CAE技术在汽车产品开发中的应用

CAE技术在汽车产品开发中的应用第1页/共28页OutlineVehicleProductDevelopmentProcessCheryCAECapabilitiesSafetyCAEApplication第2页/共28页汽车新产品开发典型流程整车系统子系统零部件产品/流程设计目标分解设计验证优化设计/生产确认下线/批量生产确认更新公司经验库外型确定立项定义设计验证/下线第3页/共28页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第4页/共28页第5页/共28页第6页/共28页第7页/共28页第8页/共28页车身轻量化流程图拓扑优化敏感性分析模态分析刚度分析强度分析碰撞模拟与耐久性CAE验证最终车身减重方案车身轻量化CAE方案分析多个优化方案供选择材料校核车身校核工艺校核第9页/共28页车身减重（863项目）理论减重方案可减轻车身重量共计约22Kg,目前已经完成所有需调整零件（4套）的试冲，实际减重约19Kg，三台减重试验车于10月12日装配下线。(与上海交通大学合作）第10页/共28页奇瑞碰撞安全设计能力评估1、CAE分析能力建设。CAE部已具备了如下能力前部碰撞：中国标准，美国法规（FMVSS208，USNCAP，IIHS），欧洲法规（ECE94/33，EuroNCAP）侧面碰撞：中国标准，美国法规（FMVSS214，USNCAP，IIHS），欧洲法规（ECE95，EuroNCAP）后部碰撞：美国法规（FMVSS301），欧洲法规（ECE32/34）车顶抗压：美国法规（FMVSS216）乘员保护：美国法规（FMVSS208）2、逐步完善企业安全设计标准3、完成CAE安全分析指南第11页/共28页碰撞安全设计标准前部正面碰撞安全设计标准前部偏置碰撞安全设计标准侧面碰撞安全设计标准后部碰撞安全设计标准第12页/共28页CAEistheprimarytoolforcrashsafetydevelopmentandassessmentCAEisusedateverystageofsafetydesignanddevelopmentprocessCAEisessentialforproductcycletimereductionSafetyCAEinProductDevelopment第13页/共28页CAE在碰撞安全中的应用第14页/共28页CAE分析流程第15页/共28页FrontalImpactEvaluation第16页/共28页PredictionConfidenceLevelCrashPulseHighIntrusion/DeformationHighRestraintPerformanceMediumOccupantResponseMediumFuelSystemIntegrityLowDoorOpenabilityLowConfidenceLevelHIGH =PredictstrendandmagnitudewithinthetestvariabilityMEDIUM =Predictstrendwithin20%oftestLOW =Cannotpredicttrendandmagnitude第17页/共28页Cherywillcontinueit’seffortinsafetyCAEtechnologyforImprovedsafetyprotectionCosteffectiveproductdevelopmentLightweightsafetydesignforbetterfueleconomy第18页/共28页SafetyChallengesMoreStringentSafetyRequirementsNew208,IIHSOffset,IIHSSide,R/O,OOPReducefeasiblesolutiondomainIncreaseofAdvanceRestraintSystemAdaptiveVenting/Column/LoadLimiter,TetherBag,DualPyro,IKB,SIR,OCS…..CertificationcomplexityStylingdemandsshorterfrontendAchieveLeadershipw.min.weight,cost,andtime第19页/共28页SafetyCAEPhilosophyPredictioninsteadofcorrelationModelthephysicscorrectwillensuregoodpredictionsDesignforsuccessinsteadofpredictforfailure(DesignfocusinsteadofVerificationfocus)RobustnessNeedstobeconsideredDeliverhighqualitysafetywhilemeetingABS第20页/共28页SafetyCAETrendsLeadDesignMoreinvolvementindefiningarchitecturalandupfronttargetingprocessCAEisnotequaltoFEAIntegrateallpossibletools.UsethemosteffectivetoolatdifferentstagesMoredisciplineCAEapproaches(CAEQOS)IncorporateOpt/RobustnesstoolsetWell-roundsafetybackgroundImprovepredictingcapability第21页/共28页SafetyActionPlanPeopleSafetyEngineeringmindsetDisciplineinfollowingCAEQualityProcessOut-of-BoxthinkingLeaddesignmindsetProcessSafetyCAEQOSStandardizedSafetyDevelopmentProcessEstablishSafetyKBETechnologyResolveCAEGapsBuildOpt/RobustnessToolsetsProcessIntegrationtoolset第22页/共28页DevelopmentofSafetyFeature19601970198019902000??...brakeassistACCABSESPtractioncontrolactivesuspensionlanedetectioncollisionmitigation(autobrake)activesteeractivedriverassist.--- Activesafetyfeature

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

PassivesafetyheadrestraintssafetypedalsadaptiverestraintscompatibilitySafetypotentialRSCactiveaccident

avoidancesteerbywireblindspotdriverstateshortrangeradarLRradarGovernmentregs/infras.brakebywirethrottlebywireIndustrystandardssensorfusion(rdr+vis)visionsystemlanekeepingassistUCC/UCW*Manyofthesetechnologieshavesignificanttechnicalhurdles;implementationcannotoccuriftheyarenotovercome.第23页/共28页TechnologyGaps

Structure-1Rupture,Failure,separationWeldBodyMounts,EngineMountsMagnesiumIP,MagnesiumRadiatorSupportFastenerLCAFrameFuelpipe/fuelrail/fueltank/senderunitLatchfailureOtherMaterial-Nyloninsert,foam,HoneycombWindshieldDelaminating第24页/共28页MechanicalBehavior/KinematicsTirerotationinoffsetVehiclePitchandrotationOccupantKinematicsDooropenmechanism(inertia/intrusion)FueltankkinematicsVehiclekinematicsduringrolloverSuspension/SteeringkinematicsTechnologyGaps

Structure-2第25页/共28页InaccuracyBodyMounts-InaccuracyofBodyPulseThickshellperformance-FramepulseContactforcepredictionOthermaterial-foam,nylon,plastic,HoneycombLocalprediction(crashzone)TechnologyGaps

Structure-3第26