Robust optimization design method for powertrain mounting systems based on six sigma quality control criteria

This paper presents a robust optimization design method based on Six Sigma quality control criteria to improve the design of a powertrain mounting system (PMS). The powertrain is modeled as a rigid body having six degrees of freedom (DOF) connected to a rigid base by four rubber mounts, and each mount is simplified as a three-dimensional spring-damper element in its local coordinate system (LCS). The calculation method based on energy decoupling is used to estimate the decoupling ratios of a PMS. The location and static stiffness of each mount and the orientations of the two anti-torsion mounts are selected as uncertain design variables, and the nominal values of these design variables are optimized to obtain a robust Six Sigma design for a PMS. The uncertain design variables are characterized by a perturbation or percent variation around their nominal values. The generalized reduced gradient (LSGRG2) optimization method is employed to solve the robust optimization problem, and a second-order Taylor series expansion is used to estimate the statistical properties of the performance constraints and objectives. The optimization results show that the robust design ensures good robustness or high reliability for the natural frequencies, decoupling ratios, and frequency separation constraints of a PMS.     

基于容差模型的发动机悬置系统稳健优化设计

应用稳健优化设计理论,考虑设计变量的不确定性对结果的影响,建立稳健优化模型。以发动机悬置系统能量解耦为目标,用Pareto遗传算法对系统的刚度参数进行稳健优化,并将优化结果运用Monte Carlo方法进行分析.结果表明,优化方法可以有效提高悬置系统的稳健性。     

基于多维平行六面体模型的动力总成悬置系统固有特性分析

工程实际中,汽车动力总成悬置系统不可避免地存在着一定的参数不确定性,且不确定参数间往往同时存在一定的相关性与独立性。本文中引入多维平行六面体模型处理系统参数相关性和独立性并存的情形,结合蒙特卡洛法提出了一种悬置系统固有特性的不确定性分析方法,并给出了方法的分析步骤。对某悬置系统的数值分析结果表明:该方法能有效处理系统不确定参数的相关性和独立性,与未考虑参数相关性的区间方法相比,该方法能获得更为合理的固有频率和解耦率区间范围;对于给定的研究模型,其左右悬置点的刚度相关性对系统固有特性的影响比较明显,在设计和研究过程中应给予重点关注。     

基于免疫进化算法的发动机悬置系统稳健优化

在分析各种优化方法优缺点的基础上,建立发动机悬置系统六自由度动力模型。以六自由度方向的解耦率为最大优化目标,以各悬置点三向刚度为设计变量,选用免疫进化算法对发动机的悬置刚度参数进行优化,最后用Monte Carlo法对悬置系统进行稳健性分析。结果表明,优化解不仅能保证六自由度方向的高解耦率,还能保证悬置系统的稳健性,提高了产品的质量。     

考虑稳健性的汽车结构耐撞性优化设计

本文中基于C-NCAP中40%重叠度的偏置碰撞工况对某轿车进行结构耐撞性优化。为提高输出响应的预测精度,使用基于粒子群算法优化的支持向量回归模型来拟合设计变量与输出响应之间的关系,并利用非支配排序多目标遗传算法Ⅱ获得该优化问题的Pareto前沿。在确定性优化的基础上,并考虑产品性能在不确定因素影响下的波动,对其进行稳健性优化设计。最后,对优化结果进行有限元仿真验证。结果表明:优化后,结构质量减轻,耐撞性能明显提升,同时保障了稳定的产品性能。     

发动机-悬置系统的能量法解耦及优化设计

本文通过发动机-悬置系统的能量分布得到系统解耦的能量指标,并以该能量指标为优化设计目标。以系统的固有频率为约束条件,应用DSFD算法对系统进行优化计算。所编制的优化设计程序具有计算可靠、收敛速度快的特点。为便于程序应用,本文指出了系统能量解耦目标、频率约束及设计变量等因素对优化计算的影响。对某一轻型货车发动机-悬置系统的优化计算表明,仅通过悬置刚度参数的调整即可使系统的解耦水平明显提高。     

田口鲁棒设计方法在汽车耐撞性优化中的应用

将田口鲁棒设计方法和稳健性理论与试验设计相结合,应用于某微型客车的前端大梁组件结构的设 计,通过与仅靠试验设计得出结果的对比分析,表明该方法不仅实现了对整车耐撞性的优化,同时提高了设计变量的稳健性,具有较强的工程实用性.     

基于PSO-SVR近似模型的乘员约束系统稳健性优化

综合运用近似模型参数优化技术和稳健性优化方法对汽车乘员约束系统进行优化。通过全局灵敏度分析,选出对加权伤害准则(weighted injury criterion,WIC)影响大的参数;采用粒子群优化(PSO)算法对支持向量回归(SVR)模型参数和核函数参数进行优化,建立高精度的PSO-SVR近似模型;在确定性优化的基础上进行基于蒙特卡罗抽样的稳健性优化。结果表明:优化后乘员约束系统性能得到明显提升且兼顾了稳健性。     

Optimal design of adaptive shaking vibration control for electric vehicles

This paper provides a complete design solution about adaptive optimal shaking vibration control for electric vehicles. A general 4-DOF and 5-order linear torsional vibration model is established under given wheel speed, and the frequency characteristics of the vibration system are elaborately analysed in terms of variation of wheel speed and different model parameters. Aiming at decreasing the shaking vibration at the least sacrifice of acceleration loss, and improving the robustness of the system against external disturbance, a combination of feed-forward and feed-backward adaptive control structure is proposed. Further, a non-linear multi-constraint optimisation problem is formulated for solving the optimal adaptive control variables within the two-dimensional design space composed of the wheel speed and driver's torque command. Furthermore, the distribution of the optimal adaptive control variables within the design space and its extended application under different tyre road conditions are discussed. Eventually, several simulation test cases are particularly designed to verify the performances of the controller on all aspects. Test results show that the optimal adaptive controller achieves satisfactory anti-shaking vibration, acceleration maintaining and robustness performances within the whole adaptive design space as desired.     

Robust design optimization of suspension system by using target cascading method

This study presents the robust design optimization process of suspension system for improving vehicle dynamic performance (ride comfort, handling stability). The proposed design method is so called target cascading method where the design target of the system is cascaded from a vehicle level to a suspension system level. To formalize the proposed method in the view of design process, the design problem structure of suspension system is defined as a (hierarchical) multilevel design optimization, and the design problem for each level is solved using the robust design optimization technique based on a meta-model. Then, In order to verify the proposed design concept, it designed suspension system. For the vehicle level, 44 random variables with 3% of coefficient of variance (COV) were selected and the proposed design process solved the problem by using only 88 exact analyses that included 49 analyses for the initial meta-model and 39 analyses for SAO. For the suspension level, 54 random variables with 10% of COV were selected and the optimal designs solved the problem by using only 168 exact analyses for the front suspension system. Furthermore, 73 random variables with 10% of COV were selected and optimal designs solved the problem by using only 252 exact analyses for the rear suspension system. In order to compare the vehicle dynamic performance between the optimal design model and the initial design model, the ride comfort and the handling stability was analyzed and found to be improved by 16% and by 37%, respectively. This result proves that the suggested design method of suspension system is effective and systematic.     

车身壁板自由阻尼层稳健性优化设计

在车身壁板自由阻尼层的优化设计中,提出了考虑阻尼材料参数不确定性波动的稳健性优化设计方法。首先,在车身防火墙、地板和顶棚等区域全敷阻尼材料;其次,以等效辐射声功率(ERP)为优化目标对阻尼层布局进行拓扑优化并验证优化效果;最后,以阻尼层厚度为随机设计变量,损耗因子和弹性模量为随机变量,质量最小为优化目标,并结合径向基函数(RBF)近似模型、蒙特卡洛模拟(MCS)和序列二次规划算法(SQP)对阻尼层进行6σ稳健性优化设计。结果表明,优化后车身自由阻尼层的总质量减少了50.45%,并且车身结构噪声性能达到了6σ质量水平,实现了保证车身轻量化要求下的阻尼层稳健性优化的目标。     

基于灵敏度分析的动力总成悬置系统优化

针对某车动力总成悬置系统固有频率偏高和振动耦合严重的问题,建立了该车动力总成悬置系统6自由度模型,并对悬置元件的主刚度参数进行了灵敏度分析.以分析找出的少量敏感参数为设计变量,结合振动解耦和固有频率匹配理论,对该悬置系统参数进行了优化,并对优化前后的动力总成悬置系统进行了台架试验.结果表明,优化后的悬置系统隔振能力有了...     

Innovative design optimization strategy for the automotive industry

In order to effectively solve modern automotive design problems including the results of nonlinear FEA and multi-body dynamics, a progressive meta-model based design optimization is presented. To reduce the number of initial sample points, two sampling methods are introduced. Then, for efficient and stable construction of meta-models, three metamodel methods are newly introduced which are numerically based on the singular value decomposition technique. To design a practical system considering manufacturing tolerances and optimizing multiple performances, a robust design optimization, 6-sigma constraints and multi-objective strategies are implemented when solving the approximate optimization problem constructed from the meta-models. Until the convergence criteria are satisfied, the initially developed meta-models are progressively improved by adding only one point that minimizes the approximate Lagrangian in the consecutive optimization iterations. Finally, one validation sample and four automotive applications are solved to show the effectiveness of the proposed approach.     

镁铝合金车轮胶栓复合连接稳健性优化设计

提出了车轮胶栓复合连接的多目标确定性与稳健性优化设计方法。首先,建立镁铝合金组装式车轮螺栓连接有限元模型,对其进行弯曲疲劳寿命仿真,对比疲劳试验结果,验证了车轮仿真模型的准确性。随后,建立结构胶弹塑性本构模型,通过试验得到其应力应变曲线和剪切强度。最后,选取胶层厚度与种类、螺栓预紧力和螺栓孔直径为设计变量,建立车轮栓胶复合连接参数化仿真模型,以车轮连接螺栓疲劳寿命、结构胶最大拉伸和最大剪切应力为优化目标,借助ISIGHT优化平台,分别采用第二代非劣排序遗传算法(NSGA-Ⅱ)和微存档遗传算法(AMGA)对车轮胶栓连接结构进行了多目标确定性和6σ稳健性优化设计。稳健性优化后车轮连接的可靠性得到进一步提升。     

Robust design optimization of suspension system considering steering pull reduction

This paper presents robust design optimization method to reduce steering pull phenomenon. One of the biggest causes of steering pull phenomenon is tolerance of suspension system such as hard point, spring, damper and bush. Therefore, the relationship between suspension systems and steering pull phenomenon has as nonlinear characteristics. But, it can be very difficult to evaluate the analytical design sensitivity. Thus, it is impossible to directly apply a well-developed optimization algorithm based on gradient information. To avoid these difficulty, this study uses sequential approximation optimization process based on a meta-model. The robust design process has 28 random design variables with tolerance. For efficient design process, the sample variances for the design goals are approximated from meta-models. The proposed approach required only 62 evaluations until it converged. Optimal design reduced the drift by 80% and its deviation by 38.7%, respectively. This result proves that the suggested design method of suspension system is effective and useful.     

新型燃料电池发动机空气增湿系统性能研究

对鼓风机、散热器和膜增湿器的工作特性进行了研究,基于系统整体性能优化进行了燃料电池发动机空气增湿系统集成设计。空气增湿系统和冷却系统得到有效耦合,对新型空气增湿系统性能研究表明:该系统效率更高,鲁棒性更强。     

基于微分几何的四轮独立驱动车辆运动解耦控制研究

针对车辆在纵向运动和横摆运动时的强耦合关系给车辆动力学控制带来的困难，以四轮独立电驱动车辆作为研究对象，基于微分几何理论设计了车辆系统运动解耦控制方法，将非线性强耦合的四轮驱动车辆动力学系统解耦为纵向和横向两个相对独立运动控制子系统，并设计了鲁棒控制器，以提高抵抗车辆行驶时不确定外力如侧风的干扰能力。基于 Trucksim 软件建立四轮驱动车辆模型，并针对车辆解耦控制策略和抗干扰策略进行了仿真测试。结果表明，相比于无解耦控制的车辆，采用微分几何解耦控制的四轮独立驱动车辆纵向速度偏差降低了 82.1%，横摆角速度偏差降低了80.7%，且微风干扰下的抗干扰能力明显改善，车辆稳定性显著提升。为验证该运动解耦控制策略在实时系统中的控制效果，还进行了硬件在环试验，结果表明，硬件在环试验的结果与仿真结果一致。     

Robust yaw stability control for electric vehicles based on active front steering control through a steer-by-wire system

A robust yaw stability control design based on active front steering control is proposed for in-wheel-motored electric vehicles with a Steer-by-Wire (SbW) system. The proposed control system consists of an inner-loop controller (referred to in this paper as the steering angle-disturbance observer (SA-DOB), which rejects an input steering disturbance by feeding a compensation steering angle) and an outer-loop tracking controller (i.e., a PI-type tracking controller) to achieve control performance and stability. Because the model uncertainties, which include unmodeled high frequency dynamics and parameter variations, occur in a wide range of driving situations, a robust control design method is applied to the control system to simultaneously guarantee robust stability and robust performance of the control system. The proposed control algorithm was implemented in a CaSim model, which was designed to describe actual in-wheel-motored electric vehicles. The control performances of the proposed yaw stability control system are verified through computer simulations and experimental results using an experimental electric vehicle.     

钢筋混凝土简支梁的多目标可靠性稳健优化设计

为提高钢筋混凝土简支梁的可靠性和稳健性,运用可靠性和稳健优化设计的理论,建立了适合可靠性稳健优化设计的多目标模型。针对可靠性稳健优化设计的多目标模型多属于高维多目标优化问题,把灰色理论中的关联分析引入粒子群优化算法中,根据灰色关联能够很好地分析目标矢量之间的接近程度,并能掌握解空间全貌的特点,提出了适合高维多目标优化问题求解的灰色粒子群算法。与传统方法相比,该方法更能迅速准确地得到钢筋混凝土简支梁的可靠性稳健优化设计信息。     

基于遗传算法的膜片弹簧的稳健化设计

在离合器膜片弹簧传统优化设计模型的基础上,应用工程稳健性的灵敏度分析,考虑了可控变量和不可控参数变差对膜片弹簧优化设计的影响,并采用遗传算法对目标函数进行了求解。结果表明,遗传算法具有比传统优化方法更强的全局寻优能力,稳健化设计能有效、可靠的减小质量波动对膜片弹簧优化设计的影响。