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.     

Analysis of a large injection-molded body using knowledge-based flow process technology

A knowledge-based flow process is presented for large injection-molded body technology (LIMBT). Injection molding of a large body is a difficult technique because of the many factors and their interactions during the molding process. The proposed flow process can support LIMBT through integration of CAE(Computer-Aided Engineering), CAI (Computer-Aided Inspection), and monitoring systems. CAE and DOE (Design of Experiment) are used to construct an optimal mold design in terms of gates and runners and to identify working conditions for the molding process. CAI and monitoring systems with temperature sensors and pressure sensors can be used to inspect the physical molding process and the molded parts. The flow process of a large body is systematically planned and constructed using a knowledge-based flow process with DOE and computer-aided technologies. The proposed flow process is implemented for the molding process of an automobile front bumper fascia.     

跨组别前向式儿童约束系统动态性能仿真研究

目前保护儿童乘员的主要方法就是推行儿童约束系统的使用。当前市场上的儿童约束系统多为跨组别的,这类产品在经济性和使用便利性方面有较大优势,但在动态性能方面却没有单一组别产品理想。结合某款跨组别前向式儿童约束系统的正面碰撞台车试验来验证利用MADYMO软件为其建立的仿真模型。以此为基础,对儿童约束系统在不同组别模式下正面碰撞的动态性能进行分析,找出其中的关键因素,再通过参数优化使其性能达到较为理想的效果,为儿童约束系统的优化设计提供一定的依据。     

儿童约束系统动态仿真研究及初步参数分析

本文利用MADYMO软件建立包含P系列儿童假人、一款国产汽车用儿童座椅和试验台车的儿童乘员约束系统的计算机仿真模型,并模拟了ECE-R44法规规定的正面碰撞台车试验环境。通过与对应产品的台车碰撞试验结果对比,对该模型有效性进行了验证。同时,在已验证模型的基础上,对儿童座椅及台车试验系统设计参数对儿童乘员响应的影响进行了分析,结果表明儿童座椅的摩擦系数、成人安全带刚度、儿童座椅安全带定位孔孔位置对儿童乘员在正面碰撞中的响应影响较大,通过适当的儿童约束系统设计可以降低儿童乘员在碰撞事故中的受伤几率。     

S形梁碰撞多参数优化设计

提出了一种新的碰撞优化方法,即将试验设计(DOE)、有限元分析(FEA)、响应面法(RSM)和遗传算法(GA)结合起来,对S形薄壁梁多结构参数进行抗撞性优化设计.通过提取实际车架上使用的S梁特征参数,建立了S梁的碰撞模型.运用方差分析(ANOVA),选取那些对S梁吸能特性影响显著的因素作为主要设计变量,采用显式非线性有限元软件PAM-CRASH进行碰撞模拟.根据有限元分析结果并结合响应面理论,建立了S梁的总吸能和最大冲击载荷的响应面模型.采用遗传算法进行优化求解,得到了S梁的最优设计参数.优化后的S梁在碰撞中的总吸能能力大大提高.     

基于数值生物力学模型的汽车正面碰撞中肥胖驾驶员头颈部损伤研究

以THUMS男性50百分位有限元模型为研究对象,使用Hypermesh软件中的Hypermorph功能对THUMS男性50百分位有限元模型进行网格变形,得到一系列不同BMI的肥胖有限元模型.建立了汽车正面100％重叠率碰撞仿真模型,对比了肥胖乘员与非肥胖乘员头、颈部的损伤差异.研究表明,头部损伤部分,BMI并未对HIC...     

防挥鞭伤安全座椅的初步研究

以Euro NCAP挥鞭伤动态评估为基础,采用DOE分析手段,得到座椅部分设计参数对挥鞭伤的影响规律.结果表明,随着座椅设计参数的变化,几个损伤评价指标呈非线性变化,而且是互相影响此消彼长.因此,防挥鞭伤安全座椅设计应是一种多目标综合优化设计.     

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。     

汽车正面碰撞后排小体位假人伤害研究及优化

提出了一种相应的伤害优化方案,基于 C-NACP正面碰撞工况搭建碰撞分析模型,同时通过与正面 100% 重叠刚性壁障碰撞试验的 Hybrid Ⅱ 5th女性假人试验数据进行对比来验证模型的可靠性。基于对标结果进行优化设计,对比分析不同优化方案对乘员安全性的影响趋势。确定优化方案,即增加碰撞锁止锁舌、线性预紧器配置,增加座椅刚度,调整安全带限力值。与原始方案相比,在碰撞过程中后排女性假人总体得分提升84%。根据C-NCAP星级评定规程,此后排女性假人得分高于94%,成绩优秀,验证了方案的有效性,可为后排小体位假人伤害的优化研究提供参考。     

稳健设计方法用于车门系统设计

将Taguch i稳健设计方法应用于车门系统设计。通过将试验设计与计算分析结合获取产品设计质量特性信息;通过实例说明将结构参数优化组合,提高车门铰接系统稳健性的方法。此方法的优点是可以从许多试验条件中选择出最有代表性的少数几项试验,获得可靠的试验结果,且分析计算简单,适用于多参数的产品优化设计。     

基于单线激光雷达的SLAM系统功能优化设计

地图与导航是无人驾驶与机器人领域的关键点,针对单线激光SLAM(同步定位与地图构建)系统功能优化问题,利用DOE(实验设计),提出了基于单线激光雷达的SLAM系统功能优化方法。首先,基于SLAM小车平台,利用Gmapping、Hector、Karto、Cartographer四种算法对室内环境进行建图,分析建图结果,提出最优建图方法。其次,依据AMCL定位算法,分别利用A*和Dijkstra两种路径规划方法,通过对比定位导航效果,提出基于参数匹配的定位导航功能优化方法。在此基础上,提出系统功能匹配优化方法,完成SLAM系统功能优化设计。     

基于C-NCAP五星碰撞的主体铝制纯电动车正碰车身框架结构设计

论文针对纯电动车与传统燃油车在造型和布置上的差异化特点带来的车身正碰框架中的设计难点和痛点,提出了一套完整、可行且有效的主体铝制量产正碰车身框架结构设计方法,此方法专门针对纯电动布置进行实体建模和正碰工况下的拓补优化设计,制定正碰主体铝材料结构设计方案,以实现吸能效率的提升,保障乘员舱的安全可靠性,同时兼顾轻量化和共线约束。基于CAE和试验验证结果,此设计车身各正碰指标均满足C-NCAP五星碰撞结构要求,比对ODB下的整车乘员伤害得分也满足相关要求,说明其可行有效性,为同类型车型的开发提供参考和指导。     

考虑气动阻力和横风稳定的汽车车身多目标优化设计

综合考虑了气动阻力特性和横风稳定性,对车身外形参数进行了多目标自动优化设计。综合利用参数化建模技术、计算流体力学(CFD)仿真、试验设计方法、响应面模型和智能优化算法,集成Pro/Engineer参数化建模和ICEM网格划分工具以及Fluent仿真软件,在多学科优化平台modeFRONTIER上,搭建了一种自动优化设计流程。利用该流程,基于遗传算法(GA)对MIRA快背式模型车身几何外形进行了改型设计,得到了考虑车身气动阻力特性和横风稳定性的最优权衡设计解集。该结果使得气动阻力因数降低了5.2%,侧向力因数降低了5.8%。因而,实现了车身气动阻力和横风稳定性的多目标优化。     

基于正交实验法的车身侧面碰撞性能优化

建立车身有限元模型进行仿真分析.输出B柱加速度曲线并与实车侧面碰撞结果对标,使有限元模型能够表征物理样车,仿真结果具有可信性及预测性.进行CAE侧面碰撞仿真,采用正交试验法分析车身侧面结构中的7个零件,考核各零件对车身侧面碰撞性能指标的影响,寻找出对车身侧面碰撞性能影响较大的零件及区域.进行优化设计,利用CAE仿真手段来验证优化方案.通过该方法,能够判断对车身侧面碰撞性能影响较大的零件和区域,以及影响因子.能够快速、合理、有针对性地进行车身结构优化,达到优化目标.     

基于踩踏刚度的踏步板结构优化

针对某车型踏步板踩踏形变过大的问题,采用CAE手段分析了踏步板的踩踏刚度,然后根据踏步板的各个支架的受力形式分别优化其结构,最后对它们的板厚进行详细的尺寸优化。改进后的踏步板支架的重量略有增加(约0.42 kg),但踩踏刚度明显提升,达到初始踩踏刚度的2.5倍。此项研究为相关车型的开发提供了重要的理论参考和技术支撑。     

Occupant injury risk analysis at NASS/CDS database

Injury information for vehicle occupants from the body regions of the head, thorax, abdomen, and upper and lower extremities, due to the restraints and interior parts of the vehicle, were extracted from the 2009 ~ 2012 NASS/CDS database. For those cases with high occurrence frequency, a detailed and comprehensive data analysis was performed to find the relationship between the accident, occupant, vehicle, and injury data. A numerical frontal impact sled model with the Hybrid III dummy and the GHBMC human body model was constructed to simulate and identify those injury risks according to NASS/CDS. Among the 5,734 injuries to the aforementioned body regions from frontal crashes are, listed by frequency of occurrence, the lower extremity (27.8 %), upper extremity (21.3 %), thorax (15.1 %), face (10.9 %), spine (8.7 %), head (7.3 %), and abdomen (6.9 %). The main injury sources to the head were the windshield, side structure, and steering wheel. For the thorax and abdomen they were the seat belt and steering wheel. For the lower extremity it was the instrument panel. The main injury patterns for the head were the concussion and the contusion. For the thorax they were vessel laceration and lung contusion. For the abdomen they were laceration and contusion of the organs. For the lower extremity they were bone fracture and ligament rupture. The steering wheel and seat positions were main factors affecting head and thorax injury risks. From the sled impact simulation, high injury risks of the head and thorax were assessed respectively at conditions of steering column tilt down and rear most seat position, which correlated well with the findings from the NASS/CDS data analysis.     

Optimum SUV bumper system design considering pedestrian performance

Until recently, passenger cars have primarily interested in pedestrian protection performance. Nowadays, however, it is important for a sport-utility vehicle (SUV) to meet the bumper system standards for pedestrian safety. For a SUV bumper system, there are some difficulties in attaining a high level of pedestrian performance for the lower legform. An SUV has a high bumper position from the ground level, and the bumper approach angle must also be secured, which has an effect on car insurance fees. Due to these reasons, it is difficult to meet the pedestrian performance of the lower legform for an SUV. In this paper, a comparative study was performed on various SUV bumper systems, and a concept model for a SUV bumper system was developed, which is expected to meet the pedestrian performance by using the Pugh method. The design control factors were defined to affect the bumper pedestrian performance through the experiences of tests and analyses. For the noise factor to affect the pedestrian performance, the deviation of the impactor position was selected at the moment of impact. The design control factors were optimized by using the Taguchi optimization technique. For the Taguchi method, an L18 orthogonal array table of design control factors was used in the optimization process. Particularly, for the optimization of the bumper corner region, an optimization analysis was performed three times to meet pedestrian performance. Based on the results of the Taguchi optimization method, the sensitivity of the bumper design parameters was studied, and a new SUV bumper system is proposed that satisfies the pedestrian performance of the lower legform. The optimized bumper system should obtain a full Euro-NCAP score of 6 points for the bumper test. The pedestrian performance of the optimized bumper system is validated by using a CAE (Computer Aided Engineering) analysis, which has been proven to be in accurate. A comparison between the test and analysis results is shown for the validation of accuracy. By using the optimized bumper system, the tests and development costs of a bumper can be reduced.     

车身结构耐撞性的概念设计仿真

车身结构耐撞性的概念设计是由车辆乘员伤害指标确定出整车碰撞波形（正面碰撞），根据波形将车身结构性能分解参数化设计，文章从CAE建模角度。探讨比较了建立车身概念设计模型的各种主要方法工具，包括LMS模型、有限元Beam—element模型和多体MadymoFrame模型。表明各模型的建模特点和基本方法主要取决于结构刚度特性和惯性特性的提取与参数化。指出三维模型在概念设计阶段具有适用性和局限性。     

汽车正面碰撞中驾驶员侧约束系统的可靠性优化

采用MADYMO仿真分析软件建立了某车型正面碰撞的驾驶员侧约束系统仿真模型;针对原始模型因假人碰撞转向盘造成的计算结果的不连续性,通过修正模型提高了乘员损伤值响应面的精度;考虑了系统中存在的随机性,对安全气囊和安全带的主要参数进行了可靠性优化,有效减小了正面刚性墙碰撞中假人的损伤值,并使乘员约束系统满足可靠性的设计要求...     

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.