In this paper, the kinematic characteristic analysis and optimization design of a minivan MacPherson-strut suspension system are performed. Design requirements of a minivan suspension system are described first, and then the design process is presented. A typical MacPherson suspension model of the minivan is conducted. Through the established model, the simulation of parallel wheel travel of the suspension system of the minivan is carried out and analyzed. After initial analysis, wheel alignment parameters especially the toe angle and camber angles need to be optimized to meet the requirements of the desired design value. The characteristic curves of wheel alignment parameters are drawn and the corresponding non-ideal characteristics are found. The optimization objective is to reduce the variation of the unreasonable alignment parameters, and the design variables are given through the sensitivity analysis. The design parameters are reasonably grouped according to different kinematic characteristics, thus, a unified objective function is established by direct weighing combination method. Finally, the established objective function is optimized and designed with neighborhood cultivation genetic algorithm. By comparing the original and optimized results, the better wheel alignment parameters are obtained and the system performances of suspension are further improved.
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