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Optimization of energy Absorber for a novel electric vehicle concept
Abstract
In the research project Next Generation Car (NGC) at the German Aerospace Center (DLR), three different novel vehicle concepts are being developed: Urban Modular Vehicle (UMV), Safe Light Regional Vehicle (SLRV) and Interurban Vehicle (IUV). The NGC project is the consolidation of tools, methods and technologies for the different vehicle concepts investigated by DLR in the field of transport. The motivation for this work was to find an optimized side crash concept for the Urban Modular Vehicle concept consisting of a door sill and a sandwich element for crash. For the development of the body in white of the NGC Urban Modular Vehicle different structure optimization strategies were used. From the analyses of global load paths, to the size and shape optimization of the floor panels were applied to increase crash performance. The focus of the presentation is on a nonlinear door sill optimization and a parametric sandwich optimization resulting in innovative solutions for car design and the identification of energy absorber mechanisms. The main field of observation by using parametric sandwich elements is to detect thickness and angle of the sandwich core for the required crash performance. For the interpretation of the topology results which defines the location of the structures different optimization tasks were required. The concept for the side impact crash of the Urban Modular Vehicle includes an energy absorbent door sill consisting out of sandwich elements. In the first step, the optimization of the door sill cross-section was done with a nonlinear topology approach. In the second step, a size and shape optimization of the sandwich crash concept were performed to increase the internal energy and to reduce the intrusion of the pole. In the end a final concept was developed according to different optimization results.
... 14. LS-DYNA Forum 2016, Bamberg © 2016 Copyright by DYNAmore GmbH Fig.7: Optimisation parameters of the energy sandwich absorber. [3] Step 8: ...
... Fig.9: Different internal structures of the door sill, which will be varied during optimisation. [3] 14. LS-DYNA Forum 2016, Bamberg ...
A methodological approach to the development of an optimised side crash concept for the battery-electric vehicle concept Urban Modular Vehicle was presented in order to meet the requirements of a fully functional concept. In addition to the load path analyses shown, and the subsequent energy absorption process, validation tests at a coupon and component level, as well as the optimisation models validated alongside these, have been demonstrated. To optimise the sandwich crash concept, the ‘morphing’ method was used to modify the geometry. This allows the main influential factors for energy absorption to be identified due to the buckling of the sandwich core, as well as allowing the determination of an optimal combination of the parameters being tested. One sole optimisation of the door sill structure was shown to be impractical, which led to the development of an analogical modelling, which yielded acceptable levels of accuracy (2.5% deviation for intrusion when compared to the full-vehicle simulation) and the best possible reduction in time (98% reduction when compared to the full-vehicle simulation ) to be achieved when optimising the internal structures of the door sill. The analogical model shows, above all else and with sufficient accuracy, the important area of deformation at the point of impact of the pole. The model also shows weaknesses in the free ends of the edge areas, which is of little importance here. Given that the variation in the door sill structure is equal to that of a discrete optimisation problem, a multi-level optimisation was used. The advantage of this is that each variant is optimised and then later compared with the discrete variants. One final check is made in the full-vehicle crash model in order to verify both the optimisation results and the analogical model. Furthermore, optimisation steps 7 and 8 improve the specific energy absorption by ~24%, and the intrusion by ~30%.
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