CAECAE技术在汽车产品开发技术在汽车产品开发中的应用中的应用OutlineVehicle Product Development ProcessChery CAE CapabilitiesSafety CAE Application汽车新产品开发典型流程汽车新产品开发典型流程整车整车系统系统子系统子系统零部件零部件产品产品/流程流程设计设计目标分解目标分解设计验证设计验证优化优化设计设计/生产生产 确认确认下线下线/批量生产批量生产确认确认更新更新公司公司经验库经验库外型确定外型确定立项立项定义定义设计设计验证验证/下线下线System Engineering FundamentalCustomerMusts/WantsCustomerSatisfaction Vehicle level InputsPurchaser/owner/operatorRegulatory(FMVSS,EPA,)Corporate(WCR,ABS,Manuf, ) Vehicle level RequirementsVehicle AttributesVehicle System Specification-DSPurchase,Operate& Maintain VehicleVerification System/Subsystem levelSystem & Subsystem Design Specifications-SDS SystemVerificationDisposalpart/Component DesignComponent Design Spec-CDSpart/ComponentVerificationCustomer FocusCustomer Experience & FeedbackCustomerRequirementsDVM/DVPDVM/DVPRequirementsCascadeRequirementsCascadeRequirementsCascadeFeasibilityFeedbackFeasibilityFeedbackFeasibilityFeedbackHighly IterativeHighly IterativeProduction车身轻量化流程图车身轻量化流程图拓扑优化拓扑优化敏感性分析敏感性分析模态分析模态分析刚度分析刚度分析强度分析强度分析碰撞模拟与耐久性碰撞模拟与耐久性CAE验证验证最终车身减重方案最终车身减重方案车身轻量化车身轻量化CAECAE方案分析方案分析多个优化方案供选择多个优化方案供选择材料校核材料校核车身校核车身校核工艺校核工艺校核车身身减减重（重（863863项目）目）理论减重方案可减轻车身重量共计约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目前已经完成所有需调整零件（件（4套）的试冲，实际减重约套）的试冲，实际减重约19Kg，三台减重试验车于三台减重试验车于10月月12日日装配下线。装配下线。(与上海交通大学合作）与上海交通大学合作）奇瑞碰撞安全设计能力评估奇瑞碰撞安全设计能力评估1 1、CAECAE分析能力建设。分析能力建设。CAECAE部已具备了如下能力部已具备了如下能力前部碰撞：前部碰撞：中国标准，美国法规（FMVSS 208，USNCAP，IIHS），欧洲法规（ECE 94/33，EuroNCAP）侧面碰撞：侧面碰撞：中国标准，美国法规（FMVSS 214，USNCAP，IIHS），欧洲法规（ECE 95，EuroNCAP）后部碰撞：后部碰撞：美国法规（FMVSS 301），欧洲法规（ECE 32/34）车顶抗压：车顶抗压：美国法规（FMVSS 216）乘员保护：乘员保护：美国法规（FMVSS 208）2 2、逐步完善企业安全设计标准逐步完善企业安全设计标准3 3、完成、完成CAECAE安全分析指南安全分析指南碰碰撞撞安全安全设计标准准前部正面碰撞安全设计标准前部正面碰撞安全设计标准前部偏置碰撞安全设计标准前部偏置碰撞安全设计标准侧面碰撞安全设计标准侧面碰撞安全设计标准后部碰撞安全设计标准后部碰撞安全设计标准CAE is the primary tool for crash CAE is the primary tool for crash safety development and assessment safety development and assessment CAE is used at every stage of safety CAE is used at every stage of safety design and development processdesign and development processCAE is essential for product cycle CAE is essential for product cycle time reductiontime reductionSafety CAE in Product DevelopmentCAE在碰撞安全中的应用在碰撞安全中的应用CAE分析流程分析流程Frontal Impact EvaluationPredictionPredictionConfidence LevelConfidence LevelCrash PulseCrash PulseHighHighIntrusion/DeformationIntrusion/DeformationHighHighRestraint PerformanceRestraint PerformanceMediumMediumOccupant ResponseOccupant ResponseMediumMediumFuel System IntegrityFuel System IntegrityLowLowDoor OpenabilityDoor OpenabilityLowLowConfidence LevelHIGHHIGH= Predicts trend and magnitude within the test variability= Predicts trend and magnitude within the test variabilityMEDIUMMEDIUM= Predicts trend within 20% of test= Predicts trend within 20% of testLOW LOW = Cannot predict trend and magnitude= Cannot predict trend and magnitudeChery will continue its effort in safety CAE technology forImproved safety protectionImproved safety protectionCost effective product developmentCost effective product developmentLight weight safety design for better fuel Light weight safety design for better fuel economyeconomySafety ChallengesSafety ChallengesMore Stringent Safety RequirementsNew 208, IIHS Offset, IIHS Side, R/O, OOPReduce feasible solution domainIncrease of Advance Restraint SystemAdaptive Venting/Column/Load Limiter, Tether Bag, Dual Pyro, IKB, SIR, OCS.Certification complexityStyling demands shorter front endAchieve Leadership w. min. weight, cost, and time Safety CAE PhilosophySafety CAE PhilosophyPrediction instead of correlationModel the physics correct will ensure good predictionsDesign for success instead of predict for failure (Design focus instead of Verification focus)Robustness Needs to be consideredDeliver high quality safety while meeting ABSSafety CAE TrendsSafety CAE TrendsLead Design More involvement in defining architectural and upfront targeting processCAE is not equal to FEAIntegrate all possible tools. Use the most effective tool at different stagesMore discipline CAE approaches (CAE QOS)Incorporate Opt/Robustness tool setWell-round safety background Improve predicting capabilitySafety Action PlanSafety Action PlanPeoplePeopleSafety Engineering mindsetSafety Engineering mindsetDiscipline in following CAE Quality ProcessDiscipline in following CAE Quality ProcessOut-of-Box thinkingOut-of-Box thinkingLead design mindsetLead design mindsetProcessProcessSafety CAE QOSSafety CAE QOSStandardized Safety Development ProcessStandardized Safety Development ProcessEstablish Safety KBEEstablish Safety KBETechnologyTechnologyResolve CAE GapsResolve CAE GapsBuild Opt/Robustness Tool setsBuild Opt/Robustness Tool setsProcess Integration toolsetProcess Integration toolsetDevelopment of Safety Feature19601970198019902000?.brake assistACCABSESPtraction controlactive suspensionlane detectioncollision mitigation (auto brake)active steeractive driver assist.- Active safety feature Active safety enablerV-V / V-I comm.safety cellsafety beltscrumple zonefront bagadvanced seat beltsside impact protectionside airbag- Passive safetyhead restraintssafety pedalsadaptive restraintscompatibilitySafety potentialRSCactive accidentactive accidentavoidanceavoidancesteer by wireblind spotdriver stateshort range radarLR radarGovernment regs/infras.brake by wirethrottle by wireIndustry standardssensor fusion(rdr+vis)vision systemlane keeping assistUCC/UCW* Many of these technologies have significant technical hurdles; implementation cannot occur if they are not overcome.Technology GapsStructure - 1Rupture, Failure, separationRupture, Failure, separationWeld Weld Body Mounts, Engine MountsBody Mounts, Engine MountsMagnesium IP, Magnesium Radiator SupportMagnesium IP, Magnesium Radiator SupportFastenerFastenerLCALCAFrameFrameFuel pipe/fuel rail/fuel tank/sender unitFuel pipe/fuel rail/fuel tank/sender unitLatch failureLatch failureOther Material - Nylon insert, foam, HoneycombOther Material - Nylon insert, foam, HoneycombWindshield DelaminatingWindshield DelaminatingMechanical Behavior/KinematicsTire rotation in offsetVehicle Pitch and rotationOccupant KinematicsDoor open mechanism (inertia/intrusion)Fuel tank kinematicsVehicle kinematics during roll overSuspension/Steering kinematicsTechnology GapsStructure - 2InaccuracyBody Mounts - Inaccuracy of Body PulseThick shell performance - Frame pulseContact force predictionOther material - foam, nylon, plastic, Honeycomb Local prediction (crash zone)Technology GapsStructure - 3FutureFutureCombine structure and occupantBetter model of interior (IP, St. Col., KB, Belt, Bag, .)Better prediction of angular, offset, VtVRobustness analysis - mindset changesTarget Cascading capabilityBest solution on performance and cost结束！结束！