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顾镭博士徐有忠博士奇瑞汽车公司奇瑞乘用车工程研究院

OutlineVehicleProductDevelopmentProcessCheryCAECapabilitiesSafetyCAEApplication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车身减重〔863工程〕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〕奇瑞碰撞平安设计能力评估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、逐步完善企业平安设计标准3、完成CAE平安分析指南碰撞平安设计标准前部正面碰撞平安设计标准前部偏置碰撞平安设计标准侧面碰撞平安设计标准后部碰撞平安设计标准CAEistheprimarytoolforcrashsafetydevelopmentandassessmentCAEisusedateverystageofsafetydesignanddevelopmentprocessCAEisessentialforproductcycletimereductionSafetyCAEinProductDevelopmentCAE在碰撞平安中的应用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