This paper focuses on the research of improving the energy efficiency of the electric drive system for pure electric heavy-duty commercial vehicles, aiming to reduce the vehicle's overall power consumption by minimizing system losses, thereby enhancing the vehicle's range and operational economy. Firstly, the composition of the motor drive system is analyzed, highlighting the motor and controller as the core components of energy consumption. Regarding the motor itself, losses primarily include stator losses, rotor losses, and friction losses; in contrast, losses in the motor controller mainly stem from switching losses and conduction losses of power devices. Secondly, to enhance system efficiency, this paper examines methods for improving system efficiency from four perspectives: system architecture, motor design, motor controller, and control strategy. Finally, the results indicate that the energy efficiency optimization of the motor drive system should focus on stator copper loss control, reducing primary losses through motor design and control algorithms, while optimizing hardware performance with high-voltage architecture and wide-bandgap devices. This systematic balance between efficiency and cost provides an effective pathway for optimizing the energy efficiency of electric drive systems.

The brake-by-wire has the advantages of fast response speed and good controllability, and is widely used in new energy vehicles. When one or more of brake-by-wire fails, it will reduce the braking strength of the vehicle and cause the safety problem of the vehicle running off. Based on the characteristics of the brake-by-wire system, this paper studies the braking force distribution and control method of vehicle under the brake-by-wire failure condition. Starting from the traditional braking force distribution, the vehicle braking dynamics under single point and multi-point failure of the brake-by-wire is analyzed respectively, and the vehicle braking force coordination control method based on the brake-by-wire system is proposed to reduce the vehicle yaw moment and ensure the safety and stability of the vehicle when the brake failure occurs.

To achieve accurate prediction of the fatigue life of torsion beam structures, this paper proposes a simulation analysis method based on the virtual iteration technique. First, a multi-body dynamic model is built in Adams, and the dynamic load spectra of key attachment points are extracted through virtual iteration. Then, the HyperMesh software and Nastran solver are used to calculate the stress distribution and stress influence coefficients of the torsion beam under unit loads. Finally, the linear superposition method is adopted in NCode software to synthesize the dynamic load spectra with the stress influence coefficients for fatigue life calculation. The analysis results show that the fatigue life distribution obtained by this method is highly consistent with the results of real vehicle road tests, which verifies the good effectiveness and engineering application value of the virtual iteration technique in the durability analysis of torsion beams.

To address the trade-offs between energy density, thermal safety, and system cost in compact electric passenger cars, this paper proposes a system design method based on multidimensional performance balancing, and designs and implements a highly integrated energy storage device for the drive system. This device is based on high-energy-density ternary lithium-ion cells, employing a modular structure and laser welding technology to achieve low-resistance connections between battery modules. Through a layered insulation structure and a multi-sensor monitoring network, the thermal runaway warning response time is reduced to less than 2 s. Combining finite element analysis and topology optimization methods, the topology-optimized aluminum alloy housing achieves a 12.3% weight reduction, and the liquid cooling system controls the module temperature difference to within 3 ℃. Real-world vehicle verification shows that the system maintains good stability at 45 ℃, achieving a capacity retention rate of 95.3% after 200 cycles, with the vehicle completing the cycle without any failures. This paper systematically elucidates the design principles and optimization path, providing a theoretical basis and reusable engineering path for the design of high-performance battery systems for compact electric vehicles.

Recently, the application demand for the traction battery frame of commercial vehicles has increased sharply, creating an urgent need for an accurate and efficient simulation method for fatigue durability analysis. The research is carried out based on OptiStruct and FEMFAT software. This paper apply the loads collected by the test vehicles to the traction battery frame, and use the modal stress recovery method to solve the fatigue damage of the structure. This method can accurately and efficiently complete the fatigue durability analysis of the traction battery frame, and the simulation results are consistent with the test results. This method has high application value in the development of new energy commercial vehicles.

Aiming at the limitations of traditional performance evaluation methods for power batteries, including an incomplete evaluation index system, strong subjectivity in weight assignment and numerous fuzzy evaluation indicators, this study establishes a scientific and systematic threeevel "target layer–criterion layer–index layer" evaluation index system through literature research and expert consultation. It adopts the analytic hierarchy process (AHP)-fuzzy comprehensive evaluation (FCE) method, combines the advantage of AHP in quantitative weight assignment with the fuzzy information processing capability of FCE, and addresses the problems of subjectivity in index weight allocation and difficulty in quantifying fuzzy indicators. Meanwhile, it develops an operable and high-precision evaluation system based on MATLAB to realize scientific, objective and accurate evaluation of power battery performance, thus providing a scientific basis for the research and development optimization, type selection and matching, as well as operation and maintenance management of power batteries.

This paper proposes a control strategy based on a domain control architecture for a dualmotor recirculating-ball steering system in commercial vehicles. The strategy achieves the calculation and distribution of steering assist torque, integrates multiple functional modules such as speed-sensitive assist and active return, and outputs corresponding torque reduction coefficients based on fault categories to ensure the smooth operation of the motors and vehicle under fault conditions. The entire strategy is integrated into a domain control unit (DCU) to assist the driver in maintaining handling stability and driving safety. The proposed control strategy is validated using a hardware-in-the-loop (HIL) experimental platform. The results show that under normal conditions, the torque reduction coefficient is 0, and the system accurately calculates and allocates 100% of the assist torque to the two steering motors. Under fault conditions, the system can implement four predefined levels of torque reduction based on the fault type, effectively balancing handling stability and driving safety.

The problem of drunk driving should not be underestimated. The existing alcohol detectors on the market have drawbacks such as complex operation and high false alarm rates. This paper designs an intelligent in-vehicle drunk driving detection system based on multi-sensor fusion. By integrating pressure sensor HX711, ultrasonic sensor HC-SR04, alcohol sensor MQ-3, air quality sensor MQ-135, temperature sensor, camera sensor, and combining sound and light alarm, organic light-emitting diode (OLED) display and relay control module to build a three-level protection mechanism of "detection–warning–forced intervention". The experiments are carried out in accordance with the Blood & Breath Alcohol Concentration and Examination for Vehicle Drivers (GB 19522–2024) standard. The results show that the accuracy of alcohol concentration detection is increased by 80%, the root mean square error is ±3%, and the response time is improved by 40%. The system effectively enhances driving safety by accurately identifying drunk driving behavior and forcibly cutting off vehicle power, providing a high-precision and low-cost solution for the research and development of intelligent in-vehicle safety equipment.

With the rapid development of the automotive industry, consumers have increasingly higher expectations for the visual experience provided by sunroofs, leading to greater diversification in sunroof types and posing new challenges for design. To address this issue, this paper introduces the concept of the "sunroof vision zone" to quantify visibility requirements and elaborates on the specific design methodology for this zone. Using a passenger vehicle as a case study, it illustrates the application process of the sunroof vision zone in practical design. Results show that the automotive sunroof design method based on the sunroof vision zone can quickly identify the optimal sunroof solution, effectively meet visibility demands, and provide significant practical guidance for the design and development of automotive sunroofs.

Regarding the cracking problem of the internal tab of a certain heavy-duty truck battery during the durability test, this article conducts a cause investigation from three aspects: wire harness pulling, layout position influence, and vibration fatigue. Through finite element simulation methods, using the actual vehicle acceleration load at the installation points of the battery frame, based on the damage equivalent method, the power spectral density (PSD) load is obtained for the analysis of relative deformation of the wire harness, the random response analysis of the battery with different layouts, and the vibration fatigue simulation analysis of the battery structure. The cracking cause is identified. At the same time, the influence of different factors on vibration fatigue is discussed, to guide the design confirmation optimization scheme. The final optimization scheme is verified by the actual vehicle, proving the effectiveness of the cause investigation and simulation verification in the article, providing ideas and references for the structural design development and durability performance simulation analysis of the battery.

To enhance the single line shifting performance of three-car articulated buses, this paper analyzes optimal turning angle relationships under varying speeds using automotive dynamics and multi-objective optimization algorithms. First, a dynamic model is established with Adams/Car based on vehicle structural parameters. An optimization platform integrating Adams/Car and MATLAB is developed in ISIGHT software, with lateral stability and trajectory tracking performance as objectives and each axle's turning angle ratio coefficients as variables. The secondgeneration non-dominated sorting genetic algorithm (NSGA-II) is applied to determine optimal turning angle ratios in the medium-high speed range (40～70 km/h), with coefficient switching for non-optimized speeds achieved through a digital table. Results demonstrate that during mediumhigh speed shifting: the lead car's two axles rotate in the same direction with coefficients increasing with speed, the middle car's two axles rotate in opposite directions, and the tail car's rear axle rotates opposite to the lead car's front axle. After optimization, target values for all speeds are significantly reduced, with the lateral trajectory deviation decreasing by 82.46% at 70 km/h. Target values for non-optimized speeds are also effectively improved through digital table interpolation. In summary, the optimized axle turning angle ratios under single-line shifting conditions effectively enhance the bus's lateral stability and trajectory tracking performance.

To reducing the engine ignition vibration of a vehicle, correlation analysis is conducted to research on the correlation between different impact factors and the ignition vibration of the seat rail, and it is found that the Y-direction vibration of the rear suspension had a strong correlation with the vibration of the seat rail, and its correlation coefficient is 0.92, meanwhile, the peak frequency of Y-direction vibration of the seat rail is distributed around 13.75 Hz. And the test results of the engine rigid modal test indicating that the mode frequency of the rigid modal rotating around the Z-axis is coupled with the ignition frequency, causing excessive Y-direction vibration of the rear mount. After reducing the Y-direction stiffness of the rear mount, the mode frequency avoided the ignition frequency, and the ignition vibration of the seat rail is reduced by 27.7%. The results show that correlation analysis method while conducted to reduce the engine ignition vibration, can be helpful to quickly locate the vibration source and improve the efficiency of noise, vibration, harshness (NVH) development.

With the development of software-defined vehicles, vehicle functions have become increasingly intelligent. In the development and testing process of a certain model's intelligent function "predictive light control", a problem of no response to terminal requests for lights is encountered. After a systematic analysis, the cause of the problem is ultimately located to the inconsistent memory arrangement of the same structure data type on different platforms during cross-platform (Android and Linux) Socket communication. This article focus on the perspective of memory alignment, elaborates in detail on various solutions such as adding padding signals and increasing the length of signal groups, and proposes the final solution. It provides important guiding significance and practical engineering value for the definition of structure data types in crossplatform Socket communication.

This article briefly describes the working principle of the mechanical parking brake system in automobiles. By analyzing the causes of faults in the operation handle at zero kilometers and at the user end, and proposing solutions, the aim is to reduce the occurrence of such faults. Meanwhile, a detailed analysis of the failure mode of the operation handle lock failure is conducted, and it is concluded that the main cause is the damage of the tooth plate and the claw. Through arguments at three levels: design prevention, manufacturing improvement, and assembly guarantee, specific improvement plans are proposed for material selection, size design and control, and surface heat treatment of the parts. The research methods and improvement measures in this article have practical reference significance for the prevention of similar failure modes in similar products.

Magnetic materials serve as the primary structural components in electromagnetic mechanics and are among the essential materials for electric vehicles. Wire electrical discharge machining (WEDM) is widely employed for processing these conductive materials, where machining precision directly impacts material performance. This study utilizes brass wire, galvanized copper wire, and Cu-Zn double-coated steel wire (HSC wire) to conduct parallel cutting experiments on 20 mm thick ledeburite steel under constant process parameters using a FANUCα-C600iA machine tool. Each group underwent three repeated trials, with results validated through data validity processing and one-way analysis of variance. The experiments demonstrates that HSC wire exhibited optimal cutting performance, achieving an average speed of 1.05 mm/min (a 23% improvement over brass wire and a 15% improvement over galvanized copper wire), with statistically significant differences in cutting speeds among the three materials. The superior performance of HSC wire stems from its high substrate stability and excellent conductive loss-reduction properties of the coating, coupled with controllable comprehensive costs, making it commercially viable. Future research could focus on composite coatings, core material modifications, and eco-friendly materials to optimize electrode performance, while also evaluating critical metrics such as coating adhesion.

In response to the fundamental requirements of the new engineering construction and moral education and talent cultivation, and to address the problems existing in the current ideological and political teaching of engineering courses, such as fragmented ideological and political elements, single teaching methods and imperfect evaluation systems. This paper takes the basic course Automobile Design of the vehicle engineering major at Shanxi Institute of Energy as an example, based on the outcome-based education (OBE) concept, the system integrates ideological and political elements with professional teaching content, builds a deep integration path, and innovatively designs a "dual-line, three-ring, four-haves" hybrid teaching model. At the same time, a diversified evaluation system for ideological and political education in courses should be established to conduct a comprehensive test of teaching effectiveness. Practice has shown that this model has effectively stimulated students' learning motivation and professional sense of mission, providing strong support for cultivating new types of vehicle engineering talents with comprehensive qualities.

In response to the core pain points of the computer aided design (CAD)/computer-aided manufacturing (CAM) courses in universities, such as the disconnection between teaching objectives and industry, the separation of practice and theory, and the single evaluation system, this study integrates the outcome-based education (OBE) concept and project-based teaching model to construct a trinity teaching reform path of "goal reconstruction-project-driven-and multiple evaluation". Based on the reverse design of industrial demands, a three-level progressive project teaching objective of "basic–comprehensive–innovative" is established. Empirical data is shown that students' engineering problem-solving abilities and the number of awards in innovation competitions are significantly improved after the pedagogical reform. This model promotes the transformation of the course from "tool operation training" to "engineering innovation ability cultivation", builds an education ecology with deep integration of industry and education, and provides a generalizable paradigm for the cultivation of intelligent manufacturing talents.

In the context of the development of ideological and political education in higher education curricula for the new era, this article explores pathways for integrating professional courses with ideological and political education. Using the Urban Rail Transit Communication course as a vehicle and based on the CDIO (conceive, design, implement, operate) engineering education model, the study reconstructs course objectives, optimizes teaching content, and innovates teaching methods. Professional ethics, craftsmanship spirit, and social responsibility are organically integrated into the entire project-based teaching process. Teaching practice demonstrates that the dual-mainline CDIO model, combining ideological and political education with technical training, effectively enhances students' engineering practical abilities and innovative awareness. Simultane-ously, it strengthens their teamwork spirit, safety regulation awareness, and sense of social responsibility, achieving the coordinated development of knowledge imparting, skill cultivation, and value guidance. This provides a reference for the reform of ideological and political education in engineering professional courses.

To exploret the reform of curriculum-certificate integration under the "1+X Certificate" system in vocational education, this article delves into the reform orientation and implementation pathways for integrating courses with vocational skill level certificates. Through an in-depth analysis of the Appraisal and Evaluation of New Energy Used Cars course, targeted reform and implementation plans are proposed regarding structural adjustments, content integration, curriculum delivery, and teaching evaluation for curriculum-certificate integration. These plans aim to address issues such as inadequate alignment between talent cultivation programs and certificates, the disconnect between courses and certificates, and insufficient exploration of how certificates can promote students' participation in skills competitions. The reform encompasses the optimized restructuring of the curriculum system, groundbreaking innovations in teaching methods, and the scientific establishment of an evaluation system, all with the goal of providing a practical case study for vocational education reform. This approach seeks to organically integrate courses and certificates in teaching and advance the "1+X" curriculum-certificate integration reform through practical application.

New Energy Vehicle Maintenance and Fault Diagnosis is the core course of higher vocational new energy vehicle technology. Traditional teaching methods face challenges such as a disconnection between teaching tasks and real job responsibilities, low levels of student engagement, and insufficient assessments of learning outcomes. This study integrates project-based learning (PjBL) theory and the Countenance Stake model to design STEM-based tasks and a multi-faceted evaluation system. Enhancement of students' practical competencies, problem-solving skills, and professional attributes is demonstrated through project-based teaching, with insights provided for adaptation to new energy vehicle technology reforms in vocational education.

With the advancement of vocational education reform, teaching measures and educational models marked by industry-education integration and school enterprise cooperation have received widespread attention. Based on this background, this article starts from the perspective of the industry education integration community, taking the intelligent connected vehicle major in vocational colleges as the research object, and constructs an innovative talent training model of "three elements (school, enterprise, industry), three loops (theory, practical training, practice), and three levels (students, apprentices, employees)". By optimizing the curriculum system, innovating project-based teaching methods, and strengthening step-by-step practical training, the deep integration and complementary advantages of school enterprise industry resources have been achieved. This model significantly enhances students' technical skills and innovation abilities, providing a replicable practical solution for the cultivation of technical and skilled talents in the field of intelligent connected vehicles.

China is transitioning from a major automobile country to a strong automobile nation, with the automotive industry accelerating technological transformation. Cultivating high-quality automotive talents adapted to new industries has become one of the key topics in vocational education. This article conducts thorough research using questionnaire surveys, literature review, and interviews to obtain relevant data. Based on these data, it analyzes the existing problems in the traditional teaching of automotive majors. It proposes strategies such as leveraging virtual simulation technology to drive the in-depth development of teaching reform, regularly updating software resources, and strengthening industry-education integration to effectively improve the teaching quality and talent cultivation quality of automotive majors, thereby better serving the transformation of automotive technology and industrial upgrading.

To promote the healthy development of the intelligent connected vehicle industry, it is necessary to establish a comprehensive policy framework. This paper aims to quantitatively analyze the characteristics of China's industrial policies for intelligent connected vehicles, providing a precise reference for formulating and optimizing industrial support measures. Based on a policy tool analysis framework and textual analysis methods, this paper conducts a quantitative analysis of 61 relevant policy documents issued by various national departments over the past decade. The results indicate that the central government maintains a high annual average number of policy releases, with vehicle-focused policies dominating. At the national level, supply-side and environmental policy tools are used more frequently, while demand-side policy tools are less utilized. Furthermore, from first-tier to second-tier and third-tier cities, the use of supply-side policy tools progressively decreases, whereas the proportion of demand-side policy tools gradually increases, with the share of environmental policy tools remaining relatively stable.

To enhance the efficiency and capacity of road intersections, this article takes urban road intersections as the research object. By combining the results of on-site data collection and relevant evaluation indicators, and using the operational analysis method of the Highway Capacity Manual (HCM) of the United States, the traffic capacity of the intersections is systematically evaluated. Based on this, targeted improvement measures are proposed, and their implementation effects are analyzed and evaluated in depth to further enhance the traffic capacity of the intersections. The research first analyzes the regional functions of the intersections, the layout of the road network, the signal timing, and the traffic flow characteristics of the sections. It selects traffic volume and service level as the core evaluation indicators, clarifies the evaluation methods and related influencing factors, and thereby calculates the current traffic volume and service level of the intersections. In response to the existing problems of this intersection, the research optimizes the signal timing scheme and uses traffic simulation methods to verify the improvement effects of the traffic capacity and service level after optimization. The research aims to improve the travel experience of residents through scientific optimization of traffic flow organization, enhancing traffic smoothness, and reducing the risk of traffic accidents.

As a critical load-bearing component of vehicle vibration damping technology, the suspension system plays a decisive role in ride comfort, handling stability, and driving safety. This article reviews the classification of automotive suspension systems, the technical characteristics and development status of various suspension types, as well as current cutting-edge research in the field– particularly summarizing advanced studies from the past five years. It concludes that current frontier research in automotive suspension systems is mainly reflected in three aspects: breakthroughs in intelligent control algorithms, innovations in energy recovery technology, and the application of new materials. By establishing a dynamic model of the suspension system and comparing the technical features and development status of different suspension types, along with an analysis of current advanced research, this paper prospects future development trends. Finally, it points out that the future development of automotive suspension systems will focus on three directions: intelligence, integration, and eco-friendliness.