某电动汽车侧面柱碰工况门槛梁截面参数优化

doi:10.3969/j.issn.1674-8484.2024.06.002

摘要/Abstract

摘要：

某电动汽车侧面柱碰工况电池模组截面峰值力（F_max）超标，为提升电池碰撞安全性，同时实现车身轻量化，开展门槛梁截面参数优化。选取26个厚度及位置参数作为优化变量，以减小F_max和门槛梁质量作为目标，以电池模组最大挤压变形量（d_max）和塑性应变（ε_pmax）作为约束。首先通过最优Latin超立方生成样本，基于样本建立全连接神经网络近似模型，然后运用NSGA-Ⅱ算法开展多目标优化，最后将优化结果代入仿真进行验证。结果表明：优化后电池模组F_max由21.8 kN降低至20 kN以下，达到了安全要求；同时，门槛梁减重1.41%~4.02%，实现了轻量化效果。进一步分析表明，部分方案电池模组d_max和ε_pmax也同步降低，在减重的同时更全面地提升了电池的碰撞安全性。

关键词: 侧面柱碰, 电池安全, 近似模型, 轻量化, 有限元仿真

Abstract:

The peak section force (F_max) of battery modules of an electric vehicle exceeded the safety range under side pole collision condition. The parameter optimization of the sill beam section was carried out to improve battery collision safety and achieve weight reduction of the vehicle body. 26 thicknesses or position parameters were selected as optimization variables to reduce F_max and the mass of sill beam. The maximum compression deformation(d_max) and plastic strain(ε_pmax)of battery modules were chosen as constrains. Firstly, the optimal Latin hypercube method was employed to generate samples. A fully connected neural network was established as approximation model based on samples, and the non-dominated sorting genetic algorithms-Ⅱ(NSGA-Ⅱ) was employed for multi-objective optimization. Finally, optimization results were verified through simulation. The results show that the F_max of battery modules is decreased from 21.8 kN to less than 20 kN, indicating safety requirement is eventually satisfied. Meanwhile, the mass of sill beam is reduced by 1.41%~4.02%, which means lightweight design is also achieved. Further analysis shows that d_max and ε_pmax of battery modules are also reduced synchronously in some solutions, which improves battery collision safety comprehensively in the meantime of weight reduction.

Key words: side pole collision, battery safety, approximation model, lightweight, finite element simulation

中图分类号:

荣海, 蒋建中, 姚再起, 马凯. 某电动汽车侧面柱碰工况门槛梁截面参数优化[J]. 汽车安全与节能学报, 2024, 15(6): 813-820.

RONG Hai, JIANG Jianzhong, YAO Zaiqi, MA Kai. Parameter optimization of the sill beam section of an electric vehicle under side pole collision condition[J]. Journal of Automotive Safety and Energy, 2024, 15(6): 813-820.

图/表 13

参考文献 20

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	变量
	基础	方案1	方案2	方案3	方案4	方案5	方案6
t1	2.0	2.0	2.0	2.0	1.9	1.9	2.1
t2	3.0	2.9	2.9	2.9	2.8	2.8	3.3
t3	2.0	2.0	1.8	1.9	2.2	2.0	1.8
t4	1.8	1.8	1.9	1.9	1.9	1.8	1.8
t5	5.5	5.0	5.1	5.6	5.0	5.8	5.9
t6	3.0	3.2	3.0	3.1	3.0	3.2	2.9
t7	1.8	1.8	1.9	1.9	2.0	1.8	1.9
t8	6.0	5.7	6.5	5.8	5.7	6.3	6.3
t9	4.5	4.1	4.4	4.2	4.6	4.5	4.1
t10	3.0	2.8	2.9	2.7	2.7	2.9	2.7
t11	5.5	5.4	5.2	5.3	5.2	5.6	5.8
t12	5.5	5.3	5.2	5.2	5.5	5.3	5.4
t13	2.0	1.9	1.9	2.2	2.0	1.9	1.9
t14	1.8	1.9	1.9	1.8	1.8	1.9	1.9
t15	2.0	2.1	1.9	1.8	2.2	1.8	1.9
t16	1.8	2.0	1.9	2.0	2.0	1.8	2.0
t17	2.0	2.1	2.0	2.1	2.0	2.1	2.1
t18	2.0	1.9	1.8	1.8	2.0	1.9	1.9
t19	2.5	2.4	2.7	2.5	2.8	2.6	2.5
t20	3.0	3.1	2.9	2.9	3.1	2.7	2.8
t21	3.0	3.0	2.7	3.1	2.9	2.9	2.8
t22	3.0	3.2	3.1	2.7	3.1	2.9	3.2
s1	0	-0.3	+0.6	-0.7	+0.6	+0.9	-0.3
s2	0	-1.7	+1.9	+2.8	-0.3	-2.2	-1.5
s3	0	+4.2	-2.1	+4.5	-3.5	-0.1	-3.1
s4	0	-0.3	+3.3	+4.0	-0.1	-3.2	+1.9

	变量
	基础	方案1	方案2	方案3	方案4	方案5	方案6
t1	2.0	2.0	2.0	2.0	1.9	1.9	2.1
t2	3.0	2.9	2.9	2.9	2.8	2.8	3.3
t3	2.0	2.0	1.8	1.9	2.2	2.0	1.8
t4	1.8	1.8	1.9	1.9	1.9	1.8	1.8
t5	5.5	5.0	5.1	5.6	5.0	5.8	5.9
t6	3.0	3.2	3.0	3.1	3.0	3.2	2.9
t7	1.8	1.8	1.9	1.9	2.0	1.8	1.9
t8	6.0	5.7	6.5	5.8	5.7	6.3	6.3
t9	4.5	4.1	4.4	4.2	4.6	4.5	4.1
t10	3.0	2.8	2.9	2.7	2.7	2.9	2.7
t11	5.5	5.4	5.2	5.3	5.2	5.6	5.8
t12	5.5	5.3	5.2	5.2	5.5	5.3	5.4
t13	2.0	1.9	1.9	2.2	2.0	1.9	1.9
t14	1.8	1.9	1.9	1.8	1.8	1.9	1.9
t15	2.0	2.1	1.9	1.8	2.2	1.8	1.9
t16	1.8	2.0	1.9	2.0	2.0	1.8	2.0
t17	2.0	2.1	2.0	2.1	2.0	2.1	2.1
t18	2.0	1.9	1.8	1.8	2.0	1.9	1.9
t19	2.5	2.4	2.7	2.5	2.8	2.6	2.5
t20	3.0	3.1	2.9	2.9	3.1	2.7	2.8
t21	3.0	3.0	2.7	3.1	2.9	2.9	2.8
t22	3.0	3.2	3.1	2.7	3.1	2.9	3.2
s1	0	-0.3	+0.6	-0.7	+0.6	+0.9	-0.3
s2	0	-1.7	+1.9	+2.8	-0.3	-2.2	-1.5
s3	0	+4.2	-2.1	+4.5	-3.5	-0.1	-3.1
s4	0	-0.3	+3.3	+4.0	-0.1	-3.2	+1.9

	m / kg	F_max / kN	d_max / mm	ε_pmax
基础	19.14	21.80	4.98	0.32
方案1	18.37	19.54	4.92	0.31
方案2	18.41	19.14	4.43	0.27
方案3	18.67	18.24	4.43	0.29
方案4	18.71	18.13	4.41	0.37
方案5	18.81	18.05	4.16	0.3
方案6	18.87	17.55	3.93	0.38

	m / kg	F_max / kN	d_max / mm	ε_pmax
基础	19.14	21.80	4.98	0.32
方案1	18.37	19.54	4.92	0.31
方案2	18.41	19.14	4.43	0.27
方案3	18.67	18.24	4.43	0.29
方案4	18.71	18.13	4.41	0.37
方案5	18.81	18.05	4.16	0.3
方案6	18.87	17.55	3.93	0.38

	m / kg	F_max / kN	d_max / mm	ε_pmax	有效性
基础	19.14	21.80	4.98	0.32	/
方案1	18.37	18.89	4.32	0.28	有效
方案2	18.41	20.14	5.03	0.29	无效
方案3	18.67	18.74	4.01	0.33	有效
方案4	18.71	18.32	4.2	0.3	有效
方案5	18.81	18.55	5.07	0.35	无效
方案6	18.87	17.53	3.63	0.39	有效