2 nd European HyperWorks Technology Conference Strasbourg September 30 th October 1 st, Welcome! 1/30

Transcription

1 2 nd European HyperWorks Technology Conference Strasbourg September 30 th October 1 st, 2008 Welcome! 1/30

2 2 nd European HyperWorks Technology Conference Strasbourg September 30 th October 1 st, 2008 Door slam simulation for durability analysis with Multibody Dynamics Takeshi Inoue TOYOTA AUTO BODY CO.,LTD. Computer Aided Engineering Div. Hiroaki Hoshino Altair Engineering September 30 th October 1 st /30

3 2 nd European HyperWorks Technology Conference Strasbourg September 30 th October 1 st, 2008 Company Profile TOYOTA AUTO BODY CO.,LTD. Toyota Auto Body is developing and producing minivans, SUVs and commercial vehicles as a main Toyota affiliate. Products Line-up ALPHARD NOAH/ VOXY ESTIMA ESTIMA HYBRID IPSUM Freezer vehicle Container van Load labor-saving vehicle COASTER SCHOOL BUS HIACE FREEZER PRIUS LAND CRUISER 200 LEXUS LX570 LAND CRUISER 70 PICKUP LAND CRUISER 70 HARDTOP HIACE REGIUSACE HIACE (for Europe) COASTER Wheelchair-customized Vehicle Transport of People with Reduced Mobility Wheelchair-customized vehicle(ramp-type) Vehicle with lift seat for rear passenger Vehicle with lift seat for front passenger Automatic Rotating and Sliding Passenger Seat Barrier free device Electric Vehicle Everyday Urtra Small Electric Vehicle COMS 3/30

4 2 nd European HyperWorks Technology Conference Strasbourg September 30 th October 1 st, 2008 Contents Door slam simulation for durability analysis with Multibody Dynamics 1. Doors of passenger car 2. Background and Objective 3. Door slam simulation 3-1. Simulation flow 3-2. Simulation conditions 3-3. Results validation 3-4. Accuracy improvement 4. Future plan Application to other door types and durability evaluation 5. Conclusion 4/30

5 2 nd European HyperWorks Technology Conference Strasbourg September 30 th October 1 st, 2008 Contents Door slam simulation for durability analysis with Multibody Dynamics 1. Doors of passenger car 2. Background and Objective 3. Door slam simulation 3-1. Simulation flow 3-2. Simulation conditions 3-3. Results validation 3-4. Accuracy improvement 4. Future plan Application to other door types and durability evaluation 5. Conclusion 5/30

6 2 nd European HyperWorks Technology Conference Strasbourg September 30 th October 1 st, 2008 Doors of passenger car Hood Side door Hatch Doors should fulfill the required functions fully in door open-close operations during whole car life. Sliding door Tail Gate Trunk 6/30

7 2 nd European HyperWorks Technology Conference Strasbourg September 30 th October 1 st, 2008 Contents Door slam simulation for durability analysis with Multibody Dynamics 1. Doors of passenger car 2. Background and Objective 3. Door slam simulation 3-1. Simulation flow 3-2. Simulation conditions 3-3. Results validation 3-4. Accuracy improvement 4. Future plan Application to other door types and durability evaluation 5. Conclusion 7/30

8 Door open-close durability evaluation conventional approach Issues Need the test of original vehicle Much cost and time Unable to change design for different input condition Need re-test! CAE Test Open-close durability with prototype Static analysis Proposal of design modification - Input (Lock, Cushion rubber) - Crack information Unable to evaluate by CAE without information from test 8/30

9 Objective Complete the evaluation without real thing Able to respond to any kind of design modification Design Reduction of number of test reduces design cost and development time CAE Dynamic analysis Geometry & Property Door behavior simulation Structure modification Stress analysis Life evaluation Test In-house system Close-open durability test 9/30

10 Door slam simulation for durability analysis with Multibody Dynamics Contents 1. Doors of passenger car 2. Background and Objective 3. Door slam simulation Simulation flow Simulation conditions Results validation Accuracy improvement 4. Future plan Application to other door types and durability evaluation 5. Conclusion 10/30

11 Study of Door behavior simulation Estimate the load acting on door during door closing Consider the non-linearity of displacement-load characteristics of lock, seal and rubber Car body is assumed as rigid Consider the door flexibility Study the simulation on the front door as initial step Clear the locations and requirements for design modification Apply to other types of door 11/30

12 Door slam simulation for durability analysis with Multibody Dynamics Contents 1. Doors of passenger car 2. Background and Objective 3. Door slam simulation 3-1. Simulation flow 3-2. Simulation conditions 3-3. Results validation 3-4. Accuracy improvement 4. Future plan Application to other door types and durability evaluation 5. Conclusion 12/30

13 Flow of door slam simulation CAD data Build MBD model Define simulation conditions Analysis FEM model creation MotionSolve MotionView HyperMesh Modal properties **.mrf (Plot) Load time history **.h3d (Animation) Deformation OptiStruct/Analysis **.h3d (Flexible body) HyperGraph HyperView 13/30

14 Door slam simulation for durability analysis with Multibody Dynamics Contents 1. Doors of passenger car 2. Background and Objective 3. Door slam simulation 3-1. Simulation flow 3-2. Simulation conditions 3-3. Results validation 3-4. Accuracy improvement 4. Future plan Application to other door types and durability evaluation 5. Conclusion 14/30

15 Model conditions Whether-strip load property Load Lock position Close velocity definition Lock load property Revolute joints Displacement Load property Cushion rubber load property Load = F = Stiffness + Damping Kx + Cv Load F= Disp + Damping coefficient * velocity Load locations Weather-strip Cushion rubber Lock 15/30

16 Door slam simulation for durability analysis with Multibody Dynamics Contents 1. Doors of passenger car 2. Background and Objective 3. Door slam simulation 3-1. Simulation flow 3-2. Simulation conditions 3-3. Results validation 3-4. Accuracy improvement 4. Future plan Application to other door types and durability evaluation 5. Conclusion 16/30

17 Simulation results Deformation Scale 30 Load time history 17/30

18 Measuring positions Load at door lock Acceleration at door lock Original model validation Acceleration at door lock Test Original acceleration Load at upper rubber Load at lower rubber smaller level after initial peak Load at door lock time larger lock damping Test Original Load at upper rubber Load at lower rubber load Test Original load load Test Original time Need to tune the damping of lock and cushion rubber respectively time larger load at first & second peaks time smaller cushion rubber damping 18/30

19 Door slam simulation for durability analysis with Multibody Dynamics Contents 1. Doors of passenger car 2. Background and Objective 3. Door slam simulation 3-1. Simulation flow 3-2. Simulation conditions 3-3. Results validation 3-4. Accuracy improvement 4. Future plan Application to other door types and durability evaluation 5. Conclusion 19/30

20 Flow of model accuracy improvement Geometry HyperMesh Input data Analysis MotionSolve OptiStruct / Analysis **.h3d (Flexible Body) HyperStudy HyperGraph Build MBD model Define simulation conditions Comparison to test results No Yes MotionView End 20/30

21 Damping optimization (HyperStudy) {parameter(lock,"cl", 1,10, 100)} {parameter(srubber,"cs", 2, 20, 200)} {parameter(wstrip,"cw", 1, 10, 100)} < Design variables > <Force_Vector_OneBody id = "30101" type = "ForceOnly" marker_id = " " ref_marker_id = " " fx_expression = "0" fy_expression = "VARVAL( )+{Lock, %8.5f}*VY( , )" fz_expression = "0" /> <Force_Vector_OneBody id = "30103" type = "ForceOnly" marker_id = " " ref_marker_id = " " fx_expression = "0" fy_expression = "VARVAL( )+{Srubber, %8.5f}*VY( , )" fz_expression = "0" /> <Force_Vector_OneBody id = "30105" type = "ForceOnly" marker_id = " " ref_marker_id = " " fx_expression = "0" fy_expression = "VARVAL( )+{WStrip, %8.5f}*VY( , )" fz_expression = "0" /> Lock Stopper rubber Weather strip 21/30

22 Damping optimization (HyperStudy) < Objective > Minimize SQRT(a^2+b^2+c^2+d^2) sqrt((max({v_1})-f0)^2+(min({v_1})+f1)^2+(max({v_2})-f2)^2+(max({v_3})-f3)^2) Load at upper rubber v_2 Load at door lock v_1 v_3 a Load f0 Load at lower rubber Time f2 c f3 Time f1 d Time b 22/30

23 Measuring positions Load at door lock Acceleration at door lock Modified model validation Acceleration at door lock Test Modify acceleration Load at upper rubber Load at lower rubber Load at door lock Similar to test results time Load at upper rubber Test M odify Load at lower rubber Test Modify load load load test Modify time time time 23/30

24 Door slam simulation for durability analysis with Multibody Dynamics Contents 1. Doors of passenger car 2. Background and Objective 3. Door slam simulation Simulation flow Simulation conditions Results validation Accuracy improvement 4. Future plan Application to other door types and durability evaluation 5. Conclusion 24/30

25 Future plan Application to other type door (Backdoor) 25/30

26 Future plan Application to other door type (Slide door) 26/30

27 Future plan Durability evaluation Geometry MotionSolve HyperMesh HyperStudy Eigen vectors Modal composite OptiStruct / Analysis **.h3d (Flexible body) In-house tool or FEMFAT strain MotionView (Build MBD model) time Validation of stress time history 27/30

28 Door slam simulation for durability analysis with Multibody Dynamics Contents 1. Doors of passenger car 2. Background and Objective 3. Door slam simulation Simulation flow Simulation conditions Results validation Accuracy improvement 4. Future plan Application to other door types and durability evaluation 5. Conclusion 28/30

29 Conclusion Developed the process of front door slam simulation in HyperWorks MultiBody dynamics technology for door slam System identification to estimate the damping coefficient to correlate with test results Confirm the ability to simulate the door slam test in HyperWorks Future plans Apply this technology to other types of door Door durability evaluation Use the developed process to product design from now 29/30

30 Thank you for your attention! 30/30