基于行人保护的SUV前保险杠防撞系统优化

为减小SUV车型在人车碰撞中对行人小腿的伤害,文章对SUV车型前保险杠造型进行了优化。分析了上支撑与下支撑布置和材料对小腿碰撞伤害值的影响,结果表明,当前保险杠上支撑安装位置处于小腿上部质心以下时,上支撑与小腿上部质心距离及上支撑材料对胫骨加速度值影响较大,上支撑与下支撑距离与下支撑材料对剪切位移影响较大。采用优化后的前保险杠防撞系统有效地控制了行人小腿伤害值,有利于该车型行人保护性能的提升,为以后SUV车型行人保护前保险杠防撞系统设计提供一些参考。     

Robust design optimization of frontal structures for minimizing injury risks of Flex Pedestrian Legform Impactor

The Flexible Pedestrian Legform Impactor (Flex-PLI) consisting of a flexible femur and tibia will be tested for pedestrian protection by Euro NCAP within the next couple of years as a potential replacement for the Transport Research Laboratory (TRL) legform impactor. The injury risks that are measured when using Flex-PLI are the elongation of the anterior/posterior cruciate ligament (A/PCL), elongation of the medial collateral ligament (MCL), and tibia bending moment (TBM). In this study, we used a correlated computer-aided engineering (CAE) model to conduct a contribution analysis of each injury with regard to the changes in the location of the frontal structures based on the results of a design of experiments (DOE) and analysis of variance (ANOVA). The frontal structures that were selected as control factors were the energy absorber (EA), lower bumper stiffener (LBS), and hood angle. A kriging interpolation model was developed using the DOE results, and its results were compared with those of the CAE model. Furthermore, for robust design optimization, the speed and height of Flex-PLI were used as the noise factors. Finally, a robust design optimization was carried out using the optimal combination of the discrete control factors for minimizing MCL elongation.     

Bumper optimum design using the dynamically equivalent beam under various impact conditions

Nowadays it is required for the bumper system to meet the various impact conditions simultaneously; barrier impact, IIHS (Insurance Institute for Highway Safety) bumper impact and pedestrian impact. Firstly, dynamically equivalent bumper beam models were developed for each impact condition and its accuracy was verified by nonlinear finite element analysis result. Dynamically equivalent pedestrian impact beam model was developed by using the equivalent forces of bumper beam and stiffeners. Pedestrian bending angle was obtained by using this equivalent pedestrian beam model. By combining these equivalent beam models, bumper optimum design program was developed. In this optimum design program, direct search method was used for the optimization algorithm. To verify the accuracy of this optimum design program, a nonlinear finite element result was used. By using this optimum design program, it can be secured the bumper impact performances in an early design stage and it will be also contributed to reduce the design time and test costs.     

考虑行人腿部保护和低速碰撞特性的保险杠系统概念设计

建立了分析保险杠系统行人腿部保护和低速冲击特性的概念模型,对模型进行了试验设计分析.基于方差分析方法,研究了保险杠系统的几何参数和刚度特性参数对其行人腿部保护和低速冲击特性的影响.综合考虑这两方面性能的要求,进行了保险杠系统的联合优化设计,给出了优化设计方案.     

Optimizing the shape of a bumper beam section considering pedestrian protection

This paper presents a design technique to optimize the shape of a vehicle bumper beam that satisfies both the safety requirements for a front rigid-wall impact and the regulations protecting pedestrians from lower leg injuries caused by bumper impacts. An intermediate response surface modeling (IRSM) technique was introduced to approximate the non-linear force-displacement curves obtained from the front impact analysis of a vehicle bumper. The accuracy of the IRSM model was tested by comparing its results with those of the non-linear finite element analysis. The maximum displacement error between the two models did not exceed 3%. Using pedestrian impact analyses based on the experimental arrangement of the Plackett-Burman design, the approximate functions describing the response values acting on the lower legs were calculated. The shape of the bumper beam was optimized by integrating the IRSM with the force-displacement model and the approximate functions on lower leg impact. The optimization results satisfied safety regulations on the maximum allowable displacement of the vehicle bumper, and also the regulations protecting pedestrians from lower leg injuries caused by bumper impacts.     

序列二次规划法在行人小腿保护的保险杠系统优化中的应用

建立汽车保险杠系统的多体模型,确定了影响行人腿部伤害的保险杠系统主要设计参数。建立相应的有限元模型,并采用LS-DYNA软件进行仿真分析。根据正交试验法得到的数据拟合出胫骨加速度、膝盖弯曲角度和剪切位移3个行人小腿伤害指标的目标函数,然后利用序列二次规划法依次对它们进行优化,最后得到了一组最优参数的保险杠系统设计,满足了法规要求,降低了行人腿部伤害值。     

国内乘用车对行人下腿碰撞保护现状

为研究我国国内乘用车对行人下腿型碰撞保护现状,文章以35款国内车型下腿型碰撞试验为基础,对试验结果数据进行了数据分段统计,并根据试验条件对结果数据进行了分析,从数据整体分布、车型特点及碰撞区域特征3个方面展开论述,提出了国内车型在改善行人下腿型碰撞保护性能方面亟需解决的问题和应当深入研究的方向。最后对行人下腿型碰撞保护试验的发展趋势进行了展望。     

行人保护下腿碰撞器模块分析

行人保护项目是世界范围内的一个安全课题,已越来越多地受到人们的关注。下腿碰撞是行人保护评价的重要内容之一,而下腿碰撞器模块直接影响评价结果。文章介绍了当前世界上的3种下腿碰撞器模块,分析了各自的结构特点和应用,总结了3种下腿碰撞器模块对车辆行人保护评价的差异性,对我国刚刚起步的车辆行人保护项目的研究和开展提供了一定的借鉴。     

基于EEVC要求的行人碰撞试验台的研制和评估

基于EEVC/WG17制定的行人碰撞保护试验标准,开展了行人模块碰撞试验台的研制工作。文中介绍了该试验台的工作原理和各个功能模块的设计,并利用该试验台进行了行人头部模块和下肢模块碰撞试验,从能量、控制精度和试验可重复性等方面对其试验能力进行了初步评估。试验结果表明,该试验台满足EEVC制定的相关试验要求,可用于行人碰撞保护的研究和设计开发。     

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.     

Assessment of the pedestrian friendliness of a vechicle using subsystem impact tests

Annually, thousands of unprotected pedestrians are killed or suffer serious injuries in accidents with moving vehicles. Numerous automobile organizations have performed research on pedestrian safety. The European Enhanced Vehicle- Safety Committee (EEVC), Working Group 17 (WG17) proposed three component subsystem tests to evaluate the friendliness of a vehicle to pedestrians: the legform to hood test, the upper legform to bonnet leading edge test and the headform to bonnet top test. In assessing the pedestrian friendliness of a vehicle, the present study adopted the WG17 regulations of the three component subsystem tests. We herein describe in detail a finite element subsystem model built to analyze the pedestrian friendliness of a vehicle using LS-DYNA. The first objective of this study was to simulate these three component subsystem impact tests and evaluate car front aggressiveness. The second objective was to analyze the frontal structures of a vehicle and, based on the simulation results, identify dangerous areas and provide suggestions for vehicle front design that may decrease pedestrian injuries. The analysis of these models and the results obtained may be used to help evaluate the pedestrian friendliness of a vehicle and guide the future development of pedestrian-friendly vehicle technologies.     

行人-汽车碰撞试验腿部模块的可变形膝关节参数设计

根据行人-汽车碰撞中对行人腿部碰撞保护相关技术法规的要求,针对行人下肢的损伤机理,分析了腿部可变形膝关节部件的设计方法。通过力学模型的建立和分析,提出了确定膝关节部件结构类型、尺寸和材料的力学计算方法以及部件标定试验验证方案。经算例和部件的标定试验验证,该设计方法满足EEVCWG10的弯曲部分技术要求,可变形膝关节设计原理和分析方法可以为其他行人腿部模块技术规范中的部件设计提供参考。     

泡沫应变率对行人小腿碰撞性能影响的研究

建立了车辆-行人小腿碰撞模型,在考虑和不考虑泡沫应变率效应的条件下进行了车辆保险杠与行人小腿的碰撞模拟分析,并与试验结果进行了对比.通过对小腿加速度、弯曲角、剪切位移3个性能参数的模拟分析结果表明,泡沫应变率对行人小腿碰撞性能影响较大,因此在实际分析中必须考虑泡沫材料的应变率效应.     

行人保护小腿冲击器有限元模型开发

针对TRL公司开发的行人保护小腿冲击器,建立了有限元模型.通过EEVC WG17规定的静态、动态标定试验及台架试验,进一步证实了该模型在高速碰撞下的精度,可用于行人保护的开发设计.     

某车型前横梁吸能板优化设计

随着汽车对行人的碰撞保护国家标准的出台,行人保护安全的研究与应用越来越受到汽车厂商的重视。文章以《欧盟行人保护法规》（Regulation（EC）No78/2009）为基础,运用CAE技术,考虑到行人保护小腿碰撞伤害值要求及制造工艺要求,对某乘用车的前横梁吸能板结构进行优化。试验结果表明,采用优化后的吸能板结构有效地降低了小腿伤害值,有利于该车型行人保护性能的提升,为以后类似设计提供参考。     

基于E—NCAP行人碰撞保护的发动机罩设计

行人头部碰撞保护一直是汽车行人安全设计的难点,随着E—NCAP对行人保护要求的不断提高,头部保护的得分比重对于获得高星级评价至关重要。文章基于某车型E—NCAPV6．2五星性能开发,采用虚拟仿真与试验测试有效结合的方法,对发动机罩进行了优化设计,提出了一种有利于行人头部碰撞保护的发动机罩。改进前后测试成绩的对比分析表明,该结构可极大优化行人头部碰撞保护效果,使发动机罩头部测试区域得分总分提升至24．43分,满足E—NCAPV6．2五星行人保护性能要求。可为后续设计提供参考,具有很高的推广价值。     

基于熵权TOPSIS法的CFRP防撞梁轻量化研究

碳纤维增强复合材料(CFRP)具有轻质高强的特点,本文中基于抗撞性要求将某乘用车保险杠原钢制防撞梁替换为CFRP,并进行铺层优化设计。首先对CFRP层合板进行力学性能试验以获得材料参数,并通过三点弯曲仿真试验验证其准确性,然后根据等刚度设计原理,确定CFRP防撞梁的厚度,并通过保险杠低速碰撞有限元仿真对比分析两种材料防撞梁的抗撞性能。在此基础上,以质量、比吸能、最大侵入量和碰撞力峰值为目标,采用熵权TOPSIS方法对CFRP防撞梁进行铺层优化,确定出最优铺层方案。结果表明,在保证抗撞性能要求的条件下,优化后的CFRP防撞梁比原钢制防撞梁减轻了76.82%。     

乘用车前悬长度总布置研究

阐述了上海通用(SGM)横置前驱乘用车前悬布置7大原则:布置与高速碰撞溃缩距离;吸能块和小腿装置与低速碰撞和行人保护;热敏感零件间隙与发动机舱热管理;转向机位置与底盘操控动态性能;动力总成位置与传动系统振动噪声;前悬长度与整车造型比例;前悬长度与整车轻量化。     

基于CFD的SUV空气动力学特性与仿真分析

为提高SUV的空气动力学性能,文章阐述了造型与空气动力学相结合的汽车造型开发流程,利用CFD方法对某SUV的空气动力争洼能进行模拟,模型模仿风洞试验,得出该车的风阻系数为0．343,根据该车压力分布、气流流动分布以及湍动能分布情况,对车身局部区域的造型提出优化建议,最终使车型空气动力学性能满足设计要求。     

某suv车型行驶跑偏问题的优化分析

行驶跑偏是指车辆在行驶过程中偏离了原来直线驾驶的状态,不仅会影响车辆的操纵稳定性和转向性能,更可能会危及乘客的人身安全。某SUV车型从设计到生产导入阶段,进行小批量投产时,出现大量车辆向左行驶跑偏现象,合格率约为60%。经过鱼骨图排查法的人、机、料、法、环等几个方面分析,列举出15种可能造成车辆行驶跑偏的因素。经过逐一排查,发现该SUV车型存在前副车架的控制臂安装支架尺寸超差,白车身的前、后副车架安装点尺寸控制不合理,前后悬模块装配一致性差及测试道路不规范等主要问题,以上四种问题造成的偏差趋势与实际该SUV车辆向左行驶跑偏现象相符,因此需要对以上问题进行优化及改进。文章是在这个背景下,针对该SUV车型的向左行驶跑偏现象,通过对问题零部件进行交叉试验,三坐标尺寸测量以及生产线生产过程一致性的逐一排查,逐一分析了四种问题发生的根本原因,并由此提出了优化改进方案,通过对比方案实施前后的实测数据,验证优化改进方案是否可行。优化后实测行驶跑偏量,符合企业行驶跑偏判定标准,行驶跑偏现象消失并保证了该SUV车型的正式量产时间。