Introduction 1.1 Railway vehicle virtual prototyping In recent years, knowledge-based new product competition has become the mainstream of manufacturing competitiveness. As an important way to simulate various problems of complex mechanical systems, virtual prototyping technology is being widely used. It supports concurrent engineering and emphasizes the overall product performance, and strives to simulate the product function and behavior. Based on considering the overall product performance in three-dimensional CAD and its following function modules, virtual prototyping does the innovative design and informs a digital prototyping which do not depends on the physical prototype. Virtual Prototyping (VP) is a new product design method generated in the recent 20 years. Based on computer simulation, VP embodies not only the product's innovative design but also the product's risk-free digital test, especially suiting for high cost trial production of complex mechanical system development. The main elements of VP are: virtual prototype model-virtual test analysis-virtual prototype evaluation (qualitative and quantitative). VP embodies the global optimization process which is based on computer simulation and aims to get more realistic products. It supports "Top-to-Down" design approach. The main techniques of VP-CAX, multi-body system modeling and analysis, simulation, optimization, visualization and VR technology are used to get a digital prototype with optimized performance, thereby the development costs and the reliance on physical prototypes are reduced, product qualities are improved, and time-to-market is accelerated. Railway vehicle system which belongs to complex mechanical system areas is composed of mechanical, electrical, active control and drive systems (power distributed EMU), and its main part is mechanical systems. The quality of vehicle performances is the key problem of the vehicle product development. Based on the railway vehicle product design, especially the design results of the whole product machine, the performances include: dynamic performance, operational safety, aerodynamics, air-condition, strength and fatigue reliability. Therefore, it is inevitable to research and develop the railway vehicle virtual prototyping for advanced manufacturing technology. It is also inevitable to research the railway vehicle virtual prototyping technique for the railway transportation equipment, especially for the high-speed, heavy haul train. The past railway vehicle product development mainly takes the following forms:
