To address the issue that hybrid vehicle driveline durability test cannot cover the customers’ usage scenario, a customer-relevant, forward-development method based on vehicle networking data has been designed. This paper started with typical usage conditions, combining it with analysis of driveline fatigue damage, to develop and standardize combinations. Based on the user’s driving habits and proving ground load spectrum, this study explored how to translate these users’ driving habits into whole-vehicle durability test specifications that meet service life requirements. Finally, the process for establishing vehicle durability test specifications within a proving ground was determined, and a rational and effective test specifications for hybrid vehicle driveline was established.

To achieve the coupling analysis of the flow field, temperature field, and structural field of the intercooler, Computational Fluid Dynamics (CFD) and thermal strain test methods were used to conduct coupling analysis and experiments on the flow field, temperature field, and stress field of the intercooler using a fluid thermal structure coupling method. The flow field structure, temperature, and stress distribution of the intercooler were obtained. The analysis results show that this method can effectively predict the flow field and temperature field of the intercooler.

In order to solve the problem that steering electric control system cannot be validated in road simulation test, this paper proposed a road simulation test bench test scheme of the steering system to verify the accuracy of the steering system based on the automobile road simulation durability test technology and the principle of automobile bus communication. Firstly, the control circuit of the steering system was built in the road simulation test bench; Then, the bus tool software was used to output the control signal of the steering system controller into the steering system according to time sequence; Finally, the effectiveness of the test scheme was verified by the strain of the steering system and the torque signal of the steering wheel. The result shows that the method enables to activate the EPS function in the traditional test rig.

In response to the lack of research on the performance, standards, and testing methods of Intelligent Speed Assistance (ISA) system for motor vehicles in China at present, this paper introduced the working principle of ISA, studied the typical test scenarios specified in EU 2021/1958. On this basis, a motor vehicles’ ISA performance testing system and scenario were developed and a road test of a passenger car’s ISA performance was carried out according to the standard. The results indicate that the test vehicle’s ISA system complies with the requirements of EU 2021/1958 and the higher the vehicle speed, the later the ISA system will recognize the speed limit sign and when developing ISA systems attention should be paid to the sensitivity of the ISA system to recognize the speed limit sign when the speed is high.

In order to verify the coordination, accuracy and smoothness of the operation of the intelligent chassis assisted driving system of the autonomous vehicle, this paper proposed a method to test the control precision and stability of intelligent chassis assisted driving system. Firstly, the communication protocol of the an integrated modular intelligent chassis was detected using CANoe, secondly, the function and performance test of the control algorithm was verified through vehicle collaboration control algorithm, and finally, a number of accuracy control tests including straight driving speed, turning, steering system, braking and so on were conducted. The results show that the intelligent chassis can achieve ±1 km/h speed control, has functions of normal braking, obstacle avoidance bypass, and steering error within 1°, further validating the feasibility of the proposed method.

In order to ensure that the automotive generator can meet the power supply requirements under different operating conditions of the vehicle, the influence of the parameters of the automotive AC generator stator assembly on the rated power and output characteristics of the generator was analyzed and verified. The results show that, under the condition of stator core size specifications unchanged, the rated power can be increased without changing the slot filling rate and reducing the number of turns, but the output power can be reduced under low-speed conditions. Changing from star connection to triangle connection or adding a neutral point can increase the rated power without changing the low-speed output power. Changing the three-phase armature winding to six phases hardly affects the rated power and output characteristics, but can reduce the ripple peak value of the output current.

This paper analyzed the cause of a 1.5 L naturally aspirated engine’s intake manifold mounting support cracking in bench test and design was optimized. The electron microscope analysis results show that fatigue cracks exist on the fracture surface of the failed support, and the main cause of the support cracking is found to be the resonance caused by the large vibration at the far end of the intake manifold through engine bench vibration test and test boundary checking. The material of the support was adjusted from SUH409L to QT500, simulation calculations and experimental verification were conducted on the new support, and no cracking was found on the new support.

The odor of four types of leather fabrics for vehicles was evaluated, and the odor substances were tested by Thermal Desorption Gas Chromatography Odor detector/Mass Spectrometry (TD-GC/OMS), and the sources of main odorants were further analyzed. The research shows that the odor substances of leather fabrics mainly come from the solvents, additives and related reaction products used in the processing, and part of them come from the volatilization of leather fabrics itself.

For the selection of vehicle trumpet based on vehicle test, there are problems of operation lag and affecting the progress of mass production of models. To address this issue, this paper proposed a trumpet near-field sound pressure simulation method based on Ray Tracing. Firstly, the hard wall panel data on the external surface of a vehicle was extracted, and Ray Tracing model solution model was established in VAOne, then the sound power of the trumpet was obtained by the inverse matrix module that was loaded into the Ray Tracing solution model to calculate the near-field sound pressure. The near-field sound pressure of trumpet simulation was compared with the test results, the result shows that the calculated near-field sound pressure value of trumpet is in good agreement with the experimental value, which can provide basis for vehicle trumpet selection in the early stage of model development.