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.     

动力电池包热管理设计与优化分析

针对动力电池包热管理中系统温度不均匀的问题,本文以某款液体循环冷暖一体化热控方式的电池包为研究对象,通过Ansys-fluent对其液冷回路进压降仿真,并优化液冷回路,最后通过实验验证优化前后系统的散热/加热性能,得出流量均匀性越好在液冷和液热时,电池包内电芯间的温差越小,散热以及加热效率更高。为后续热管理设计可将流道的设计作为重点考察对象进行优化。     

基于新型液冷板的电池热管理系统多目标优化

为提升电池热管理系统(BTMS)散热效果,采用计算流体力学(CFD)和基于快速非支配排序遗传算法(NGSA-II)的多目标优化相结合的方法设计优化了一种新型液冷板模型。通过电池实验,得到不同放电倍率下单体电池产热量。以通道夹角、通道宽度、冷却液的质量流量为设计变量,平均温度、温度标准差和压降为目标函数,采用拉丁超立方体抽样(LHS)方法,在设计空间中选取了35个设计点,利用响应面近似模型(RSM)拟合出目标函数的表达式。结果表明:在5C放电倍率下,优化后液冷板的散热性能得到有效提升,与初始模型相比,液冷板的平均温度和温度标准差分别下降了11%、51.2%,压降仅增加了3.3Pa。     

PHEV发动机冷却系统优化设计

基于台架测试,对某款PHEV发动机的冷却系统不同水泵转速的流量分布,不同发动机负荷的热量分布,以及能量流进行研究,发现薄弱环节并进行优化设计,基于AMESim仿真平台进行建模及仿真预测.结果表明,通过优化乘员舱采暖回路控制以及取消无效流量回路,可以实现系统水阻降低2.8％,电子水泵功耗下降23％,暖风回路流量提高27％...     

Hydraulic control system design for a PHEV considering motor thermal management

In this paper, a design method for a PHEV hydraulic control system was proposed considering motor thermal management. Dynamic models of the target PHEV were developed including the hydraulic system, which consists of one mechanical and one electric oil pump. The required motor cooling flow was designed based on the motor temperature, which was obtained from a one-dimensional thermal equivalent circuit model including the heat source and oil spray cooling. Combining the PHEV powertrain model, hydraulic control system model, and the motor thermal model including the cooling system, an integrated simulator was developed for the target PHEV. Using the integrated simulator, the temperatures of MG1 and MG2 were investigated for various motor cooling flow rates when the PHEV underwent a highway driving cycle. The energy consumption of the hydraulic control system was also evaluated. It was found from the simulation results that a hydraulic control system of the target PHEV could be designed that satisfied the required flow for the motor cooling, lubrication and brake control using the design procedure proposed in this study.     

基于响应面法的内燃机曲轴优化

针对内燃机曲轴的结构强度问题,以内燃机实际运行工况下整体曲轴有限元仿真为基础,通过中心组合试验方法进行采样,运用最小二乘法、显著性分析和拟合精度检测,构建并修正了曲轴结构强度计算的响应面模型,选择关键几何结构参数为设计变量,采用模拟退火与直接搜索相结合的协同优化方法对响应面模型进行优化。对某内燃机曲轴的优化算例表明,该优化方法能大大提高曲轴设计的优化效率,具有较高的精度。     

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%.     

特种车辆重载电动轮用轮毂电机热特性分析及冷却水道优化

为了准确分析轮毂电机温度场,基于电磁场有限元分析,采用考虑旋转磁化及谐波磁场的方法计算铁耗,并计算了轮毂电机各部件生热率。采用基于有限体积法的流固耦合分析和基于热网络法的磁热耦合分析,分别计算了额定工况下轮毂电机温度场,将轮毂电机温升试验和仿真结果进行了对比。结果表明,基于有限体积法的流固耦合分析得出的绕组稳态温度计算误差为1.8%,基于热网路法的磁热耦合分析计算误差为2.5%,验证了两种温度场分析方法的正确性。对不同结构冷却水道的热阻和压降进行了理论分析,基于Pareto遗传算法对螺旋型水道进行多目标优化,在保证额定工况电机稳态温升基本不变的情况下使水道压降降低了22.9%。     

摩托车发动机水冷化初探

摩托车发动机水冷化需要进行整个系统的设计、分析及计算。由于摩托车发动机本身结构紧凑、体积小,再设计布置水道有一定的难度,最好进行三维实体造型设计。为了在设计时尽量减少投入、简化结构和降低制造成本,在进行水冷化的过程中应注意产品的继承性和通用性。     

冲压件扭转与回弹问题研究与测量方法

乘用车冲压单件尺寸检查时,常用到三坐标设备及测量支具。因为车身外覆盖件直接对车身外观有重要影响,所以车身外覆盖件的型面尺寸有很高的精度要求。外覆盖单件具有材料薄、无加强支撑件等特点,所以在使用三坐标测量时,零件自身重力、零件回弹以及支具支撑和夹紧方式对测量结果都有非常大的影响。文章通过重复性实验、设计不同夹紧方式及顺序等方法,以后备箱内板的三坐标测量为例,给出针对不同冲压零件问题的测量解决方案。同时归纳总结了影响测量结果的主要因素,阐述了如何分析真实的零件状态,并指导模具优化的通用经验方法。     

轿车发动机冷却水套流动与传热CFD计算分析

通过UG软件对某汽油机冷却水套建立三维模型,利用计算流体力学软件FLUENT分析发动机内部冷却水的流场分布、换热系数分布以及压力损失,同时对该发动机的冷却水套提出了优化方案并对其计算结果与原方案进行了对比分析。原发动机冷却水套的流动传热计算表明:缸盖进气侧冷却水流动较均匀,3缸和4缸缸体冷却水套排气侧冷却能力较差,1缸和2缸缸盖冷却水套排气侧冷却能力较差,通过改进前后换热系数比较,说明改进后的发动机冷却水套的换热能力优于原发动机冷却水套。     

Analysis of the performance of the evaporator of automotive air conditioning system

The purpose of this research was to establish a theoretical model for the evaporator of automotive air conditioning system and conducting simulations to evaluate the effect of operation parameters, environmental conditions, and design parameters on the performance of evaporator. An automotive air conditioning system primarily consists of four components: the compressor, the condenser, the refrigerant controller, and the evaporator. The refrigerant flow in the evaporator can be divided into two regions: the evaporating region and the superheat region. The refrigerant in the first region is a two-phase flow, while the refrigerant in the latter region is in the state of superheated vapor. The air flowing through the interior of the evaporator can also be divided into two zones: the unsaturated zone and the saturated zone. Water vapor is condensed in the saturated zone while in the unsaturated zone, no water condenses. Because the refrigerant flow and the airflow are perpendicular to each other, the distribution of refrigerant in the evaporating region and the superheat region does not coincide with the distribution of air in the unsaturated zone and the saturated zone. This study examines the effects of different design parameters, environmental conditions and operating parameters on the cooling capacity and superheat of an air conditioning system. Design parameters include the length of the refrigerant channel, the length of the air channel, and the thickness of the fins. Environmental conditions include the air inlet temperature and absolute humidity. Operation conditions include the refrigerant inlet enthalpy, inlet air flow rate, and refrigerant mass flow rate. Results of simulation demonstrated that fins with 50 micron meters width has the greatest cooling capacity for identical outer dimensions; thicker or thinner fins only decreased cooling capacity. Under different outer dimensions, longer refrigerant tubes and air channels created a greater cooling capacity. However, the increase in cooling capacity becomes less and less if the refrigerant flow was fixed because the heat transfer capability of the gaseous refrigerant was limited. In this study, an increase of 19% in cooling capacity can be reached as the length of refrigerant channels was increased, and the increased length of the air channels can promote the cooling capacity by 22%. Besides, it was found in this study that a decrease in the refrigerant inlet enthalpy, the inlet air flow rate, the air inlet temperature, and the inlet absolute humidity, or an increase in the refrigerant mass flow rate, would extend the superheat region and decrease the refrigerant’s superheat. It was also found that the cooling capacity of air conditioners is extremely sensitive to changes in the refrigerant mass flow rate and the inlet enthalpy, and variations more than 50% were found in the operating ranges examined in this study. However, changes in the inlet temperature, absolute humidity, and inlet air flow rate only resulted in variations between 10% and 20% in the examined ranges of conditions. Finally, a correlation among these variables and the simulated cooling capacity was obtained in this study, enabling the relevant researchers to evaluate automotive air conditioning performance under different environmental conditions and operation parameters more easily.     

Comparison of the optimum designs of center pillar assembly of an auto-body between conventional steel and ahss with a simplified side impact analysis

This study compares the optimum designs of center pillar assembly with advanced high-strength steel (AHSS) to that of conventional steel for crashworthiness and weight reduction in side impacts. A simplified side impact analysis method was used to simulate the crash behavior of the center pillar assembly with efficient computing time. Thickness optimization aims to perform an S-shaped deformation of the center pillar toward the cabin to reduce the injury level of a driver in a crash test. Center pillar members were regarded as an assembly of parts that are fabricated with tailor-welded blanks, and the thickness of each part was selected as a design variable. The thickness variables of parts that have significant effects on the deformation mechanism were extracted as the main design variables for thickness optimization based on the results of a sensitivity analysis with design of experiments. The optimization condition was constructed to induce an S-shaped deformation mode and reduce the weight of the center pillar assembly. An optimum design was obtained after several iterations with response surface methodology (RSM). Optimization was first performed with conventional steel and then with AHSS with the same procedure to optimize the crashworthiness of the center pillar assembly. After thickness optimization, optimum designs were applied to the full vehicle analysis to evaluate the validity of the optimization scheme with the simplified side impact analysis method. Then, the crashworthiness of optimum designs with conventional steel and AHSS were compared using the full vehicle analysis. This comparison demonstrates that AHSS can be more effectively utilized than conventional steel to obtain a lightweight design of an auto-body with enhanced crashworthiness.     

Topology optimization of gas flow channel routes in an automotive fuel cell

An efficient topology optimization method for fluid-structure problems was developed in an effort to determine the optimum flow channel route in a fuel cell bipolar plate from first principles. This study describes the derivation and solution of new mathematical equations for topology optimization combining a density-based algorithm, the interpolation method of moving asymptotes (MMA), and the incompressible Navier-Stokes equation with a term representing the chemical reaction between hydrogen and the catalyst. The present method is based on the finite element method with a newly developed reaction rate equation. In this model, a topology variable of 0 represents viscous flow, whereas a value of 1 indicates porous flow. The flow velocity and pressure were obtained from the Navier-Stokes equation and constraints and element matrices for sensitivity analyses during the optimization. MMA was utilized to calculate the optimum flow routes in the design domain. The influence of the key design parameter q and the pressure drop on the optimum topology were also investigated. The channel topology became smoother with decreasing q, and the number of channels increased with increasing pressure drop.     

基于响应面法的钢-混组合桥面系优化设计

对桥梁结构进行优化设计和可靠性研究时,采用传统的设计方法可能会遇到计算工作量繁重的问题,应用响应面法进行优化设计是有效解决该问题的途径之一。以某大跨悬索桥钢-混组合桥面系为研究对象,结合节段缩尺模型试验研究,以有限元软件Workbench为计算平台,建立相应的参数化有限元模型。以组合桥面系重量最轻为经济目标,最大变形及最大弯曲应力为约束,基于响应面法对其进行多参数优化设计,并对优化结果进行了有限元分析验证。计算结果表明:节段缩尺模型静力试验结果与有限元分析结果吻合较好,建立的有限元模型很好地反映了试验模型实际的受力状态;基于响应面法优化设计后组合桥面系质量减小了3.57%,在满足力学性能要求的同时,减轻了结构自重,降低了工程造价,为钢-混组合桥面系设计提供了良好的概念设计模型。     

电动汽车电池组热管理系统的关键技术

电池组热管理系统的研究与开发对于电动汽车的安全可靠运行有着非常重要的意义。本文分析了温度对电池组性能和寿命的影响,概括了电池组热管理系统的功能,介绍了电池组热管理系统设计的一般流程,并对设计热管理系统提出了建议。文章重点分析了设计电池组热管理系统过程中的关键技术,包括电池最优工作温度范围的确定、电池生热机理研究、热物性参数的获取、电池组热场计算、传热介质的选择、散热结构的设计等。     

Shape optimization of rubber isolators in automotive cooling modules for the maximization of vibration isolation and fatigue life

Rubber isolators are mounted between a cooling module and a carrier to isolate the car body from vibration due to the rotation of the cooling fan. The isolators should be durable against fatigue loads originating from fan rotation and road disturbance. Thus, the design of rubber isolators is required to maximize both vibration isolation and fatigue life. In this study, the shapes of the rubber isolators are optimally designed using a process integration and design optimization (PIDO) tool that integrates the various computer-aided engineering (CAE) tools necessary for vibration and fatigue analyses, automates the analysis procedure and optimizes the design solution. In this study, we use CAE models correlated to the experimental results. A regression-based sequential approximate optimizer incorporating Process Integration, Automation and Optimization (PIAnO), a commercial PIDO tool, is employed to handle numerically noisy responses with respect to the variation in design variables. Using the analysis and design procedure established in this study, we successfully obtained the optimal shapes of the rubber isolators in two different cooling modules; these shapes clearly have better vibration isolation capability and fatigue lives than those of the baseline designs used in industry.     

任意分布参数的拉杆可靠性优化设计

讨论了随机参数服从任意分布时拉杆的可靠性优化设计问题。在基本随机参数的前四阶矩已知的情况下，应用随机摄动法和Edgeworth级数方法对拉杆进行可靠性优化设计，通过计算机程序可以实现随机参数服从非正态分布的拉杆可靠性优化设计，迅速准确地得到了拉杆的可靠性优化设计信息。     

富春江通航隧道建筑限界及内轮廓设计研究

基于目前国内外对大断面通航隧道的设计和施工尚无可参照的标准规范,以富春江七里泷航道通航隧道工程项目为依托,分析满足隧道水下断面形状要求、水上部分建筑界限要求以及通航隧道安全保障的措施要求,并结合围岩及隧道结构的受力特点,应用最优化方法及相关分析计算,对隧道内轮廓进行优化设计,提出了满足Ⅳ级单线航道的大断面通航隧道断面,综合经济性及结构受力角度合理性考虑推荐采用曲墙式断面。     

车载动力电池液体冷却非线性优化方法研究

电动汽车动力电池散热需求会受到外部环境温度、风速和负载电流变化等因素的影响,如果不及时散热,动力电池的温度会迅速攀升,进而影响电动汽车的驾驶性和安全性。基于此提出一种锂离子电池非线性冷却优化方法。首先,通过对锂离子电池生热、散热机理分析,建立考虑传热系数随冷却液流速变化的锂离子电池集中热模型,通过电池特性测试试验确定电池内阻和熵热系数等热物性参数,并与AMESim模型对比,验证模型的有效性。然后,基于电池冷却系统非线性和易受负载电流变化影响的特征,提出一种考虑电池冷却系统的稳态特性以及参考变量前馈功能和闭环反馈消除静态误差机制的非线性冷却优化方法,并对其稳定性和鲁棒性进行研究。仿真结果表明:在NEDC-HWFET-US06组合工况下,非线性冷却优化方法调节下的电池温度与目标温度的最大偏差较PID方法减小了0.8 K,并且冷却过程的能耗降低了6.3%,具有更好的调节效果。