车身碰撞安全的若干关键技术研究
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摘要
随着我国汽车工业的快速发展，我国民用汽车保有量也大幅增加，与此同时，全国每年发生的交通安全事故也在不断增多，甚至数项恶性交通事故引起了全国人民的强烈关注。但在我国目前的国情下，造成汽车事故频繁发生的根本性原因在可以预见的未来必然还将长期存在，也因此，对我国而言，道路交通事故实际上已经危害到了国家安全，进行汽车安全性研究，以提高司乘人员以及道路行人的安全指标就显得极为必要而且极为迫切。
本文结合国家自然基金重点项目“冲压成形与模具设计的基础理论、计算方法和关键技术”、国家杰出青年基金项目“基于KBE的冲压模具CAD专家系统理论以及聚合物板成形理论与计算方法研究”和国家汽车电子产业化重大专项（批准号：No.2004-2563）研究项目，针对当前汽车碰撞安全领域中的被动安全技术和行人安全保障技术的部分关键技术开展了研究，主要内容及成果有：
1）提出了一种双向参数化的设计优化过程，能够有效发挥CAD参数化和CAE参数化设计方法的优势，将每一次CAE分析结果实时反馈至覆盖件的CAD过程中，并实时动态显示车身零件的结构优化结果，可完成仿真分析对前期结构设计的方向驱动。这种方法不但可以用于车身的局部覆盖件设计，对其整体设计也有很好的效果，能够有效减少车身零件的设计周期，是未来车身设计领域的一种发展趋势。为了较好的展示双向参数化方法的使用，本章以某自主品牌汽车某车型的前横梁覆盖件的耐撞性优化设计为例，对整车车身骨架结构建立了参数化的有限元模型：以车身骨架结构的关键参数为设计变量，以覆盖件的轻量化设计为目标，以满足覆盖件的正面抗撞性为约束条件，建立整车的有限元优化模型；通过求解该优化模型，获得满足安全性要求，同时达到轻量化目的的设计参数。然后，根据优化得到的设计参数，建立整车碰撞模型，进行安全性和轻量化的实验验证。
2）结合某车型的保险杠实际设计过程，对行人小腿保护技术进行了深入研究。首先根据当前保险杠的实际使用，提出了一种新型的保险杠结构，即：在保险杠前端用一个吸能缓冲板替换填充泡沫，让其充分吸收小腿碰撞能量；其次基于响应表面模型，提出了一种符合Euro-NCAP法规的保险杠与腿部冲击器的碰撞有限元模型，并进行了碰撞仿真与试验的验证；再次，对保险杠吸能板的设计，采用全因子试验设计方法对不同材料性能和板料厚度组合进行仿真计算，并对计算结果进行分析总结，得到优化的设计方案；最后结合基于行人小腿保护的保险杠吸能板开发过程，提出一种有效的保险杠设计优化流程，为汽车行业保险杠的优化设计形成有价值的参考。
3）针对行人头部保护的发动机罩开发技术进行了研究。首先结合多刚体动力学的理论，分析了行人运动特性对自身保护的影响，给出了基于中国人特征的行人参数，从碰撞事例研究了汽车与行人碰撞过程中行人产生损伤的特征，获取了在此过程中各项影响元素的分布规律；
通过分析发动机罩结构特点以及大量的碰撞仿真结果，总结了发动机罩区域中所有潜在碰撞点处的HIC值规律，证明了头部碰撞伤害值和发动机罩碰撞点与头部潜在二次碰撞点的距离、二次碰撞点处的材料屈服强度具有高度相关性，并总结出了相关性经验公式，为汽车车身设计者快速预测发动机罩板上各碰撞子分区的危险点提供了有力依据；根据该相关性公式，可在进行碰撞仿真计算和实车碰撞试验之前，根据发动机罩及其下部结构计算出HIC相对值大小的分布趋势图，找出各子区域内的“最危险点”，从而为仿真计算和实车试验提供有用参考。最后本文还通过实车试验验证，表明了该方法寻找危险点的可靠性。
4）B柱零件是保障汽车侧面耐撞性的重要部件，在保证B柱零件轻量化的前提下，B柱零件仍需具有较好的耐撞性，基于此本文提出了基于轻量化的B柱零件满足耐撞性的优化设计方法，该设计方法对于目前的汽车轻量化设计过程具有一定的指导作用；本文建立了以整车碰撞过程为边界条件的局部子模型，并将子模型与整车模型进行了对比分析，使其可以作为整车模型优化计算的代理模型，从而大大减少仿真计算时间；提出了在子模型中采用热成形B柱外板对原始外板进行替换、去掉B柱加强内板的方案，并通过Optimus建立了B柱外板和内板厚度的优化流程，最终获取了符合工程实际需求的板材厚度匹配，可实现侧面结构减重4.64kg左右；将子模型的优化结果返回到整车模型中进行了优化结果验证，结果证明本文的优化设计方案是可行的。
With the rapid development of Chinese automobile industry, the number of civil vehicleownership has grown very much. At same time, the number of traffic accident happened inchina for every year has increased constantly. Several malignant accidents caused a strongfocus on by national people. Under the current situation in our country, the fundamentalcause of car accidents would inevitably exist for a long time in the foreseeable future.Therefore, road traffic accident has harm to national security. It was urgent that safety studyof vehicle in order to protect drivers and passengers.
This research was based on the key project of national nature fund “the basic theory,calculation methods and key technology of Stamping and die design”, National outstandingyouth fund projects “Stamping die CAD based on KBE expert system theory and thepolymer plate shape theory and the calculation method for the research” and the majorproject of national automotive electronics industry. This research was focus on the keytechnology of passive safety and pedestrian protection. The main content and researchresults were followed as:
1) A design and optimization method of two-way parameterized was proposed. Thismethod could bring advantage of design optimization whose main characteristics wasrealized parameterization of CAD and CAE. In this design optimization method, the result ofCAE analysis would been feedback to the CAD processing. The design optimization resultof car body parts was displayed in real time and could realize the function that the CAEanalysis guided the structure design early stage. This method could be used design ofauto-body panels not only part but also as a whole. This method could shorten the cycle ofparts design and would be the developing trend of future in the field of auto-body design. Inorder to display the function of the optimization method of two-way parameterize, using thecrashworthiness design optimization of front beam as example, Parameterized finite elementmodel of the vehicle body frame structure was constructed. With the key parameters ofvehicle body frame structure as design variable, the lightweight of the structure as object, thecrashworthiness of front impact as constraint, the design optimization model was constructed.Using the results of design optimization, the design parameters were obtained that they meet the requirements of crashworthiness and lightweight. According the obtained variables, thereal vehicle model was manufacture, and was been validation.
2) Firstly, the pedestrian leg protection technology was researched with the designprocess of bumper as example. A new style bumper structure was designed according theactual usage of current bumper. In this new bumper, the filled foam was instead by a newenergy absorption buffer plate. This new style bumper could absorb energy fully. Secondly, anew impact finite element model was proposed based on the response surface model. Theimpact finite element model was validated by simulation and experiment. This finite elementmodel met the regulations of Euro-NCAP. Thirdly, the design optimization of absorb panelof bumper was carried out. With full factors design of experiment method, the combinationof different material property and thickness of panel was simulated. After the analysis ofresults, the final design scheme was determinate. Finally, based on the development processof absorb panel of bumper, a method of technological design optimization process of bumperwas proposed. This method could be referenced by the auto industry.
3) The research about pedestrian head protection of auto-body engine hood was carriedout. Based on the theory of multi rigid body, the influence that pedestrian movementcharacteristics to its own protection. The pedestrian parameters based on Chinesecharacteristic were obtained. Through the impact examples, the injury characteristic ofpedestrian in impact between pedestrian and vehicle was researched. The distributionregularities of different influence factors was obtained. Through analysis of the feature ofengine hood structure and impact results, the distribution regularities of HIC value on theengine hood was obtained. It was been proved that HIC value was directly proportional tothe distance between engine hood impact position and second impact position. This relationwas same with material yield strength of second impact position. The correlation empiricalformula was summarized. This formula could be used as the basis of rapidly predictiondangerous position on the engine hood for auto-body designer. According this correlationformula, the trend diagram of relative HIC value could be calculated and the most dangerousposition in each domain could be obtained, before the impact simulation and experiment.These could be referenced by impact simulation and experiment later. Finally, the searchmost dangerous position method was validated by experiment and the result indicated thatthis method was reliable.
4) The B pillar was the important part which guaranteed the side crashworthiness ofauto-body. In order to guarantee the crashworthiness and lightweight of B pillar at same time, a design optimization method was proposed. This method could be referenced by lightweightdesign in auto-body. The sub model was constructed using the motion of whole vehicleimpact process as the boundary conditions. Through the comparative analysis of sub andwhole model, the sub model could be used as the surrogate model of the whole. With the submodel, the time of simulation could be decreased. In the sub model, the original outer panelof B pillar was replaced by hot-formed panel, and the original inner reinforcing panel of Bpillar was no using. The design optimization model was constructed using software Optimus.The thickness of outer and inner panels was set as design variable. Through the designoptimization model, the thickness of panel that met the engineering needing was obtained.Comparing with the original panel structure, the weight of new structure decreased4.65kg.Then, the results of optimization were set back the whole model, and validation test wascarried out. The result of validation proved that the proposed design optimization methodwas feasible.
本文结合国家自然基金重点项目“冲压成形与模具设计的基础理论、计算方法和关键技术”、国家杰出青年基金项目“基于KBE的冲压模具CAD专家系统理论以及聚合物板成形理论与计算方法研究”和国家汽车电子产业化重大专项（批准号：No.2004-2563）研究项目，针对当前汽车碰撞安全领域中的被动安全技术和行人安全保障技术的部分关键技术开展了研究，主要内容及成果有：
1）提出了一种双向参数化的设计优化过程，能够有效发挥CAD参数化和CAE参数化设计方法的优势，将每一次CAE分析结果实时反馈至覆盖件的CAD过程中，并实时动态显示车身零件的结构优化结果，可完成仿真分析对前期结构设计的方向驱动。这种方法不但可以用于车身的局部覆盖件设计，对其整体设计也有很好的效果，能够有效减少车身零件的设计周期，是未来车身设计领域的一种发展趋势。为了较好的展示双向参数化方法的使用，本章以某自主品牌汽车某车型的前横梁覆盖件的耐撞性优化设计为例，对整车车身骨架结构建立了参数化的有限元模型：以车身骨架结构的关键参数为设计变量，以覆盖件的轻量化设计为目标，以满足覆盖件的正面抗撞性为约束条件，建立整车的有限元优化模型；通过求解该优化模型，获得满足安全性要求，同时达到轻量化目的的设计参数。然后，根据优化得到的设计参数，建立整车碰撞模型，进行安全性和轻量化的实验验证。
2）结合某车型的保险杠实际设计过程，对行人小腿保护技术进行了深入研究。首先根据当前保险杠的实际使用，提出了一种新型的保险杠结构，即：在保险杠前端用一个吸能缓冲板替换填充泡沫，让其充分吸收小腿碰撞能量；其次基于响应表面模型，提出了一种符合Euro-NCAP法规的保险杠与腿部冲击器的碰撞有限元模型，并进行了碰撞仿真与试验的验证；再次，对保险杠吸能板的设计，采用全因子试验设计方法对不同材料性能和板料厚度组合进行仿真计算，并对计算结果进行分析总结，得到优化的设计方案；最后结合基于行人小腿保护的保险杠吸能板开发过程，提出一种有效的保险杠设计优化流程，为汽车行业保险杠的优化设计形成有价值的参考。
3）针对行人头部保护的发动机罩开发技术进行了研究。首先结合多刚体动力学的理论，分析了行人运动特性对自身保护的影响，给出了基于中国人特征的行人参数，从碰撞事例研究了汽车与行人碰撞过程中行人产生损伤的特征，获取了在此过程中各项影响元素的分布规律；
通过分析发动机罩结构特点以及大量的碰撞仿真结果，总结了发动机罩区域中所有潜在碰撞点处的HIC值规律，证明了头部碰撞伤害值和发动机罩碰撞点与头部潜在二次碰撞点的距离、二次碰撞点处的材料屈服强度具有高度相关性，并总结出了相关性经验公式，为汽车车身设计者快速预测发动机罩板上各碰撞子分区的危险点提供了有力依据；根据该相关性公式，可在进行碰撞仿真计算和实车碰撞试验之前，根据发动机罩及其下部结构计算出HIC相对值大小的分布趋势图，找出各子区域内的“最危险点”，从而为仿真计算和实车试验提供有用参考。最后本文还通过实车试验验证，表明了该方法寻找危险点的可靠性。
4）B柱零件是保障汽车侧面耐撞性的重要部件，在保证B柱零件轻量化的前提下，B柱零件仍需具有较好的耐撞性，基于此本文提出了基于轻量化的B柱零件满足耐撞性的优化设计方法，该设计方法对于目前的汽车轻量化设计过程具有一定的指导作用；本文建立了以整车碰撞过程为边界条件的局部子模型，并将子模型与整车模型进行了对比分析，使其可以作为整车模型优化计算的代理模型，从而大大减少仿真计算时间；提出了在子模型中采用热成形B柱外板对原始外板进行替换、去掉B柱加强内板的方案，并通过Optimus建立了B柱外板和内板厚度的优化流程，最终获取了符合工程实际需求的板材厚度匹配，可实现侧面结构减重4.64kg左右；将子模型的优化结果返回到整车模型中进行了优化结果验证，结果证明本文的优化设计方案是可行的。
With the rapid development of Chinese automobile industry, the number of civil vehicleownership has grown very much. At same time, the number of traffic accident happened inchina for every year has increased constantly. Several malignant accidents caused a strongfocus on by national people. Under the current situation in our country, the fundamentalcause of car accidents would inevitably exist for a long time in the foreseeable future.Therefore, road traffic accident has harm to national security. It was urgent that safety studyof vehicle in order to protect drivers and passengers.
This research was based on the key project of national nature fund “the basic theory,calculation methods and key technology of Stamping and die design”, National outstandingyouth fund projects “Stamping die CAD based on KBE expert system theory and thepolymer plate shape theory and the calculation method for the research” and the majorproject of national automotive electronics industry. This research was focus on the keytechnology of passive safety and pedestrian protection. The main content and researchresults were followed as:
1) A design and optimization method of two-way parameterized was proposed. Thismethod could bring advantage of design optimization whose main characteristics wasrealized parameterization of CAD and CAE. In this design optimization method, the result ofCAE analysis would been feedback to the CAD processing. The design optimization resultof car body parts was displayed in real time and could realize the function that the CAEanalysis guided the structure design early stage. This method could be used design ofauto-body panels not only part but also as a whole. This method could shorten the cycle ofparts design and would be the developing trend of future in the field of auto-body design. Inorder to display the function of the optimization method of two-way parameterize, using thecrashworthiness design optimization of front beam as example, Parameterized finite elementmodel of the vehicle body frame structure was constructed. With the key parameters ofvehicle body frame structure as design variable, the lightweight of the structure as object, thecrashworthiness of front impact as constraint, the design optimization model was constructed.Using the results of design optimization, the design parameters were obtained that they meet the requirements of crashworthiness and lightweight. According the obtained variables, thereal vehicle model was manufacture, and was been validation.
2) Firstly, the pedestrian leg protection technology was researched with the designprocess of bumper as example. A new style bumper structure was designed according theactual usage of current bumper. In this new bumper, the filled foam was instead by a newenergy absorption buffer plate. This new style bumper could absorb energy fully. Secondly, anew impact finite element model was proposed based on the response surface model. Theimpact finite element model was validated by simulation and experiment. This finite elementmodel met the regulations of Euro-NCAP. Thirdly, the design optimization of absorb panelof bumper was carried out. With full factors design of experiment method, the combinationof different material property and thickness of panel was simulated. After the analysis ofresults, the final design scheme was determinate. Finally, based on the development processof absorb panel of bumper, a method of technological design optimization process of bumperwas proposed. This method could be referenced by the auto industry.
3) The research about pedestrian head protection of auto-body engine hood was carriedout. Based on the theory of multi rigid body, the influence that pedestrian movementcharacteristics to its own protection. The pedestrian parameters based on Chinesecharacteristic were obtained. Through the impact examples, the injury characteristic ofpedestrian in impact between pedestrian and vehicle was researched. The distributionregularities of different influence factors was obtained. Through analysis of the feature ofengine hood structure and impact results, the distribution regularities of HIC value on theengine hood was obtained. It was been proved that HIC value was directly proportional tothe distance between engine hood impact position and second impact position. This relationwas same with material yield strength of second impact position. The correlation empiricalformula was summarized. This formula could be used as the basis of rapidly predictiondangerous position on the engine hood for auto-body designer. According this correlationformula, the trend diagram of relative HIC value could be calculated and the most dangerousposition in each domain could be obtained, before the impact simulation and experiment.These could be referenced by impact simulation and experiment later. Finally, the searchmost dangerous position method was validated by experiment and the result indicated thatthis method was reliable.
4) The B pillar was the important part which guaranteed the side crashworthiness ofauto-body. In order to guarantee the crashworthiness and lightweight of B pillar at same time, a design optimization method was proposed. This method could be referenced by lightweightdesign in auto-body. The sub model was constructed using the motion of whole vehicleimpact process as the boundary conditions. Through the comparative analysis of sub andwhole model, the sub model could be used as the surrogate model of the whole. With the submodel, the time of simulation could be decreased. In the sub model, the original outer panelof B pillar was replaced by hot-formed panel, and the original inner reinforcing panel of Bpillar was no using. The design optimization model was constructed using software Optimus.The thickness of outer and inner panels was set as design variable. Through the designoptimization model, the thickness of panel that met the engineering needing was obtained.Comparing with the original panel structure, the weight of new structure decreased4.65kg.Then, the results of optimization were set back the whole model, and validation test wascarried out. The result of validation proved that the proposed design optimization methodwas feasible.
引文
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