电动汽车用内置式永磁同步电机气隙磁场解析建模与多目标优化

为提高电动汽车用内置式永磁同步电机气隙磁场解析计算精度和优化效率，利用混合解析法建立考虑转子铁心磁桥饱和效应的电机气隙磁场参数化解析模型。首先利用联合等效磁路法的子域法建立内置式永磁同步电机开路气隙磁场解析模型；然后利用同样方法建立转子磁桥虚拟磁场解析模型，从而得到考虑转子磁桥饱和效应的电枢反应磁场解析模型；最后通过叠加原理建立内置式永磁同步电机合成气隙磁场解析模型。通过有限元仿真和转矩测试验证内置式永磁同步电机气隙磁场解析模型的准确性。基于所建立的解析模型，以永磁体极弧宽度、定子槽口宽度和转子端部磁桥厚度为优化变量，以特定阶次频率的径向力波、转矩和效率为优化目标，利用带精英策略的非支配排序遗传算法，对一台电动汽车用内置式永磁同步电机样机进行多变量多目标优化。研究结果表明：与试验结果相比，解析计算误差小于5%,而计算时间较有限元仿真缩短90%以上；优化后，电机特定阶次频率的径向力波减小了9.2%,最大转矩提升了2.49%,最大效率提升了0.69%,高效区面积扩大了约54.46%;所提方法既解决了内置式永磁同步电机强非线性和高饱和的解析建模共性难点，又极大提高了电机多目标优化效率；研究可...     

Development of an electric motor-driven pump unit for electro-hydraulic power steering with 42V power-Net

Motorization in vehicles is expanding rapidly for fuel efficiency, customer comfort, convenience, and safety features. These new electric loads represent an increase in the required electric power. This has generated interest in new, higher power systems such as the 42V Power Net. The electro-hydraulic power steering (EHPS) system is one of these systems. This paper presents the development of the electric motor-driven pump unit for the EHPS system using a 42V power-Net. The interior type permanent magnet synchronous motor (IPMSM) can be applied to this system with more power density per volume for compactness of the EHPS. In order to improve the system, the IPMSM and its control method was optimized for improved torque characteristics and electric power consumption. The performances of both the pump unit and the IPMSM have been verified by experimental results. Finally, all in one type the electric motor-driven pump unit are developed from the experiment verification.     

Cross-sectional shape design and optimization of automotive body with stamping constraints

At conceptual design stage, automotive body is usually simplified as a frame structure, which consists of thinwalled beams (TWBs). Therefore, the most important issue is to determine the cross-sectional shape of TWBs under the requirement of mechanical properties. However, design engineers mostly depend on their experience or repeated modification to design the cross-sectional shape of TWBs. So this paper presents a rapidly cross-sectional shape design and optimization method to satisfy the demand of mechanical properties and meanwhile minimize the weight of TWB. Firstly, cross-sectional mechanics property formulations are summarized. Especially, the torsional rigidity formulation of three-cell cross section is derived for the first time in this paper. Secondly, the shape optimization model is created to minimize the weight of TWB and improve the mechanical properties, which is solved by genetic algorithm. Moreover, three stamping constraints, draft angle, chamfer radius and assembly, are introduced to promote the cross-sectional shape more practice. Lastly, numerical examples verify the effectiveness of the optimization model and show the application in structural modification of automotive frame.     

多功能电动车车架的优化设计

汽车车架作为汽车总成的重要组成部分,其结构设计在汽车总体设计中至关重要。为进一步合理优化车架的性能,提高车辆的轻便性和工作效率,文章以某型多功能电动车车架设计为例,用ANSYS软件进行优化分析,阐述了拓扑优化的设计方法。通过优化,提高了车架的总体性能及材料的利用率。结果表明,该优化设计可以在改善结构性能的基础上实现材料的最优分布,减轻了结构质量,节省了设计成本。其方法可广泛应用于承载机构的优化设计工程。     

汽车结构耐撞性设计与优化研究综述

汽车的碰撞安全问题是汽车行业一直重点关注的问题之一,开展汽车结构的耐撞性设计已成为提升车辆碰撞安全性的重要手段。文章对国内外汽车结构耐撞性设计与优化的研究成果进行回顾与总结,鉴于碰撞过程的强非线性与众多设计准则相互耦合等特性,重点对近似多目标耐撞性优化方法及其应用进行综述,并分析存在的问题和进一步深入研究的方向。     

Structural design of an outer tie rod for a passenger car

This study proposes a structural design method for an outer tie rod installed in a passenger car. The weight of the outer tie rod is optimized by using the aluminum alloy Al6082M, which is developed as a steel-substitute material, and applying structural optimization techniques. The high strength aluminum with improved mechanical properties was developed to reduce the weight of the outer tie rod. The newly developed aluminum alloy Al6082M is applied as the material of the outer tie rod. The static strength due to inertia force, durability and buckling performances are considered in the structural design of the outer tie rod. At the proto design stage of a new outer tie rod, it is cost-effective to utilize FE (finite element) analysis to predict each of these performances. In addition, the current trend in the structural design of automobile parts is to use optimization techniques to reduce the weights of the parts. First, for an arbitrary base design, the static strength, the life cycle and the buckling load are calculated to check whether the design satisfies its criteria. Then, the critical performance is selected so as to include its loading condition only in the optimization process. In this study, the metamodel based optimization process using kriging is adopted to obtain the minimum weight satisfying the critical design requirement. Then, the feasibility of the determined optimum shape is investigated against the other performances. Finally, the optimum design of outer tie rod is modified by considering forging efficiency. The performances of the final design are investigated through simulation and experiment.     

A robust optimization for the frequency and decoupling ratio of a powertrain mounting system based on interval analysis

This paper presents a robust optimization method to decrease the variations in the performance of the designed system caused by the unavoidable manufacturing, installation or measurement errors of the design variables. Generally, it is difficult and costly to determine statistical information with sufficient precision for uncertain design variables; in this study, interval numbers are used to describe the uncertain design variables, and only the bounds of these variables are required. An improved interval truncation method is presented for estimating the variation ranges of the system performances. The robustness estimations of the system performances are incorporated into the optimization formulation to obtain the nominal design variables, which could make the system performances relatively robust; therefore, the design robustness is estimated and improved in the optimization iteration process. The robust optimization method is applied to a general powertrain mounting system (PMS) to improve the design robustness of the PMS decoupling layout and frequency allocation. The optimization results show that the robust optimization method could effectively increase the decoupling ratios in the interested vertical and pitch directions, and the frequency allocation is more robust than that obtained using the traditional deterministic optimization.     

Design Optimization of a Rear Independent Suspension for the Korean Light Tactical Vehicle

Steering and suspension handle the direction of a vehicle according to the driver’s intentions and control the disturbance from the road surface while supporting the vehicle body. The static and dynamic characteristics of two systems are critical factors for the ride comfort and the directional stability. In the layout stage, the hard points of steering and suspension systems are determined. In the next design stage, the detailed design of the system, including gearboxes, springs, shock absorbers, and control links, is carried out. While the optimal hard points of a suspension are determined at the precedent design, interference with other peripheral components should be carefully examined in the detailed design process. In the case of the design point change should be made to avoid the interference, subsequent position and shape changes of the link mechanism are required. Therefore, there is a need to examine the optimization of suspension compliance characteristics with chassis design changes and the durability performance of the modified design. This study proposes an integrated analysis method for the design optimization and the durability evaluation of such optimized design specifications of the rear independent suspension for a military vehicle.     

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.     

Aerodynamic design optimization of rear body shapes of a sedan for drag reduction

This study proposes an aerodynamically optimized outer shape of a sedan by using an Artificial Neural Network (ANN), which focused on modifying the rear body shapes of the sedan. To determine the optimization variables, the unsteady flow field around the sedan driving at very fast speeds was analyzed by CFD simulation, and fluctuations of the drag coefficient (C _D ) and pressure around the car were calculated. After consideration of the baseline result of CFD, 6 local parts from the end of the sedan were chosen as the design variables for optimization. Moreover, an ANN approximation model was established with 64 experimental points generated by the D-optimal methodology. As a result, an aerodynamically optimized shape for the rear end of the sedan in which the aerodynamic performance is improved by about 5.64% when compared to the baseline vehicle is proposed. Finally, it is expected that within the accepted range of shape modifications for a rear body, the aerodynamic performance of a sedan can be enhanced so that the fuel efficiency of the sedan can be improved. The YF SONATA, a sedan manufactured by Hyundai Motors Corporate, played a major role in this research as the baseline vehicle.     

基于拓扑优化的车架结构可靠性设计

为了提高某载货车车架的力学性能并减轻重量,将可靠性理论引入车架结构的优化设计。考虑了多种行驶工况的冲击载荷对车架的破坏作用,给出多工况条件下拓扑优化结果,建立满足各总成的布置和实际行驶要求的新设计结构,基于结构可靠性和有限元法对新设计车架的结构参数进行了可靠性优化设计。理论分析和车架的实际应用情况表明,该车架设计合理,说明该优化设计方法进行车架结构设计的有效性和可行性,为结构优化设计提供一种思路。     

Isight平台理论与方法及其在产品结构设计与优化中的应用研究

Isight平台是集成、自动化和优化设计过程的通用软件框架,广泛应用于产品结构设计和优化工作中。文章不仅对其理论和方法进行了详细的描述,而且给出了一个工业实例,以说明该平台的应用。结果表明,Isight平台能够集成多种类型的软件,并基于其数据集成和数据处理等能力实现自动分析,与传统的产品设计和优化方法相比具有更大的优势。此外,文章对同类研究问题也具有一定的指导意义和参考价值。     

Development of a fiber-reinforced plastic armrest frame for weight-reduced automobiles

This paper presents the design optimization process of a short fiber-reinforced plastic armrest frame to minimize its weight by replacing the steel frame with a plastic frame. The analysis was carried out with the equivalent mechanical model and design of experiment (DOE) method. Instead of considering the whole structure, it is divided into three simpler regions to reduce the complexity of the problem through examining its structural characteristics and load conditions. The maximum stress and deflection of the regions that carry the normal load are calculated by the analytical mathematical form derived from an equivalent model. The other regions loaded by contact stress are handled by FEM (finite element method), the DOE method, and the RSM (response surface model). To optimize the design variables in both cases, the object functions derived from these calculations are solved with a CAE (computer aided engineering) tool. This method clearly shows the mechanical and mathematical representation of structural optimization and reduces the computing costs. After design optimization, the weight of the optimum plastic-based armrest frame is reduced by about 18% compared to the initial design of a plastic frame and is decreased by 50% in comparison with the steel frame. Some prototypical armrest frames were also made by injection molding and tested. The research results fulfilled all of the design requirements.     

Gate shape optimization using design of experiment to reduce the shear rate around the gate

Numerical analysis is used to optimize the gate shape of the mold part in the molding process. The objective of this research was to develop a procedure that will optimize the gate shape of the mold part by using Design of Experiments approach. The computer-aided engineering software Moldflow was used to simulate the plastic injection molding process and the Minitab software was used to analyze the computational results from Moldflow. The Bulk Molding Compounds (BMC) UNI-203S thermoset material was chosen as the molding material. Four different types of gate shapes were analyzed to find the gate shape to be used in the optimization. The Type 3 gate shape was selected as basis for the gate optimization because this shape yielded the minimum shear rate around the gate among all. The thickness, width, length and angle of the gate were selected as the design variables. Erosion around a gate due to repetitive shear flow during molding process was considered as an important issue to extend the service life of the expensive mold. It is normally very difficult to prevent erosion due to high injection pressure and repetitive use of the mold, especially in certain molding parts as BMC reflector in automotive parts, so it has become the subject of researches. The effectiveness of design variables was evaluated by observing shear rate around the gate. The objective of the optimization was to minimize the average shear rate around the gate. Response Surface Method was applied to identify the optimum values of the design variables. The computed optimum values were validated numerically. The optimized gate shape showed the reduced shear rate by about 11%.     

Shape optimization of a torsion beam axle for improving vehicle handling performance

In this study, shape optimization was conducted for a vehicle’s rear suspension torsion beam to improve its dynamic handling performance. To determine the design variables affecting the vehicle roll characteristics, a sensitivity analysis was conducted using the result of a Taguchi experiment with 6 factors in 8 runs. The upper and lower-flange lengths and web thickness of the torsion beam section, as well as the vertical height difference between the inner and outer of torsion beams, were determined as design variables through sensitivity analysis of the opposite wheel travel test for optimization of the torsion beam axle. The Box–Behnken experimental design with 4 factors and 27 runs was performed using the selected design variables and by performing opposite wheel travel analysis according to the experimental design, and the response surface functions of the roll stiffness, roll steer coefficient, roll center height, and mass of the torsion beam were generated. Using these response functions, shape optimization was conducted for the torsion beam of the rear suspension system. Dynamic performance analysis was performed by applying the optimized H-shaped torsion beam to the rear suspension of the vehicle dynamics model, and it was validated that the dynamic response performance of the optimized vehicle was improved.     

基于混合粒子群算法的土钉支护结构设计参数优化

在土层工程地质情况一定的条件下,如何寻找一组最佳设计参数,以达到既经济又安全的目的,是土钉支护设计的一个重要问题。这是一个复杂的优化设计问题。就此,提出基于混合粒子群优化(PSO)算法的基坑土钉支护优化设计方法,以单位长度土钉墙的土钉材料造价作为优化的目标函数。该方法保持了PSO算法结构简单的特点,改善了PSO算法的全局寻优能力,提高了算法的收敛速度和计算精度,不活动粒子的处理使算法避免了“早熟”现象的出现。工程实例计算表明,该方法是进行土钉支护结构优化设计的有效方法。     

发动机标定方法及性能预测的探讨

电控发动机性能开发是一项系统工程,包括性能设计、结构设计、标定数据优化以及整机性能优化。通过分析电控系统的标定方法、试验设计方法,认为标定方法不仅要做到优化电控系统与发动机的匹配,还应具备预测缺陷、性能和改进方向的功能。     

Design of conformal cooling channels for an automotive part

The cooling system plays a crucial role in determining the productivity and quality of an injection molding process. With the current growth of Solid Freeform Fabrication (SFF) techniques, mold designers have been striving for not only improvement in cooling system performance but also for a method to do so automatically. In this paper, a method is proposed for developing a conformal cooling system that facilitates uniform cooling over the entire mold surface with minimum cycle time. Based on the temperature distribution after the filling stage, the mold surface is split into zones which will be cooled by optimized subconformal channels obtained from the optimization process. The optimization process in which the objective function is stated as minimization of the cooling time with boundaries ensuring a realistic design will optimize the cooling system layout in terms of cooling channel size and location. Finally, all subcooling channels are combined to generate the entire conformal cooling system for the injection mold.     

基于阶段的相位设计逐步优化法

相位设计是信号控制交叉口进行配时设计时需要首先解决的问题,直接决定着控制方案的效果.当前使用的相位设计主要依赖经验判断或穷举确定,不能保证最优.文中提出了基于相位阶段的相位设计"分组、相位搭接、相序调整"逐步优化法,能保证相位设计结果接近最优,并以4路交叉为例说明了其可行性.     

发动机曲轴二级并联橡胶扭转减振器优化设计

为降低曲轴扭转振动对发动机前端附件驱动系统的影响,在介绍曲轴减振器参数优化设计方法及数学模型的基础上,对曲轴二级并联橡胶扭转减振器参数设计提出了一种新的优化方法,这种方法以同时降低曲轴和带轮的扭转振幅为目标对减振器进行优化。计算结果表明,采用文中提出的优化设计方法设计的减振器,不但曲轴的扭转振动特性得到改善,曲轴带轮的振动也得到很好控制。