Intelligent Car Body. Fachhochschule Aachen Fachbereich Luft- und Raumfahrttechnik Lehr- und Forschungsgebiet Karosserietechnik

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1 Fachhochschule Aachen Fachbereich Luft- und Raumfahrttechnik Lehr- und Forschungsgebiet Karosserietechnik Intelligent Car Body A Design Approach for Construction of a Virtual Car Body for Small Sized Batch Production based on LS-DYNA simulations M.Sc. Anuja Nagle / FH Aachen Prof. Dr.-Ing. T. Roeth / Imperia GmbH 11 th LS-DYNA Forum th 10th October 2012

2 Contents Introduction What is Intelligent Car Body - ICB Motivation Features of ICB The Flexbody Methodology of ICB Fields of Intelligence in ICB Structural Intelligence Attribute Configurator Section Configurator Virtual Validation Final remarks Contact FH AACHEN UNIVERSITY OF APPLIED SCIENCES 18. Oktober

3 What is Intelligent Car Body - ICB Intelligent Car Body is an approach, which aims at: Creating a tool which can guide the design engineer through the car body construction process in the initial design stages Constructing a car body which possesses intelligence in the fields of construction, manufacturing techniques and structural performance ICB FH AACHEN UNIVERSITY OF APPLIED SCIENCES 18. Oktober

4 Motivation Challenges for small sized batch production Restricted knowledge for design High development time High development costs High capital investment Fast launching in market Intelligent Car Body (ICB) FH AACHEN UNIVERSITY OF APPLIED SCIENCES 18. Oktober

5 The Flexbody Flexbody construction concept + + = Topology Profiles Joints Car body Source: Imperia GmbH Flexbody is advantageous for small series vehicle production Optimizes production cost according to batch size Quick adaption to meet individual vehicle specifications FH AACHEN UNIVERSITY OF APPLIED SCIENCES 18. Oktober

6 Methodology: Intelligent Car Body Vehicle Base Information Level of Intelligence Attribute Configurator Topology Configurator Section Configurator Joint Configurator ec2go e-car-sharing Source: FH Aachen Conventional CAE methods Virtual Validation Lampo3 Source: Protoscar / TK-SE / Imperia GmbH Geometrical Intelligence Manufacturing Intelligence Structural Intelligence / CAE data FH AACHEN UNIVERSITY OF APPLIED SCIENCES 18. Oktober

7 Fields of Intelligence in ICB ICB employes knowlegdebase at three levels Geometrical Intelligence For parametric CAD construction Manufacturing Intelligence For selection of materials and manufacturing processes Structural Intelligence For optimum design of profile cross sections Step 1: Topology Step 2: Profiles Profile database Load distribution Analytical evaluation Step 3: Joints Joint database Profile selection FH AACHEN UNIVERSITY OF APPLIED SCIENCES 18. Oktober

8 Structural intelligence Aim: To predict the structural performance of a car body in early design stages and hence reduce the optimization time. Attribute Configurator Targets for structural performance Section Configurator Validation of analytical basics Using knowledge gained through simulations Structurally intelligent car body FH AACHEN UNIVERSITY OF APPLIED SCIENCES 18. Oktober

9 a. Attribute Configurator: Safety Model Step 1: Creating a Safety Model for the target car body Safety Model Static stiffness Roof Rear Frontal Pole Side Level 0: mandatory 1: recommended 2: best-in-class Selected loadcases Level 0 2 FH AACHEN UNIVERSITY OF APPLIED SCIENCES 18. Oktober

10 a. Attribute Configurator: Benchmark Step 2: Generating a benchmark using numerical simulations Chrysler Neon Ford Taurus Knowledge gained from the numerical simulations Typical trends of force-displacement curves Energy of deformation Distribution of deformation energy in the car body components FH AACHEN UNIVERSITY OF APPLIED SCIENCES 18. Oktober

11 a. Attribute Configurator: Targets definition Step 3: Defining performance level for the target car body* Distribution of energy during deformation 75-80% 20-25% Frontal against rigid wall Car body Other parts Targets for individual profiles Targets Mode of deformation Profiles having high influence *Example for frontal FH AACHEN UNIVERSITY OF APPLIED SCIENCES 18. Oktober

12 b. Section Configurator: Types of loads Modes of deformation observed in Flexbody profiles Axial folding Crumpling Mixture of folding and bending Source: ec2go, FH Aachen Components not loaded to their full capacity Basic modes of deformation (-> simple loads) Axial failure Bending failure FH AACHEN UNIVERSITY OF APPLIED SCIENCES 18. Oktober

13 b. Section Configurator: Analytical Basics Available analytical models for simple loads Quasi-static loading Axial Bending Square / rectangle Circle Square / rectangle Circle Axisymmetric deformation Non-axisymmetric deformation Mahmood / Paluszny (1981) Abramowicz / Jones (1986) Mahmood / Paluszny (1984) Abramowicz / Jones (1986) Wierzbicki (1992) Singace (1995, 1999) Mahmood / Paluszny (1984) Abramowicz / Jones (1986) Kecman (1983) FH AACHEN UNIVERSITY OF APPLIED SCIENCES 18. Oktober

14 b. Section Configurator: Validation Validation of analytical models for simple loads Test and simulation data Three point bending Axial compression Comparison with analytical models Models for different types of loads 250,00 200,00 150,00 100,00 50,00 0,00 run01 run06 run10 run12 run26 run29 run30 run32 run37 run39 run53 run54 run57 FH AACHEN UNIVERSITY OF APPLIED SCIENCES 18. Oktober

15 c. Virtual Validation Validating the constructed car body for various loadcases NVH Static stiffness Dynamic stiffness Component based (ICB approach) Complete vehicle (CAE) Vehicle testing X X no Crash / Crush X X optional Durability no optional X Static stiffness Roof Rear Frontal Pole Side FH AACHEN UNIVERSITY OF APPLIED SCIENCES 18. Oktober

16 Final remarks Advantages of the proposed approach Connects various steps in car body development process in a logical order and hence facilitates transfer of data Data is generated from CAD / CAE and is proposed to use as knowledgebase for car body design FH AACHEN UNIVERSITY OF APPLIED SCIENCES 18. Oktober

17 Contact Thank you for your attention! M.Sc. A. Nagle Automotive Body Engineering University of Applied Science Aachen Boxgraben Aachen Tel.: 0241/ Prof. Dr.-Ing. T. Roeth Imperia GmbH University of Applied Science Aachen Soerser Weg Aachen Tel.: 0241/ roeth@imperia.info FH AACHEN UNIVERSITY OF APPLIED SCIENCES 18. Oktober