重型商用车驾驶室轻量化分析与优化
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摘要
伴随着能源危机和全球气候变暖等问题的出现，汽车轻量化已经是炙手可热的话题。降低汽车的整备质量，不仅可以降低汽车的燃油消耗，减少有害物质排放，还可以提高汽车的装载量或载客量，提高汽车运输效率。汽车结构的轻量化，可以从材料、工艺和结构设计三个方面入手。结构轻量化设计是汽车轻量化的重要途径之一，是轻量化汽车产品开发的基础和前提，通过轻量化设计使合适的材料、最优的结构形状和尺寸用在汽车结构合适的位置，使每部分材料都能发挥出其最大的承载、吸能和加刚作用，可提高材料利用率、降低车重，减少材料成本，实现节能、减排、降耗。
本文结合省科技科技发展计划重大项目“商用车驾驶室轻量化分析与应用”（20086007），对重型商用车驾驶室的轻量化设计与评价方法及其应用进行了系统、深入的理论分析与试验研究。通过对重型商用车驾驶室白车身结构进行轻量化设计与试验，取得良好的减重效果。
首先应用有限元方法，分别建立了驾驶室白车身的有限元模态分析、强度、刚度和被动安全性分析模型，分析了驾驶室在自由状态下的固有振动特性；确定了重型商用车在转向、制动、加速和直线行驶四种典型工况下驾驶室所承受最大动载荷，分析了驾驶室在上述四种工况下的强度、刚度；基于ECE R29法规规定的试验方法，对驾驶室的前摆锤冲击、顶压和后推的被动安全性进行了分析和评价，为驾驶室轻量化设计改进后的对比分析提供了依据。
应用拓扑优化和形貌优化方法，对驾驶室白车身结构进行了轻量化优化设计，确定了驾驶室白车身的轻量化结构设计方案，通过对轻量化驾驶室的强度、刚度、振动特性和被动安全性进行有限元分析，并与轻量化前原驾驶室结构的相应性能进行对比，检验了轻量化驾驶室结构的性能。
提出了用轻量化系数来评价驾驶室白车身轻量化水平方法，并对驾驶室白车身进行了轻量化分析与评价。
为了考核轻量化设计后驾驶室的性能是否满足使用要求，研制了轻量化驾驶室样件，测量了轻量化驾驶室前10阶弹性模态频率和振型及其静态弯曲和扭转刚度特性；对轻量化前后驾驶室一阶扭转频率和刚度特性进行了分析对比。结果表明，虽然轻量化后驾驶室一阶扭转频率和静态弯扭刚度有所降低，但其一阶扭转频率仍>16Hz，弯曲刚度>14000N/mm，扭转刚度>35000Nm/°,可以满足对驾驶室刚度和振动特性要求。依据ECE R29法规要求，对轻量化驾驶室进行了被动安全性仿真分析和试验研究，结果表明，轻量化驾驶室的正面摆锤冲击、顶静压和后推的被动安全性满足ECER29法规要求。
轻量化驾驶室装车后8000km可靠性强化道路试验结果表明，轻量化驾驶室在试验过程中未出现异常，说明轻量化驾驶室可靠性满足使用要求。
减重后的轻量化驾驶室在保持其材料不变、满足使用要求的情况下实现减重46kg。
提出并设计开发出一种框架式商用车轻量化驾驶室，优化了框架式驾驶室的结构和尺寸，对框架式驾驶室进行了有限元模态分析、强度、刚度和被动安全性分析，并与原驾驶室相应特性进行了对比评价；结果表明所开发的框架式驾驶室不仅在强度和刚度上有明显的提高，也具有优越的振动特性，并能更好满足ECER29被动安全性要求，与原驾驶室相比可减重95kg，达到了更好的轻量化效果。
项目研发轻量化驾驶室已经用于重型商用车驾驶室的产品生产和销售，取得了良好的减重和节能效果。论文的研究结果作为一种共性技术可广泛应用于不同商用车驾驶室的轻量化设计。对于提高国产重型商用车驾驶室的正向开发设计能力和轻量化水平，节能减排，增强国际市场竞争力，促进汽车工业技术进步具有重要作用。
Accompanied by the emergence of the energy crisis and global warming issues,Vehicle weight reduction is a hot topic. Reduce the curb weight of the car, not onlycan reduce a car's fuel consumption and reduce emissions of harmful substances, butalso can improve the car loading or patronage to improve the efficiency of automobilemotor transport. The Lightweight analysis of the vehicle structure can be startedwiththe using of light materials, new processing method and structureoptimization.Structural lightweight design is the most important approaches of vehicle lightweightanalysis, it is the basis and prerequisite for lightweight automotive productdevelopment. Through the lightweight design, we can not only use the suitablematerial, shape and size of the optimal structure at suitable position in automotivestructures, so that every part of the material play its right role such asloading,energy-absorbing and stiffness improving, but also can improve material utilizationand reduce vehicle weight,material costs and emission, saveenergy.
According to the major projects of the Provincial Science and TechnologyScience and Technology Development Plan "Lightweight Analysis and ApplicationsofCommercial VehicleCab ", this paper performed deeply theoretical analysis andexperimental research on lightweight design, evaluation methods and itsapplicationsystems of heavy-duty commercial vehicle cab.Through the lightweightdesign and testing of heavy commercial vehicle cab white body structure to achievegood weight reduction results.
Firstly, using the finite element method, some FEA models of white Cab werebuiltto perform modal analysis, strength, stiffness and passive safetyanalysisrespectively. The natural vibration characteristics of the cab in the free statewas analyzed, the maximum dynamic load on the cab was determined as the heavy commercial vehicles in the four typical operating conditions steering,braking,acceleration and driving straight. The strength and stiffness analysis were performedunder the above four operating conditions.Based on ECE R29regulations, the cabpassive safety analysis and evaluation was made on front pendulumimpact, roofstrength and rear wall strength,toprovide a reference for comparative analysis of cablightweight design and improvement.
Applying topology optimization and topography optimization methods,lightweight design of white cab structure was performed and the lightweight plan wasdetermined. According to the strength, stiffness, vibration characteristics and passivesafety finite element analysis results on lightweight white cab and thecompartmentswith the original cab performance, the performance of the lightweight white cab wasverified.
A new proposal of using lightweight coefficient as lightweight evaluatingmethod was made, and had been used to analysis and evaluates the lightweight levelof the white cab.
In order to assesswhether the lightweight design can meet the operatingrequirements, we developed a lightweight cab sample, measured the first10elasticmodal frequencies and mode shapes and their static bending and torsional stiffnesscharacteristics of the lightweight cab; the first torsional frequency and stiffnesscharacteristics were analyzedand compared between the original and lightweight cab.Although lightweight cab first torsional frequency and static bending and torsionstiffness decreased, but the first torsional frequencywas larger than16Hz, the bendingstiffness>14000N/mm and torsional stiffness35000Nm/°, which meaned that itcan meet the driving chamber stiffness and vibration characteristics requirements.Based on ECE R29Regulatory requirements, lightweight cab passive safetysimulation analysis and experimental research were performed, the results showedthat the lightweight cab can meet the ECER29regulatory requirement of frontpendulum impact, roof strength and rear wall strength.
The8000km road test results showed that the lightweight cab performed well during the test, the lightweight cab reliability can meet the reliability requirements.
After lightweight analysis and optimization, the cab reduced weight46kg in thecase of maintaining the same material and meeting the operating requirements.
Proposed and developed a frame-type lightweight commercial vehicle cab,optimized the structure and size of the cab frame, performed the model state analysis,strength, stiffness and passive safety analysis of the cab frame, and compared thecorresponding characteristics withthe original cab; The results showed that thedeveloped frame-type lightweight cab significantly improved the strength andstiffness, superior vibration characteristics, and can better meet ECER29passivesafety requirements. It was lighter95kg than the original cab.
The cab developed in this paper has been used for the production and sales ofheavy commercial vehicle cab and got good weight reduction and energy-savingeffect. The research results can be widely used as a common technology lightweightdesign on different commercial vehicle cab and play an important role to improvethe forward design capabilities of domestic heavy commercial vehicle cab,implementthe energy saving and emission reduction, enhanced competitiveness in internationalmarkets and promote industry technological progress.
本文结合省科技科技发展计划重大项目“商用车驾驶室轻量化分析与应用”（20086007），对重型商用车驾驶室的轻量化设计与评价方法及其应用进行了系统、深入的理论分析与试验研究。通过对重型商用车驾驶室白车身结构进行轻量化设计与试验，取得良好的减重效果。
首先应用有限元方法，分别建立了驾驶室白车身的有限元模态分析、强度、刚度和被动安全性分析模型，分析了驾驶室在自由状态下的固有振动特性；确定了重型商用车在转向、制动、加速和直线行驶四种典型工况下驾驶室所承受最大动载荷，分析了驾驶室在上述四种工况下的强度、刚度；基于ECE R29法规规定的试验方法，对驾驶室的前摆锤冲击、顶压和后推的被动安全性进行了分析和评价，为驾驶室轻量化设计改进后的对比分析提供了依据。
应用拓扑优化和形貌优化方法，对驾驶室白车身结构进行了轻量化优化设计，确定了驾驶室白车身的轻量化结构设计方案，通过对轻量化驾驶室的强度、刚度、振动特性和被动安全性进行有限元分析，并与轻量化前原驾驶室结构的相应性能进行对比，检验了轻量化驾驶室结构的性能。
提出了用轻量化系数来评价驾驶室白车身轻量化水平方法，并对驾驶室白车身进行了轻量化分析与评价。
为了考核轻量化设计后驾驶室的性能是否满足使用要求，研制了轻量化驾驶室样件，测量了轻量化驾驶室前10阶弹性模态频率和振型及其静态弯曲和扭转刚度特性；对轻量化前后驾驶室一阶扭转频率和刚度特性进行了分析对比。结果表明，虽然轻量化后驾驶室一阶扭转频率和静态弯扭刚度有所降低，但其一阶扭转频率仍>16Hz，弯曲刚度>14000N/mm，扭转刚度>35000Nm/°,可以满足对驾驶室刚度和振动特性要求。依据ECE R29法规要求，对轻量化驾驶室进行了被动安全性仿真分析和试验研究，结果表明，轻量化驾驶室的正面摆锤冲击、顶静压和后推的被动安全性满足ECER29法规要求。
轻量化驾驶室装车后8000km可靠性强化道路试验结果表明，轻量化驾驶室在试验过程中未出现异常，说明轻量化驾驶室可靠性满足使用要求。
减重后的轻量化驾驶室在保持其材料不变、满足使用要求的情况下实现减重46kg。
提出并设计开发出一种框架式商用车轻量化驾驶室，优化了框架式驾驶室的结构和尺寸，对框架式驾驶室进行了有限元模态分析、强度、刚度和被动安全性分析，并与原驾驶室相应特性进行了对比评价；结果表明所开发的框架式驾驶室不仅在强度和刚度上有明显的提高，也具有优越的振动特性，并能更好满足ECER29被动安全性要求，与原驾驶室相比可减重95kg，达到了更好的轻量化效果。
项目研发轻量化驾驶室已经用于重型商用车驾驶室的产品生产和销售，取得了良好的减重和节能效果。论文的研究结果作为一种共性技术可广泛应用于不同商用车驾驶室的轻量化设计。对于提高国产重型商用车驾驶室的正向开发设计能力和轻量化水平，节能减排，增强国际市场竞争力，促进汽车工业技术进步具有重要作用。
Accompanied by the emergence of the energy crisis and global warming issues,Vehicle weight reduction is a hot topic. Reduce the curb weight of the car, not onlycan reduce a car's fuel consumption and reduce emissions of harmful substances, butalso can improve the car loading or patronage to improve the efficiency of automobilemotor transport. The Lightweight analysis of the vehicle structure can be startedwiththe using of light materials, new processing method and structureoptimization.Structural lightweight design is the most important approaches of vehicle lightweightanalysis, it is the basis and prerequisite for lightweight automotive productdevelopment. Through the lightweight design, we can not only use the suitablematerial, shape and size of the optimal structure at suitable position in automotivestructures, so that every part of the material play its right role such asloading,energy-absorbing and stiffness improving, but also can improve material utilizationand reduce vehicle weight,material costs and emission, saveenergy.
According to the major projects of the Provincial Science and TechnologyScience and Technology Development Plan "Lightweight Analysis and ApplicationsofCommercial VehicleCab ", this paper performed deeply theoretical analysis andexperimental research on lightweight design, evaluation methods and itsapplicationsystems of heavy-duty commercial vehicle cab.Through the lightweightdesign and testing of heavy commercial vehicle cab white body structure to achievegood weight reduction results.
Firstly, using the finite element method, some FEA models of white Cab werebuiltto perform modal analysis, strength, stiffness and passive safetyanalysisrespectively. The natural vibration characteristics of the cab in the free statewas analyzed, the maximum dynamic load on the cab was determined as the heavy commercial vehicles in the four typical operating conditions steering,braking,acceleration and driving straight. The strength and stiffness analysis were performedunder the above four operating conditions.Based on ECE R29regulations, the cabpassive safety analysis and evaluation was made on front pendulumimpact, roofstrength and rear wall strength,toprovide a reference for comparative analysis of cablightweight design and improvement.
Applying topology optimization and topography optimization methods,lightweight design of white cab structure was performed and the lightweight plan wasdetermined. According to the strength, stiffness, vibration characteristics and passivesafety finite element analysis results on lightweight white cab and thecompartmentswith the original cab performance, the performance of the lightweight white cab wasverified.
A new proposal of using lightweight coefficient as lightweight evaluatingmethod was made, and had been used to analysis and evaluates the lightweight levelof the white cab.
In order to assesswhether the lightweight design can meet the operatingrequirements, we developed a lightweight cab sample, measured the first10elasticmodal frequencies and mode shapes and their static bending and torsional stiffnesscharacteristics of the lightweight cab; the first torsional frequency and stiffnesscharacteristics were analyzedand compared between the original and lightweight cab.Although lightweight cab first torsional frequency and static bending and torsionstiffness decreased, but the first torsional frequencywas larger than16Hz, the bendingstiffness>14000N/mm and torsional stiffness35000Nm/°, which meaned that itcan meet the driving chamber stiffness and vibration characteristics requirements.Based on ECE R29Regulatory requirements, lightweight cab passive safetysimulation analysis and experimental research were performed, the results showedthat the lightweight cab can meet the ECER29regulatory requirement of frontpendulum impact, roof strength and rear wall strength.
The8000km road test results showed that the lightweight cab performed well during the test, the lightweight cab reliability can meet the reliability requirements.
After lightweight analysis and optimization, the cab reduced weight46kg in thecase of maintaining the same material and meeting the operating requirements.
Proposed and developed a frame-type lightweight commercial vehicle cab,optimized the structure and size of the cab frame, performed the model state analysis,strength, stiffness and passive safety analysis of the cab frame, and compared thecorresponding characteristics withthe original cab; The results showed that thedeveloped frame-type lightweight cab significantly improved the strength andstiffness, superior vibration characteristics, and can better meet ECER29passivesafety requirements. It was lighter95kg than the original cab.
The cab developed in this paper has been used for the production and sales ofheavy commercial vehicle cab and got good weight reduction and energy-savingeffect. The research results can be widely used as a common technology lightweightdesign on different commercial vehicle cab and play an important role to improvethe forward design capabilities of domestic heavy commercial vehicle cab,implementthe energy saving and emission reduction, enhanced competitiveness in internationalmarkets and promote industry technological progress.
引文
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