基于虚拟样机的轿车天窗运动执行机构的设计与研究
|
摘要
轿车天窗运动执行机构的设计是整个轿车天窗产品设计中的关键技术,也是困扰国内轿车天窗自主开发的难点。本文研究工作的目的在于与企业合作共同开发具有自主知识产权的新型轿车天窗的全塑化运动执行机构。通过采用虚拟样机技术和ADAMS机械设计软件,依次完成了轿车天窗的整体三维建模和虚拟装配、运动仿真之后,重点对采用塑料制件组成的并简化结构的新型运动执行机构进行了设计研究和参数优化设计。经过仿真分析、设计研究与优化设计后的新型运动执行机构,不但保证了轿车天窗的使用功能,而且照此制作的物理样机达到了所要求的技术指标并达到性能测试所要求的行业标准。
本文的研究成果,对指导轻量化新型轿车天窗的投产具有一定的指导意义,同时还可收到缩短研发周期30%,减少产品开发费用20%以上的经济效益。
With the development of automotive industry and improving people’s living standard, the automotive manufacturers and drivers pursue to improve the driving environment inner the car and driving safety. The air quality inner car has a great effect on the driving comfort and safety. The air condition can adjust the temperature and humidity inner car to some extent. But the ventilation effect is not good, because it is a close space in the car. And it can also result in asymmetric distribution of the air and humidity. With the side windows the ventilation can also been done, but it will result in great wind noise and air eddy, which will increase the driving resistance and the fuel consumption. The sunroof has the advantage of gut lighting, improved air quality in inner car, more energy saving and it can also make the car looking more luxurious. Therefore, now the sunroof becomes more and more popular.
In the past five years, the Chinese automotive industry developed very fast. The turnout of passenger car has broken through 2.5 million per year. In order to meet the requirement of customer, the turnout of passenger car with sunroof increased rapidly. At present 80 percent share of china sunroof market is monopolized by Webasto Company. Although there are more than ten local corporations in Guangdong and Zhejiang Province etc., who are producing sunroof for passenger car with a small batch, all of them have no independent product development capacity and their competitive ability is very bad. They are still in the phase of copy or imitation. In order to break the technology quarantine and market monopolization, enhance the local sunroof corporations’competition ability; it is necessary to build a sunroof independent development platform with modern design technique.
According to the Project of sunroof independence development platform for passenger car with modern design technique, the research object in this paper is the sunroof drive mechanism. We used the modern design technique to solve the key technical problems for sunroof development, researched the new development process for car sunroof development with modern design method. And we also built the parameter simulation model of sunroof motion mechanism for the optimization, which can supply technical support for variation sunroof development. The following is the main content:
1. The reverse engineering method was used to get the geometrical parameters of the typical structure parts of the sunroof, such as glass assemble, deflector and drain system which are very difficult to be modeled with the forward design. After the measure we achieved the cloud datum. After the analysis, processing and surface restructure with software CATIA we achieved the 3D digital model from the cloud datum. All of the other parts were built with the forward method. Finally, all of the parts were assembled in CATIA with assembly design module and then we received the whole 3D digital model.
2. The dynamical simulation model based on ADAMS software for the Sunroof motion mechanism is built up with the 3D Data. And the research and analysis about the model are carried out. The simulation results show the motion mechanism of this sunroof has good consistent movement discipline during the opening and the closing process, which ensure that the window glass and the car roof still match with each other perfectly. Meanwhile we found that the velocity of driving soft shaft does not affect the driving force significantly. From the result we can get the die displacement of driving soft shaft assembly and the max. driving force etc. during the sunroof opening or closing case. These data can be used for choosing the Motor, driving soft shaft and so on.
3. The simplified parameter simulation model for Sunroof motion mechanism is built up. And the model is validated by comparing the simulation data with the physical experimental data. Applied with the function Design Study of ADAMS the sensitivity of design variables to the sunroof rising height are carried out. Then the design variables with higher sensitivity to the sunroof rising height are divided into two groups and studied with the function DOE of ADAMS. Finally, an optimization calculation with the target function max of sunroof rising height and constraint driving force on driving soft shaft less than 25N were executed with the design variables obtain from the last step.
In a word, in this paper a deep and systematic study of the sunroof motion mechanism has been carried out. And we have obtained some innovational achievements for the sunroof motion mechanism design theory and applying the modern design technique in Productions development. The study of design theory provides the theoretical foundation for sunroof motion mechanism design and improvement. And the theory has solved the key technical problem in sunroof motion mechanism design. The applied modern design techniques can shorten the development period, reduce the development cost, and enhance the independent development capacity of the sunroof enterprise. These design theory and method have already accepted and applied in the new sunroof product design by Shenghuabo Group Ltd. Co. The trial produce has already finished and they have signed a contract with a certain automotive manufacturer for a small batch of production. The Study in this paper can also be an example for the development of others automotive parts with high technology.
本文的研究成果,对指导轻量化新型轿车天窗的投产具有一定的指导意义,同时还可收到缩短研发周期30%,减少产品开发费用20%以上的经济效益。
With the development of automotive industry and improving people’s living standard, the automotive manufacturers and drivers pursue to improve the driving environment inner the car and driving safety. The air quality inner car has a great effect on the driving comfort and safety. The air condition can adjust the temperature and humidity inner car to some extent. But the ventilation effect is not good, because it is a close space in the car. And it can also result in asymmetric distribution of the air and humidity. With the side windows the ventilation can also been done, but it will result in great wind noise and air eddy, which will increase the driving resistance and the fuel consumption. The sunroof has the advantage of gut lighting, improved air quality in inner car, more energy saving and it can also make the car looking more luxurious. Therefore, now the sunroof becomes more and more popular.
In the past five years, the Chinese automotive industry developed very fast. The turnout of passenger car has broken through 2.5 million per year. In order to meet the requirement of customer, the turnout of passenger car with sunroof increased rapidly. At present 80 percent share of china sunroof market is monopolized by Webasto Company. Although there are more than ten local corporations in Guangdong and Zhejiang Province etc., who are producing sunroof for passenger car with a small batch, all of them have no independent product development capacity and their competitive ability is very bad. They are still in the phase of copy or imitation. In order to break the technology quarantine and market monopolization, enhance the local sunroof corporations’competition ability; it is necessary to build a sunroof independent development platform with modern design technique.
According to the Project of sunroof independence development platform for passenger car with modern design technique, the research object in this paper is the sunroof drive mechanism. We used the modern design technique to solve the key technical problems for sunroof development, researched the new development process for car sunroof development with modern design method. And we also built the parameter simulation model of sunroof motion mechanism for the optimization, which can supply technical support for variation sunroof development. The following is the main content:
1. The reverse engineering method was used to get the geometrical parameters of the typical structure parts of the sunroof, such as glass assemble, deflector and drain system which are very difficult to be modeled with the forward design. After the measure we achieved the cloud datum. After the analysis, processing and surface restructure with software CATIA we achieved the 3D digital model from the cloud datum. All of the other parts were built with the forward method. Finally, all of the parts were assembled in CATIA with assembly design module and then we received the whole 3D digital model.
2. The dynamical simulation model based on ADAMS software for the Sunroof motion mechanism is built up with the 3D Data. And the research and analysis about the model are carried out. The simulation results show the motion mechanism of this sunroof has good consistent movement discipline during the opening and the closing process, which ensure that the window glass and the car roof still match with each other perfectly. Meanwhile we found that the velocity of driving soft shaft does not affect the driving force significantly. From the result we can get the die displacement of driving soft shaft assembly and the max. driving force etc. during the sunroof opening or closing case. These data can be used for choosing the Motor, driving soft shaft and so on.
3. The simplified parameter simulation model for Sunroof motion mechanism is built up. And the model is validated by comparing the simulation data with the physical experimental data. Applied with the function Design Study of ADAMS the sensitivity of design variables to the sunroof rising height are carried out. Then the design variables with higher sensitivity to the sunroof rising height are divided into two groups and studied with the function DOE of ADAMS. Finally, an optimization calculation with the target function max of sunroof rising height and constraint driving force on driving soft shaft less than 25N were executed with the design variables obtain from the last step.
In a word, in this paper a deep and systematic study of the sunroof motion mechanism has been carried out. And we have obtained some innovational achievements for the sunroof motion mechanism design theory and applying the modern design technique in Productions development. The study of design theory provides the theoretical foundation for sunroof motion mechanism design and improvement. And the theory has solved the key technical problem in sunroof motion mechanism design. The applied modern design techniques can shorten the development period, reduce the development cost, and enhance the independent development capacity of the sunroof enterprise. These design theory and method have already accepted and applied in the new sunroof product design by Shenghuabo Group Ltd. Co. The trial produce has already finished and they have signed a contract with a certain automotive manufacturer for a small batch of production. The Study in this paper can also be an example for the development of others automotive parts with high technology.
引文
[1]郑建荣. ADAMS—虚拟样机技术入门与提高[M].北京:机械工业出版社,2007.8
[2]李增刚. ADAMS入门详解与实例[M].北京:国防工业出版社,2007.1
[3]M.Durali. A Neural Network Approximation of Nonlinear Car Model Using Adams Simulation Results. SAE Paper No.2001-01-3324
[4]张越今.汽车多体动力学及计算机仿真[M].吉林:吉林科学技术出版社,1998
[5]陈乐生,王以伦.多刚体动力学基础[M].哈尔滨:哈尔滨工程大学出版社,1995
[6][美] C.H. Suh,C.W. Radcliffe.运动学及机构设计[M].上海交通大学机械原理及零件教研室译,北京:机械工业出版社,1983
[7]黄锡凯,郑文纬.机械原理[M].北京:高等教育出版社,1989
[8]楼鸿棣,邹慧君.高等机械原理[M].北京:高等教育出版社,1990
[9]郭卫东.虚拟样机技术与ADAMS应用实例教程[M].北京:北京航空航天大学出版社,2007
[10]谷正气.轿车车身[M].北京:人民交通出版社,2002
[11]冯国胜,杨绍普.车辆现代设计方法[M].北京:科学出版社,2005
[12]赵国强,孙海涛.现代轿车天窗应用及匹配优化[J].上海汽车,2004.5
[13]时美.伟巴斯特天窗及其使用[J].汽车与配件,1999.4
[14]林鹰.时尚轿车电动天窗[J].交通与运输,2003
[15]方斌.轿车天窗的功能、结构及性能要求[J].设计与计算,2005.5
[16]范进桢,秦贵林.轿车电动天窗的结构、控制原理及维修[J].使用与维修,2005.8
[17]Markus G.Kliffken. Obstacle Detection for Power-Operated Window-lift and Sunroof Actuation Systems. SAE paper No.2001-01-0466
[18]J.P.Chiou. Sunroofs and the Cooling Loads of Automobile Air Conditioners. SAE paper No.870031
[19]洪鹏.关于汽车天窗[J].汽车实用技术,2003 No.10
[20]韩英淳.汽车制造工艺学[M].北京:人民交通出版社,2009.3
[21]Kenji Maeta. Development of Resin-Made,Belt-Type Sunroof With Light Weight. SAE paper No. 2003-01-1177
[22]Ping Fu. Reverse Engineering. SAE Paper No. 2-24-8-37
[23]张萌. CATIA机械结构设计[M].北京:机械工业出版社,2006
[24]兰凤崇,陈吉清,魏文,等.汽车外表面模型测量数据处理及曲面建模[J].航空制造技术,2006.4
[25]盛选禹. CATIA三维模型入门与提高[M].北京:机械工业出版社,2003
[26]祖英利.液压挖掘装载机WZ30-25反铲装置仿真优化[D].硕士学位论文,2005
[27]谷鸣宇.六自由度机械手运动学、动力学分析及计算机仿真[D].硕士学位论文,2005
[28]Jesper Slattengren. Utilization of Adams to Predict Tracked Vehicle Performance. SAE paper No.2000-01-0303
[29]田锋. CAE与相关技术的接口[J].计算机辅助设计与制造,2000.6
[30]张应龙.一种三自由度并联机器人的运动学分析[J].机械传动,2006.3
[31]崔向群,孙晓娜.基于ADAMS的气动压管机工作机构虚拟样机设计与动态仿真[J].信技术新工艺,2006.5
[32]边宇虹.分析力学与多刚体动力学基础[M].北京:机械工业出版社,1998
[33]彼得.艾伯哈特.现代接触动力学[M].南京:东南大学出版社,2003
[34]文传源,杨新.飞机六自由度模型及仿真研究[J].系统仿真学报,2000.12
[35]赵世宜,刘子建,王辉.虚拟样机技术在汽车变速箱设计中的应用[J].计算机仿真,2006.3
[36]邱显焱,孙晓.基于ADAMS的包装机械设计研究[J].轻工机械,2005.2
[37]Chang-Fa An. Optimization Study for Sunroof Buffeting Reduction. SAE paper No.2006-01-0138
[38]Divesh Mittal. Characterization of the key Vehicle Parameters Affecting Dynamic Vehicle Rollover Propensity using Adams Simulation and 1/10th Scale Model Testing. SAE paper No.2006-01-1951
[39]Arun Kumar Chandrasekaran. Design Optimization of Heavy Vehicles By Dynamic Simulations. SAE paper No.2002-01-3061
[40]赵文英,王玉刚.集中连杆操纵机构的参数化建模及优化设计[J].火控雷达技术,2005.4
[41]Pham,Huy Hoang. Kinematics workspace and static analysis of 2-DOF flexure parallel mechanism[J]. ICARCV2002
[42]Teodorescu,M.,Rahneijat,H.,Rothberg,S.J.. Multi-body analysis and measurement of valve train motions[J]. Multi Body Dyn. Monit. Simul. Tech.,2004
[43]Peter Adamczyk. Lightweight Robotic Mobility by Template-Based Modeling for Dynamics and Controls Using Adams and Matlab. SAE paper No.2003-01-0269
[44]申文清,王金刚.基于Adams的装载机工作装置优化设计[J].建筑机械(上半月),2006.5
[45]Zenon Mroz. Variational Approach to Shape Sensitivity Analysis of Structural Systems[C]. Academic Press,1986
[46]R L福克斯.工程设计的优化方法[M].北京:科学出版社,1981
[47]孙靖民.机械结构优化设计[M].哈尔滨:哈尔滨工业大学出版社,2004
[48]P E Gill W Murray,M H Wright. Practical Optimization. Academic Press Inc LTD,1981
[49]D G鲁恩伯杰.线性与非线性规划引论[M].北京:科学出版社,1980
[50]程极泰.最优设计的数学方法[M].北京:国防工业出版社,1981
[51]黄天泽,黄金陵.汽车车身结构与设计[M].北京:机械工业出版社,1997
[2]李增刚. ADAMS入门详解与实例[M].北京:国防工业出版社,2007.1
[3]M.Durali. A Neural Network Approximation of Nonlinear Car Model Using Adams Simulation Results. SAE Paper No.2001-01-3324
[4]张越今.汽车多体动力学及计算机仿真[M].吉林:吉林科学技术出版社,1998
[5]陈乐生,王以伦.多刚体动力学基础[M].哈尔滨:哈尔滨工程大学出版社,1995
[6][美] C.H. Suh,C.W. Radcliffe.运动学及机构设计[M].上海交通大学机械原理及零件教研室译,北京:机械工业出版社,1983
[7]黄锡凯,郑文纬.机械原理[M].北京:高等教育出版社,1989
[8]楼鸿棣,邹慧君.高等机械原理[M].北京:高等教育出版社,1990
[9]郭卫东.虚拟样机技术与ADAMS应用实例教程[M].北京:北京航空航天大学出版社,2007
[10]谷正气.轿车车身[M].北京:人民交通出版社,2002
[11]冯国胜,杨绍普.车辆现代设计方法[M].北京:科学出版社,2005
[12]赵国强,孙海涛.现代轿车天窗应用及匹配优化[J].上海汽车,2004.5
[13]时美.伟巴斯特天窗及其使用[J].汽车与配件,1999.4
[14]林鹰.时尚轿车电动天窗[J].交通与运输,2003
[15]方斌.轿车天窗的功能、结构及性能要求[J].设计与计算,2005.5
[16]范进桢,秦贵林.轿车电动天窗的结构、控制原理及维修[J].使用与维修,2005.8
[17]Markus G.Kliffken. Obstacle Detection for Power-Operated Window-lift and Sunroof Actuation Systems. SAE paper No.2001-01-0466
[18]J.P.Chiou. Sunroofs and the Cooling Loads of Automobile Air Conditioners. SAE paper No.870031
[19]洪鹏.关于汽车天窗[J].汽车实用技术,2003 No.10
[20]韩英淳.汽车制造工艺学[M].北京:人民交通出版社,2009.3
[21]Kenji Maeta. Development of Resin-Made,Belt-Type Sunroof With Light Weight. SAE paper No. 2003-01-1177
[22]Ping Fu. Reverse Engineering. SAE Paper No. 2-24-8-37
[23]张萌. CATIA机械结构设计[M].北京:机械工业出版社,2006
[24]兰凤崇,陈吉清,魏文,等.汽车外表面模型测量数据处理及曲面建模[J].航空制造技术,2006.4
[25]盛选禹. CATIA三维模型入门与提高[M].北京:机械工业出版社,2003
[26]祖英利.液压挖掘装载机WZ30-25反铲装置仿真优化[D].硕士学位论文,2005
[27]谷鸣宇.六自由度机械手运动学、动力学分析及计算机仿真[D].硕士学位论文,2005
[28]Jesper Slattengren. Utilization of Adams to Predict Tracked Vehicle Performance. SAE paper No.2000-01-0303
[29]田锋. CAE与相关技术的接口[J].计算机辅助设计与制造,2000.6
[30]张应龙.一种三自由度并联机器人的运动学分析[J].机械传动,2006.3
[31]崔向群,孙晓娜.基于ADAMS的气动压管机工作机构虚拟样机设计与动态仿真[J].信技术新工艺,2006.5
[32]边宇虹.分析力学与多刚体动力学基础[M].北京:机械工业出版社,1998
[33]彼得.艾伯哈特.现代接触动力学[M].南京:东南大学出版社,2003
[34]文传源,杨新.飞机六自由度模型及仿真研究[J].系统仿真学报,2000.12
[35]赵世宜,刘子建,王辉.虚拟样机技术在汽车变速箱设计中的应用[J].计算机仿真,2006.3
[36]邱显焱,孙晓.基于ADAMS的包装机械设计研究[J].轻工机械,2005.2
[37]Chang-Fa An. Optimization Study for Sunroof Buffeting Reduction. SAE paper No.2006-01-0138
[38]Divesh Mittal. Characterization of the key Vehicle Parameters Affecting Dynamic Vehicle Rollover Propensity using Adams Simulation and 1/10th Scale Model Testing. SAE paper No.2006-01-1951
[39]Arun Kumar Chandrasekaran. Design Optimization of Heavy Vehicles By Dynamic Simulations. SAE paper No.2002-01-3061
[40]赵文英,王玉刚.集中连杆操纵机构的参数化建模及优化设计[J].火控雷达技术,2005.4
[41]Pham,Huy Hoang. Kinematics workspace and static analysis of 2-DOF flexure parallel mechanism[J]. ICARCV2002
[42]Teodorescu,M.,Rahneijat,H.,Rothberg,S.J.. Multi-body analysis and measurement of valve train motions[J]. Multi Body Dyn. Monit. Simul. Tech.,2004
[43]Peter Adamczyk. Lightweight Robotic Mobility by Template-Based Modeling for Dynamics and Controls Using Adams and Matlab. SAE paper No.2003-01-0269
[44]申文清,王金刚.基于Adams的装载机工作装置优化设计[J].建筑机械(上半月),2006.5
[45]Zenon Mroz. Variational Approach to Shape Sensitivity Analysis of Structural Systems[C]. Academic Press,1986
[46]R L福克斯.工程设计的优化方法[M].北京:科学出版社,1981
[47]孙靖民.机械结构优化设计[M].哈尔滨:哈尔滨工业大学出版社,2004
[48]P E Gill W Murray,M H Wright. Practical Optimization. Academic Press Inc LTD,1981
[49]D G鲁恩伯杰.线性与非线性规划引论[M].北京:科学出版社,1980
[50]程极泰.最优设计的数学方法[M].北京:国防工业出版社,1981
[51]黄天泽,黄金陵.汽车车身结构与设计[M].北京:机械工业出版社,1997