面向行人下肢碰撞保护的汽车前端结构快速优化设计研究
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摘要
行人与车碰撞保护设计具有相当的技术挑战，在汽车工业界的车型设计开发实践中，面向下肢模块碰撞保护的车前端结构设计主要依赖于基于工程经验的试验和计算仿真。本论文深入分析了车前端结构设计参数对下肢模块损伤指标的影响机理，建立了一个参数化分析模型，为车型前期设计中协调车前端结构的造型、部件布置以及预留碰撞吸能空间的矛盾关系提供依据；通过引入并改进空间映射算法，为车型开发后期设计改进提供了高效的优化工具。
论文首先分析了车前端结构参数对下肢模块损伤指标的影响机理，对车前端结构的前期设计提供了指导。通过建立并简化行人下肢模块刚体动力学模型，得到了下肢模块损伤指标的近似解析解，并借助有限元模拟验证了该近似解析解与下肢模块损伤指标的相关性。基于动力学方程的近似解析解，论文分析了下肢模块胫骨加速度峰值、膝关节弯曲角度和剪切位移峰值的控制策略。
论文基于下肢模块与车前端结构碰撞的有限元模型，对车前端的吸能空间进行了更准确的估计，为车型前期设计中确定针对下肢碰撞保护所需的吸能空间提供了理论支持。能量分析的结果表明，下肢模块初始动能仅有约三分之一被车前端结构吸收。本论文通过引入了能量转化率，吸能效率和有效质量系数等三个参数，改进了现有吸能空间估计方法。通过试验设计统计了以上三个参数的取值，计算得到了更合理的吸能空间估计值。
车前端结构的参数化模型被广泛用于行人下肢模块碰撞保护的参数分析研究中，然而传统的将车前端结构分为三个区域的参数化模型不能准确反映下肢模块与实车结构碰撞的响应。论文提出了四区域模型，将保险杠区域的吸能结构分为两部分，准确反映了实车对下肢模块膝关节区域碰撞力的作用点。
为了提高优化设计效率，论文将空间映射算法引入到车前端结构参数优化设计中。精度较高的实车前端有限元模型往往计算效率较低。空间映射优化算法允许设计者通过精度较低、计算效率高的粗糙模型作为辅助设计工具，对精细模型进行优化设计。与传统的响应面优化方法相比，空间映射优化算法对精细模型的计算次数显著减少，优化效率高于基于响应面的直接优化方法。作为一个应用性算例，论文最后建立了以梯形薄壁管为吸能结构的车前端参数化模型，应用空间映射优化算法对薄壁吸能结构的截面形状进行了优化设计，结果表明空间映射优化算法能够适用于行人下肢模块碰撞保护的优化设计。
Vehicle front-end design for pedestrian impact protection has been a challenge forstructural engineers. For engineering practices during the vehicle development forpedestrian leg protection, expert experience and intuitive judgment have been mainlydepended on to conduct the tests and simulations. This study is to exploit how thevehicle front-end structures influence the pedestrian legform injury parameters, andbuild a parametric analytical model, which provides more basis in the concept designstage for balancing the requirements of styling, general layout and energy-absorberpackaging. Also, the space mapping algorithm is introduced and modified to developa more efficient optimization tool for the detail design stage, which will shorten thedevelopment period and improve the design quality.
In order to provide guidance for the front-end design in the early stage of vehicledevelopment, the influence mechanism of the front-end structure design on the legforminjury parameters is analyzed. The kinetic equation of the legform movement is built.To develop a kind of approximate analytic solution of the legform injury parameters,the legform knee joint is simplified to be rigid. The finite element (FE) model isutilized to verify the correlation between the legform injury parameters and the vehiclefront-end design. Based on the approximate analytic solution, the design strategies arediscussed to prevent legform injury parameters from exceeding the standard scope.
By using the FE model of legform to vehicle bumper impact, a more reasonableequation to estimate the energy absorption (EA) space is proposed, which providestheoretical support for determining appropriate space in the early stage design. Theenergy partitioning analysis indicates that about one third of the initial kinematic energyof legform was absorbed by vehicle front-end structures. A modified method forestimating EA space is proposed by introducing3parameters (energy absorbing rate,EA efficiency and effective mass). Then parametric study is conducted to statisticallydetermine values of the3parameters, and more reasonable estimation of the EA spaceis obtained.
Vehicle front-end parametric model has been widely used in the variablesensitivity study related to the legform impact test. It is, however, inaccurate for traditional3-part parametric model to represent real vehicle front-end structures inlegform impact simulation. Thus, a4-part parametric model is developed based on adetailed FE model of a real vehicle front-end, in which the structure near the bumperbeam area is modeled as two parts. The4-part parametric model could better simulatethe contact force of vehicle acted on the legform.
Then, space mapping algorithm is utilized to improve the efficiency of optimizingthe vehicle front-end structures. In the vehicle design for legform impact protection,detailed FE model of real vehicle is able to ensure the predicting accuracy, butcomputationally time-consuming. The optimization algorithm with the space mappingtechnique allows the designer to use a computationally efficient, but inaccurate FEmodel (coarse model) as a meta-model for predicting the optimal design of the detailedFE model. Compared to the traditional response surface optimization method, the SMbased method requires much fewer number of detailed FE model simulations, so it ismore efficient. Finally, a new vehicle front-end system consisting of trapezoidal tubesis developed, and the cross section shape parameters are optimized using the SM basedoptimization method, which demonstrated that the SM based optimization method couldsolve the problem related to the pedestrian legform protection design.
论文首先分析了车前端结构参数对下肢模块损伤指标的影响机理，对车前端结构的前期设计提供了指导。通过建立并简化行人下肢模块刚体动力学模型，得到了下肢模块损伤指标的近似解析解，并借助有限元模拟验证了该近似解析解与下肢模块损伤指标的相关性。基于动力学方程的近似解析解，论文分析了下肢模块胫骨加速度峰值、膝关节弯曲角度和剪切位移峰值的控制策略。
论文基于下肢模块与车前端结构碰撞的有限元模型，对车前端的吸能空间进行了更准确的估计，为车型前期设计中确定针对下肢碰撞保护所需的吸能空间提供了理论支持。能量分析的结果表明，下肢模块初始动能仅有约三分之一被车前端结构吸收。本论文通过引入了能量转化率，吸能效率和有效质量系数等三个参数，改进了现有吸能空间估计方法。通过试验设计统计了以上三个参数的取值，计算得到了更合理的吸能空间估计值。
车前端结构的参数化模型被广泛用于行人下肢模块碰撞保护的参数分析研究中，然而传统的将车前端结构分为三个区域的参数化模型不能准确反映下肢模块与实车结构碰撞的响应。论文提出了四区域模型，将保险杠区域的吸能结构分为两部分，准确反映了实车对下肢模块膝关节区域碰撞力的作用点。
为了提高优化设计效率，论文将空间映射算法引入到车前端结构参数优化设计中。精度较高的实车前端有限元模型往往计算效率较低。空间映射优化算法允许设计者通过精度较低、计算效率高的粗糙模型作为辅助设计工具，对精细模型进行优化设计。与传统的响应面优化方法相比，空间映射优化算法对精细模型的计算次数显著减少，优化效率高于基于响应面的直接优化方法。作为一个应用性算例，论文最后建立了以梯形薄壁管为吸能结构的车前端参数化模型，应用空间映射优化算法对薄壁吸能结构的截面形状进行了优化设计，结果表明空间映射优化算法能够适用于行人下肢模块碰撞保护的优化设计。
Vehicle front-end design for pedestrian impact protection has been a challenge forstructural engineers. For engineering practices during the vehicle development forpedestrian leg protection, expert experience and intuitive judgment have been mainlydepended on to conduct the tests and simulations. This study is to exploit how thevehicle front-end structures influence the pedestrian legform injury parameters, andbuild a parametric analytical model, which provides more basis in the concept designstage for balancing the requirements of styling, general layout and energy-absorberpackaging. Also, the space mapping algorithm is introduced and modified to developa more efficient optimization tool for the detail design stage, which will shorten thedevelopment period and improve the design quality.
In order to provide guidance for the front-end design in the early stage of vehicledevelopment, the influence mechanism of the front-end structure design on the legforminjury parameters is analyzed. The kinetic equation of the legform movement is built.To develop a kind of approximate analytic solution of the legform injury parameters,the legform knee joint is simplified to be rigid. The finite element (FE) model isutilized to verify the correlation between the legform injury parameters and the vehiclefront-end design. Based on the approximate analytic solution, the design strategies arediscussed to prevent legform injury parameters from exceeding the standard scope.
By using the FE model of legform to vehicle bumper impact, a more reasonableequation to estimate the energy absorption (EA) space is proposed, which providestheoretical support for determining appropriate space in the early stage design. Theenergy partitioning analysis indicates that about one third of the initial kinematic energyof legform was absorbed by vehicle front-end structures. A modified method forestimating EA space is proposed by introducing3parameters (energy absorbing rate,EA efficiency and effective mass). Then parametric study is conducted to statisticallydetermine values of the3parameters, and more reasonable estimation of the EA spaceis obtained.
Vehicle front-end parametric model has been widely used in the variablesensitivity study related to the legform impact test. It is, however, inaccurate for traditional3-part parametric model to represent real vehicle front-end structures inlegform impact simulation. Thus, a4-part parametric model is developed based on adetailed FE model of a real vehicle front-end, in which the structure near the bumperbeam area is modeled as two parts. The4-part parametric model could better simulatethe contact force of vehicle acted on the legform.
Then, space mapping algorithm is utilized to improve the efficiency of optimizingthe vehicle front-end structures. In the vehicle design for legform impact protection,detailed FE model of real vehicle is able to ensure the predicting accuracy, butcomputationally time-consuming. The optimization algorithm with the space mappingtechnique allows the designer to use a computationally efficient, but inaccurate FEmodel (coarse model) as a meta-model for predicting the optimal design of the detailedFE model. Compared to the traditional response surface optimization method, the SMbased method requires much fewer number of detailed FE model simulations, so it ismore efficient. Finally, a new vehicle front-end system consisting of trapezoidal tubesis developed, and the cross section shape parameters are optimized using the SM basedoptimization method, which demonstrated that the SM based optimization method couldsolve the problem related to the pedestrian legform protection design.
引文
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