CAE技術在汽車產(chǎn)品開發(fā)中的應用

CAE技術在汽車產(chǎn)品開發(fā)中的應用顧鐳博士徐有忠博士奇瑞汽車公司奇瑞乘用車工程研究院

OutlineVehicleProductDevelopmentProcessCheryCAECapabilitiesSafetyCAEApplication汽車新產(chǎn)品開發(fā)典型流程整車系統(tǒng)子系統(tǒng)零部件產(chǎn)品/流程設計目標分解設計驗證優(yōu)化設計/生產(chǎn)確認下線/批量生產(chǎn)確認更新公司經(jīng)驗庫外型確定立項定義設計驗證/下線SystemEngineeringFundamentalCustomerMusts/WantsCustomerSatisfaction

VehiclelevelInputsPurchaser/owner/operatorRegulatory(FMVSS,EPA,…)Corporate(WCR,ABS,Manuf,…)

VehiclelevelRequirementsVehicleAttributesVehicleSystemSpecification-DSPurchase,Operate&Maintain

VehicleVerification

System/SubsystemlevelSystem&SubsystemDesignSpecifications-SDS

SystemVerificationDisposalpart/ComponentDesignComponentDesignSpec-CDSpart/ComponentVerificationCustomerFocusCustomerExperience&FeedbackCustomerRequirementsDVM/DVPDVM/DVPRequirementsCascadeRequirementsCascadeRequirementsCascadeFeasibilityFeedbackFeasibilityFeedbackFeasibilityFeedbackHighlyIterativeHighlyIterativeProduction車身輕量化流程圖拓撲優(yōu)化敏感性分析模態(tài)分析剛度分析強度分析碰撞模擬與耐久性CAE驗證最終車身減重方案車身輕量化CAE方案分析多個優(yōu)化方案供選擇材料校核車身校核工藝校核車身減重〔863工程〕理論減重方案可減輕車身重量共計約22Kg,目前已經(jīng)完成所有需調(diào)整零件〔4套〕的試沖，實際減重約19Kg，三臺減重試驗車于10月12日裝配下線。(與上海交通大學合作〕奇瑞碰撞平安設計能力評估1、CAE分析能力建設。CAE部已具備了如下能力前部碰撞：中國標準，美國法規(guī)〔FMVSS208，USNCAP，IIHS〕，歐洲法規(guī)〔ECE94/33，EuroNCAP〕側(cè)面碰撞：中國標準，美國法規(guī)〔FMVSS214，USNCAP，IIHS〕，歐洲法規(guī)〔ECE95，EuroNCAP〕后部碰撞：美國法規(guī)〔FMVSS301〕，歐洲法規(guī)〔ECE32/34〕車頂抗壓：美國法規(guī)〔FMVSS216〕乘員保護：美國法規(guī)〔FMVSS208〕2、逐步完善企業(yè)平安設計標準3、完成CAE平安分析指南碰撞平安設計標準前部正面碰撞平安設計標準前部偏置碰撞平安設計標準側(cè)面碰撞平安設計標準后部碰撞平安設計標準CAEistheprimarytoolforcrashsafetydevelopmentandassessmentCAEisusedateverystageofsafetydesignanddevelopmentprocessCAEisessentialforproductcycletimereductionSafetyCAEinProductDevelopmentCAE在碰撞平安中的應用CAE分析流程FrontalImpactEvaluationPredictionConfidenceLevelCrashPulseHighIntrusion/DeformationHighRestraintPerformanceMediumOccupantResponseMediumFuelSystemIntegrityLowDoorOpenabilityLowConfidenceLevelHIGH =PredictstrendandmagnitudewithinthetestvariabilityMEDIUM =Predictstrendwithin20%oftestLOW =CannotpredicttrendandmagnitudeCherywillcontinueit’seffortinsafetyCAEtechnologyforImprovedsafetyprotectionCosteffectiveproductdevelopmentLightweightsafetydesignforbetterfueleconomySafetyChallengesMoreStringentSafetyRequirementsNew208,IIHSOffset,IIHSSide,R/O,OOPReducefeasiblesolutiondomainIncreaseofAdvanceRestraintSystemAdaptiveVenting/Column/LoadLimiter,TetherBag,DualPyro,IKB,SIR,OCS…..CertificationcomplexityStylingdemandsshorterfrontendAchieveLeadershipw.min.weight,cost,andtimeSafetyCAEPhilosophyPredictioninsteadofcorrelationModelthephysicscorrectwillensuregoodpredictionsDesignforsuccessinsteadofpredictforfailure(DesignfocusinsteadofVerificationfocus)RobustnessNeedstobeconsideredDeliverhighqualitysafetywhilemeetingABSSafetyCAETrendsLeadDesignMoreinvolvementindefiningarchitecturalandupfronttargetingprocessCAEisnotequaltoFEAIntegrateallpossibletools.UsethemosteffectivetoolatdifferentstagesMoredisciplineCAEapproaches(CAEQOS)IncorporateOpt/RobustnesstoolsetWell-roundsafetybackgroundImprovepredictingcapabilitySafetyActionPlanPeopleSafetyEngineeringmindsetDisciplineinfollowingCAEQualityProcessOut-of-BoxthinkingLeaddesignmindsetProcessSafetyCAEQOSStandardizedSafetyDevelopmentProcessEstablishSafetyKBETechnologyResolveCAEGapsBuildOpt/RobustnessToolsetsProcessIntegrationtoolsetDevelopmentofSafetyFeature19601970198019902000??...brakeassistACCABSESPtractioncontrolactivesuspensionlanedetectioncollisionmitigation(autobrake)activesteeractivedriverassist.--- Activesafetyfeature

ActivesafetyenablerV-V/V-Icomm.safetycellsafetybeltscrumplezonefrontbagadvancedseatbeltssideimpactprotectionsideairbag---

PassivesafetyheadrestraintssafetypedalsadaptiverestraintscompatibilitySafetypotentialRSCactiveaccident

avoidancesteerbywireblindspotdriverstateshortrangeradarLRradarGovernmentregs/infras.brakebywirethrottlebywireIndustrystandardssensorfusion(rdr+vis)visionsystemlanekeepingassistUCC/UCW*Manyofthesetechnologieshavesignificanttechnicalhurdles;implementationcannotoccuriftheyarenotovercome.TechnologyGaps

Structure-1Rupture,Failure,separationWeldBodyMounts,EngineMountsMagnesiumIP,MagnesiumRadiatorSupportFastenerLCAFrameFuelpipe/fuelrail/fueltank/senderunitLatchfailureOtherMaterial-Nyloninsert,foam,HoneycombWindshieldDelaminatingMechanicalBehavior/KinematicsTirerotationinoffsetVehiclePitchandrotationOccupantKinematicsDooropenmechanism(inertia/intrusion)FueltankkinematicsVehiclekinematicsduringrolloverSuspension/SteeringkinematicsTechnologyGaps

Structure-2InaccuracyBodyMounts-InaccuracyofBodyPulseThickshellperformance-FramepulseContactforcepredictionOthermaterial-foam,nylon,plastic,HoneycombLocalprediction(crashzone)T