Abstract:

Robustness optimization and light-mass of side crash performance were performed for an ownedbrand
multi-purpose vehicle (MPV). The optimization method was a combination method based on discrete
design variables and noise factors, which including the design of experiments (DOE), the approximation model,
the Monte Carlo sampling technique, and the robust optimization based on a respond surface model, and
considering with the process parameters of side crash performance (the thicknesses of key parts) and the
differences of a crash load case (the position and the height of a movable barrier). A three-stage optimization
was used to analyzing the sensitivity, the deterministic, and the 6-sigma robustness for side crash. The results
show that the body structure mass is reduced by 4.60 kg, while the reliability of side crash performance is higher
than 99.97%, after the optimization. Therefore, the method ensures the accuracy of the approximate model to
meet the optimization requirements.

Key words: vehicle safety, side crash, light-mass, design of experiments (DOE), six sigma robustness
optimization, respond surface model