Systems engineering philosophy and virtual prototyping design are effective for development of electric and hybrid vehicles (EVs) for a low-volume market. These concepts were demonstrated in development of fully Federal Motor Vehicle Safety Standards-certified upfit EVs,including a light truck and a car. Crashworthiness simulation was an important part of EV virtual prototyping, but rapid crashworthiness model development was required for the process to be effective. A highly automated and reliable treatment of contact and a robust, accurate finite element formulation were key DYNA3D components in cutting vehicle model development/debugging time and allowing use of full vehicle simulation in the iterative design cycle. The new automatic contact and the YASE shell element developed for DYNA3D were used in full vehicle crashworthiness simulation programs for an upfit electric pickup and an upfit electric passenger car. Agreement between DYNA3D simulation predictions and crash test results for occupant compartment accelerations was demonstrated for both the frame-and-body pickup truck and the unibody passenger car using simulation models developed in less than 12 weeks. Using these crash simulation models, several unique aspects of EV crash behaviour were identified, including the effect of added batery mass and a more rearward centre of gravity on vehicle rotation in oblique frontal impact. Ongoing research and programmatic efforts are continuing to focus on improvement of modelling techniques, data management and the DYNA3D software for more rapid model development. Continued enhancement of DYNA3D modelling to include crashworthiness of less ductile aluminium spaceframe structures and polymeric composite monocoque vehicle structures is also underway. Examples show a preliminary pole impact simulation of a composite monocoque purpose-built electric vehicle, a difficult crashworthiness design problem faced by composite vehicles. Advanced crashworthiness simulation and structural integrity/durability design tools will be required to effectively utilize lightweight structural materials such as composites and aluminium in the development of next-generation purpose-built electric and hybrid vehicles.
Electric and hybrid vehicle crashworthiness simulation
Simulation der Aufprallsicherheit von Elektro- und Hybridfahrzeugen
International Journal of Vehicle Design ; 18 , 5 ; 413-432
1997
20 Seiten, 18 Bilder, 6 Quellen
Article (Journal)
English
rechnerunterstützter Entwurf , graphische Datenverarbeitung , Rechnergraphik , dreidimensionale Darstellung , Simulationsprogramm , Simulationsmodell , Rechnersimulation , Aufprall , Karosserie , Fahrzeugsicherheit , Hybridantrieb , Elektroauto , Finite-Elemente-Methode , Verformung , Dehnbarkeit , Plastizität , Systemtechnik , Werkstofftechnik , Schale (Flächentragwerk) , Personenkraftwagen , Rahmen (Fahrzeug) , Algorithmus
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