Control method and device for producing a vehicle component

Abstract

The application relates to a control method and device for producing a vehicle part. The control method for producing the vehicle part comprises the following steps: obtaining an optimized vehicle part model based on a topological optimization of an original model; splitting the vehicle part model into a main part and a supplementary part; obtaining a main structure of the vehicle part through 3D printing according to the main part; and obtaining a supplementary structure through 3D printing on the basis of the main structure according to the supplementary part, so as to obtain the vehicle part. The control method for producing the vehicle part adopts a topological optimization method, and then a vehicle part model with a complex structure is printed through 3D printing. Before printing, the vehicle part model is split into two smaller parts, so that a 3D printing device can be used to produce a vehicle part exceeding the printing range. The control method for producing the vehicle part can realize a process from lightweight design to actual production for the vehicle part, and a vehicle part with a higher lightweight degree can be obtained.

Description

Technical Field

[0001] This application relates to the field of vehicle manufacturing technology, and in particular to a control method and apparatus for producing vehicle parts. Background Technology

[0002] In the course of development, the automotive industry is increasingly pursuing lightweight vehicles, especially for new energy commercial vehicles. Lightweighting is significant for improving their carrying capacity and driving range, and vehicle lightweighting depends on the lightweighting of various components.

[0003] Vehicle components are typically designed for lightweighting beforehand, followed by mold and process design, and finally production verification through casting, stamping, forging, etc. However, due to limitations in subsequent production processes, it is difficult to produce complex lightweight structures, thus greatly restricting lightweighting and resulting in products with limited lightweighting. Summary of the Invention

[0004] Therefore, it is necessary to provide a control method for producing vehicle components that can produce vehicle components with a higher degree of lightweighting, in order to address the above-mentioned problems.

[0005] Firstly, this application provides a control method for producing vehicle components. The method includes:

[0006] Obtain the original model of the vehicle component to be produced, and call the topology optimization software to perform topology optimization based on the original model to obtain the optimized vehicle component model;

[0007] The vehicle component model is divided into a main part and a supplementary part;

[0008] The main structure of the vehicle component is obtained by 3D printing based on the main body.

[0009] The supplementary structure is obtained by 3D printing based on the main structure to obtain the vehicle component.

[0010] In one embodiment, obtaining an original model of the vehicle component to be manufactured, and then using topology optimization software to perform topology optimization based on the original model to obtain an optimized vehicle component model, includes:

[0011] Obtain the original model of the vehicle component to be produced, determine the original model as the current target model, and determine the optimization area of ​​the current target model;

[0012] Obtain the boundary conditions for topology optimization, wherein the boundary conditions include the maximum design space;

[0013] Based on the boundary conditions, the finite element analysis software is invoked to perform topology optimization calculations on the optimization region of the current target model, and the calculation results are obtained.

[0014] Based on the calculation results and the maximum design space, a geometric reconstruction is performed to obtain an initial optimization model;

[0015] The performance of the initial optimized model was verified using finite element simulation software.

[0016] If the performance verification is passed, the initial optimized model will be output as the vehicle component model.

[0017] In one embodiment, after calling finite element simulation software to perform performance verification on the initial optimized model, the method further includes:

[0018] If the performance verification fails, the verification result is obtained;

[0019] Based on the verification results and the current initial optimization model, the current target model and its optimization region are redefined, and the process returns to the step: according to the boundary conditions, the finite element analysis software is called to perform topology optimization calculations on the optimization region of the current target model to obtain the calculation results.

[0020] In one embodiment, the current target model and its optimization region are re-determined based on the verification results and the current initial optimization model, including:

[0021] The initial optimization model is redefined as the current target model;

[0022] Based on the verification results, the current target model is divided into regions that pass the verification and regions that fail the verification.

[0023] The regions that failed the verification are redefined as the current optimization regions of the target model.

[0024] In one embodiment, based on the boundary conditions, finite element analysis software is invoked to perform topology optimization calculations on the optimization region of the current target model, and the calculation results are obtained, including:

[0025] Determine the location information of the assembly holes within the maximum design space in the optimized region;

[0026] Based on the assembly hole location information, the optimized area located within the maximum design space is divided into a design domain and a non-design domain;

[0027] The design domain is subjected to topology optimization calculation based on the boundary conditions to obtain the calculation results.

[0028] In one embodiment, obtaining the main structure of the vehicle component by 3D printing based on the main body portion includes:

[0029] The printing process for the main body is designed to obtain a main body printing model;

[0030] A 3D printing simulation software was used to perform a printing feasibility analysis on the main printing model.

[0031] If the printing feasibility analysis is not passed, return to step: design the printing process for the main body.

[0032] If the printing feasibility analysis is passed, the main semi-finished product can be obtained by SLM printing based on the main printing model;

[0033] The main body semi-finished product is wire-cut using a wire cutting device to obtain the main body structure.

[0034] In one embodiment, obtaining the supplementary structure by 3D printing based on the supplementary portion on the main structure includes:

[0035] The supplementary structure is obtained by LSF printing based on the main structure, according to the supplementary part.

[0036] The supplementary structure is subjected to heat treatment using heat treatment equipment.

[0037] In one embodiment, the step of designing the printing process for the main body to obtain a main body printing model includes:

[0038] Add auxiliary structures and machining allowances to the main body to obtain the main body printing model;

[0039] The auxiliary structure includes auxiliary reinforcing ribs, printing supports, and a process table.

[0040] In one embodiment, after obtaining the semi-finished body through SLM printing based on the main body printing model, the method further includes:

[0041] The main semi-finished product is subjected to heat treatment using heat treatment equipment.

[0042] In one embodiment, the step of splitting the vehicle component model into a main part and a supplementary part includes:

[0043] To obtain the maximum print size of the 3D printing equipment;

[0044] The size of the overlapping area is determined by matching the maximum print size with the size of the vehicle component model.

[0045] The vehicle component model located within the overlapping area is designated as the main body, and the vehicle component model located outside the overlapping area is designated as the supplementary body.

[0046] In one embodiment, after obtaining the supplementary structure by 3D printing based on the supplementary portion on the main structure to obtain the vehicle component, the method further includes:

[0047] The vehicle components are machined and post-processed.

[0048] Secondly, this application also provides an apparatus for producing vehicle parts. The apparatus includes:

[0049] The topology optimization module is used to obtain the original model of the vehicle component to be produced, and to call the topology optimization software to perform topology optimization based on the original model to obtain the optimized vehicle component model.

[0050] The splitting module is used to split the vehicle component model into a main part and a supplementary part;

[0051] The first printing module obtains the main structure of the vehicle component through 3D printing based on the main body portion; and

[0052] The second printing module obtains the supplementary structure based on the main structure through 3D printing, according to the supplementary part, so as to obtain the vehicle part.

[0053] The aforementioned control method and apparatus for producing vehicle parts utilize topology optimization to optimize the original model, resulting in a complex yet highly lightweight vehicle part model. This complex model is then 3D printed. Simultaneously, before printing, the vehicle part model is split into two smaller parts, which are then 3D printed in two steps to obtain the complete vehicle part. This overcomes the limitations of the 3D printing equipment's printing range, enabling its use in producing large-sized vehicle parts exceeding its printing capacity. The control method for producing vehicle parts enables a streamlined process from lightweight design to actual production, ultimately resulting in vehicle parts with an even higher degree of lightweighting. Attached Figure Description

[0054] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0055] Figure 1This is one of the flowcharts illustrating a control method for producing vehicle components according to an embodiment of this application.

[0056] Figure 2 This is a schematic diagram of a vehicle component model in one embodiment of this application.

[0057] Figure 3 for Figure 2 The diagram shown illustrates the vehicle component model broken down into a main body and supplementary parts.

[0058] Figure 4 for Figure 2 A schematic diagram showing the main body after the printing process design.

[0059] Figure 5 for Figure 2 This is a schematic diagram from another angle after the main body has undergone printing process design.

[0060] Figure 6 This is a second schematic flowchart of a control method for producing vehicle components according to an embodiment of this application.

[0061] Figure 7 This is the third flowchart illustrating the control method for producing vehicle components in one embodiment of this application.

[0062] Figure 8 This is the fourth flowchart illustrating a control method for producing vehicle components according to one embodiment of this application.

[0063] Figure 9 This is the fifth flowchart illustrating a control method for producing vehicle components according to an embodiment of this application.

[0064] Figure 10 This is a schematic flowchart of the control method for producing vehicle components in one embodiment of this application.

[0065] Figure 11 This is the seventh flowchart illustrating a control method for producing vehicle components according to an embodiment of this application.

[0066] Figure 12 This is the eighth flowchart illustrating a control method for producing vehicle components according to an embodiment of this application.

[0067] Figure 13 This is the ninth flowchart illustrating a control method for producing vehicle components according to an embodiment of this application.

[0068] Figure 14 This is the tenth flowchart illustrating a control method for producing vehicle components according to an embodiment of this application.

[0069] Figure 15 This is eleventh of a flowchart illustrating a control method for producing vehicle components according to an embodiment of this application.

[0070] Figure 16 This is a structural block diagram of an apparatus for producing vehicle parts according to one embodiment of this application.

[0071] Explanation of reference numerals in the attached drawings: 100, vehicle component model; 10, main body; 30, supplementary part; 50, auxiliary reinforcing rib; 70, printing support; 90, process table; 200, printing substrate; 301, topology optimization module; 303, splitting module; 305, first printing module; 307, second printing module. Detailed Implementation

[0072] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0073] In the description of this application, it should be understood that if terms such as "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential" appear, these terms indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0074] Furthermore, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects have an "or" relationship. The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of those features. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0075] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0076] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0077] It should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0078] As described in the background section, existing production methods face the challenge of manufacturing products with complex structures. Furthermore, increasing lightweighting often necessitates increasing structural complexity, making the limitations of current production methods a significant factor hindering improvements in vehicle lightweighting. While 3D printing technology might be considered for producing complex structures, its application is largely limited to relatively small parts due to the printing range of 3D printing equipment. For vehicles, especially commercial vehicles, the components requiring lightweighting are often large. In summary, current production methods force products to maintain relatively simple structures, resulting in limited lightweighting. This manifests in the design phase as conservative lightweighting designs with low levels of lightweighting. Therefore, a comprehensive solution for lightweighting vehicle components, from design to production, is currently lacking.

[0079] Based on the background technology and the above statements, please refer to Figures 1 to 3One embodiment of this application provides a control method for producing vehicle components, including:

[0080] S10. Obtain the original model of the vehicle component to be produced, and call the topology optimization software to perform topology optimization based on the original model to obtain the optimized vehicle component model 100.

[0081] S30. Disassemble the vehicle component model 100 into a main part 10 and a supplementary part 30;

[0082] S50. Obtain the main structure of the vehicle component by 3D printing based on the main body 10;

[0083] S70. Based on the main structure, the supplementary structure is obtained by 3D printing according to the supplementary part 30 to obtain the vehicle parts.

[0084] The original model refers to a model that has not yet undergone structural optimization. Models that have undergone some structural optimization can also be used directly as the original model, or models restored to their original state after optimization can be used as the original model. The original model can be stored, transferred, calculated, or retrieved in the form of information data. Products directly produced based on the original model have low lightweighting, therefore the original model is a model that needs optimization. After topology optimization based on the original model, a structurally optimized vehicle component model 100 can be obtained. Vehicle components produced based on vehicle component model 100 have significantly better lightweighting. The topology optimization software used can include finite element analysis software, finite element simulation software, and other software and tools that can be used to implement topology optimization.

[0085] 3D printing is achieved by using 3D printing equipment. The vehicle part model 100 is divided into two parts: a main part 10 and a supplementary part 30. Each part can be used independently as a production model and is 3D printed using the 3D printing equipment. The structure printed from the main part 10 is the main structure, and the structure printed from the supplementary part 30 is the supplementary structure. The supplementary structure can be multiple spatially separate structures. In essence, the vehicle part model 100 is divided into two parts and printed sequentially: first, the main structure is printed, and then the supplementary structure is printed based on the main structure. The supplementary structure printed on the main structure naturally combines with the main structure to form the target vehicle part.

[0086] In one embodiment, the vehicle component can be the vehicle subframe. Understandably, the vehicle component can also be other components in the vehicle, such as frame longitudinal beams, frame crossbeams, suspensions, etc., without specific limitations.

[0087] The aforementioned control method for producing vehicle components utilizes topology optimization to refine the original model, resulting in a complex yet highly lightweight vehicle component model 100. This complex model is then 3D printed. Simultaneously, before printing, the vehicle component model 100 is disassembled into two smaller parts, which are then 3D printed in two steps to obtain the complete vehicle component. This overcomes the limitations of the 3D printing equipment's printing range, enabling its use in producing large-sized vehicle components exceeding its printing capacity. This control method for producing vehicle components enables a streamlined process from lightweight design to actual production, ultimately resulting in vehicle components with an even higher degree of lightweighting.

[0088] The control methods for the aforementioned production vehicle components can be implemented manually by operators or automatically by computer programs, and no specific limitations are made here.

[0089] Please see Figures 4 to 6 In some embodiments, step S50, namely the step of obtaining the main structure of the vehicle component by 3D printing based on the main body 10, includes:

[0090] S51. Design the printing process for the main body 10 to obtain the main body printing model;

[0091] S53. Use 3D printing simulation software to perform a printing feasibility analysis on the main printing model;

[0092] S55. Determine whether the main printing model has passed the printing feasibility analysis. If it has not passed the printing feasibility analysis, return to step S51, i.e., step: design the printing process for the main body 10.

[0093] S57. If the printing feasibility analysis is passed, the main semi-finished product can be obtained by printing the main printing model using SLM (Selective Laser Melting).

[0094] S59. Use wire cutting equipment to wire cut the main semi-finished product to obtain the main structure.

[0095] After the main body 10 undergoes printing process design, a main body printing model for printing can be obtained. This model requires a printing feasibility analysis, specifically using Simufact Additive software. The feasibility of the existing printing process design is judged based on simulation results of printing thermal deformation and thermal stress. Understandably, if the printing feasibility analysis fails, it indicates a printing quality risk, requiring a redesign of the printing process, especially for areas with quality risks, to enhance their strength, and a re-analysis of feasibility. If there is no quality risk, printing can proceed. SLM printing is performed directly on the printing substrate 200, with a selectable printing thickness of 0.04mm, resulting in a semi-finished main body. This semi-finished product is then processed by wire cutting to obtain the main body structure.

[0096] Please refer to the following: Figure 7 Furthermore, step S51, namely the step of designing the printing process for the main body 10 to obtain the main body printing model, includes:

[0097] Add auxiliary structures and machining allowances to the main body 10 to obtain the main body print model;

[0098] The auxiliary structure includes auxiliary reinforcing ribs 50, printing support 70, and process table 90.

[0099] Auxiliary reinforcing ribs 50 refer to auxiliary reinforcing structures added to structurally weak areas such as suspended ribs of vehicle components to improve their rigidity and strength, ensuring stability during the printing process. The process table 90 is for facilitating the clamping and fixing of the main structure during supplementary printing and machining. The ease of subsequent removal must also be considered when adding auxiliary structures. Machining allowance refers to the allowance added at assembly holes requiring high dimensional accuracy, compensating for dimensional deviations generated during printing and heat treatment through subsequent machining.

[0100] The printing support 70 needs to be determined according to the printing placement plan and can be completed by the 3D printing preprocessing software Magics. The added areas are mainly between the printed structures and between the printed structure and the printing substrate 200, serving as forming supports, structural positioning, heat conduction to prevent deformation, and ensuring printing quality. The auxiliary reinforcing ribs 50 and the printing support 70 can be removed in subsequent wire cutting, and machining allowances are removed in subsequent machining. The printing placement plan refers to the placement angle after printing. A reasonable placement plan can better and more effectively add the printing support 70, allowing for greater connection between the easily deformable areas of the vehicle part and the printing substrate 200, ensuring minimal deformation during printing and subsequent processes, and controlling the dimensional accuracy of the vehicle part. For the subframe, a placement method where its top is connected to the substrate can be selected.

[0101] For printing process design schemes that fail the printing feasibility analysis and pose quality risks, auxiliary structures can be added or modified in the quality risk area. For areas that cannot be improved by adding or modifying auxiliary structures, the quality can be improved by compensating for the machining allowance in the opposite direction and by subsequent machining to make up for the quality.

[0102] Please refer to the following: Figure 8 Furthermore, after step S57, that is, after obtaining the semi-finished main body by SLM printing based on the main body printing model, the following is also included:

[0103] S58. Use heat treatment equipment to heat treat the main semi-finished product.

[0104] The main structure obtained through heat treatment can have better mechanical and processing properties. Specifically, heat treatment can be stress-relief annealing, which aims to remove internal stress and reduce the tendency to deform and crack.

[0105] Please refer to the following: Figure 9 In some embodiments, step S70, which involves obtaining the supplementary structure based on the main structure using 3D printing according to the supplementary portion 30, includes:

[0106] S71. Based on the main structure, the supplementary structure is obtained by LSF (Laser Solid Forming) printing according to the supplementary part 30.

[0107] S73. Use heat treatment equipment to heat treat the supplementary structure.

[0108] LSF printing is well-suited for additive printing supplementary structures on top of a main structure, and these supplementary structures are then subjected to heat treatment.

[0109] Please refer to the following: Figure 10 In some embodiments, after step S70, which is the step of obtaining the supplementary structure by 3D printing based on the supplementary part 30 to obtain the vehicle part, the method further includes:

[0110] S90. Machining and post-processing of vehicle parts.

[0111] The vehicle parts obtained after 3D printing may still have some imperfections, such as surface roughness or deviations caused by machining allowances, requiring subsequent machining and post-processing. Machining can compensate for dimensional deviations generated during printing and can be performed CNC-machined on key holes and other compensation areas according to the drawing requirements. Post-processing may include hand grinding, sandblasting, and polishing.

[0112] Understandably, in some other embodiments, vehicle parts whose structures already meet the standards may be used directly as the final product without machining or post-processing.

[0113] Please refer to the following: Figure 11 In some embodiments, step S10, which involves obtaining the original model of the vehicle component to be produced and then using topology optimization software to perform topology optimization based on the original model to obtain the optimized vehicle component model 100, includes:

[0114] S11. Obtain the original model of the vehicle parts to be produced, determine the original model as the current target model, and determine the optimization area of ​​the current target model;

[0115] S12. Obtain the boundary conditions for topology optimization, including the maximum design space;

[0116] S13. Based on the boundary conditions, call the finite element analysis software to perform topology optimization calculations on the optimization region of the current target model and obtain the calculation results;

[0117] S14. Based on the calculation results and the maximum design space, perform geometric reconstruction to obtain the initial optimization model;

[0118] S15. Use finite element simulation software to verify the performance of the initial optimization model;

[0119] S16. Determine whether the initial optimization model has passed the performance check;

[0120] S17. If the performance verification is successful, the initial optimized model will be output as vehicle component model 100.

[0121] Understandably, boundary conditions include not only the maximum design space but also conventional printing materials and ultimate loads under various operating conditions. Boundary conditions need to be determined beforehand. The maximum design space refers to the largest design profile within the assembly space of the part that does not interfere with other parts when stationary or in motion. The selection of printing materials needs to be determined based on the actual mass-production materials used in the design; that is, the mechanical properties of the two materials should be similar, specifically including tensile strength, yield strength, and elongation. The aim is to achieve lightweighting while providing a reference for mass production solutions. For example, when the vehicle component is a subframe, the mass-production material used in its design could be QTD1050-6, and the printing material could be stainless steel 17-4PH. Finally, the ultimate loads under the aforementioned operating conditions can include braking conditions, vertical conditions, and lateral conditions.

[0122] The finite element analysis software can be Inspire. Import the information such as the maximum design space, printing material, and ultimate loads under various working conditions, and add shape control constraints as necessary. After determining the quality target and minimum thickness, perform topology optimization calculations on the optimization region of the target model. The calculation results are used for subsequent geometric reconstruction. The target model can be selected as an optimization region in whole or in part as needed. Understandably, when the optimization region is only a part of the target model, the remaining regions are regions that do not need optimization. Subsequent topology optimization calculations and geometric reconstruction are performed on the optimization region, and the optimized region can be directly geometrically reconstructed onto the regions that do not need optimization to obtain the initial optimized model. Geometric reconstruction can be completed using the 3D design software Inspire Studio. Specifically, it can use its PolyNURBS tool to fit the calculation results for modeling, ensuring that the created structure does not exceed the maximum design space to obtain the initial optimized model.

[0123] The initial optimized model is a preliminary model, and its feasibility needs to be verified. Specifically, it will be tested using finite element analysis software based on the properties of the printing material and the ultimate load under various working conditions to verify its performance and feasibility. The finite element simulation software used is Abaqus, with a calculated safety factor ≥1 as the indicator of meeting the performance requirements. The simulation results will determine whether the initial optimized model meets the performance requirements. If it does, the model can be output and used as vehicle component model 100.

[0124] An initial optimized model was obtained through calculation and modeling, and its performance was verified through simulation. The initial optimized model that passed the performance verification was used as vehicle component model 100 for the production of vehicle components. Therefore, the final produced product, while being sufficiently lightweight, still meets the performance requirements for a vehicle component. The traditional lightweight design and production method is: design-production-verification. This method requires designing production processes and molds after completing the lightweight design, conducting actual production, and then verifying the product. This process is repeated until a qualified design solution is obtained. Obviously, compared with the traditional method, the method of this application can perform verification during the design stage. It can also perform repeated verification, but since it does not require actual production of every initial optimized model, it saves a lot of time, shortens the cycle, and significantly improves the efficiency of optimization iteration.

[0125] Please refer to the following: Figure 12 Furthermore, in step S16, after calling the finite element simulation software to verify the performance of the initial optimized model, the following is also included:

[0126] S18. If the performance verification fails, the verification result is obtained.

[0127] S19. Based on the verification results and the current initial optimization model, redetermine the current target model and its optimization region, and return to step S13, i.e., step: call the finite element analysis software to perform topology optimization calculation on the optimization region of the current target model according to the boundary conditions, and obtain the calculation results.

[0128] If the initial optimized model fails the performance check, it needs to be optimized again and reconstructed to complete the iteration, obtain a new initial optimized model, and repeat the performance check steps until an initial optimized model that meets the performance requirements is obtained as vehicle component model 100.

[0129] Please refer to the following: Figure 13 Furthermore, step S19, which is the step of redetermining the current target model and its optimization region based on the verification results and the current initial optimization model, includes:

[0130] S191. Redefine the initial optimization model as the current target model;

[0131] S192. Based on the verification results, divide the current target model into regions that pass the verification and regions that fail the verification.

[0132] S193. The regions that failed the verification are redefined as the optimization regions of the current target model.

[0133] The information of the regions that passed the verification and those that failed the verification is used as the verification results. When recalculating the topology and reconstructing the geometry, the target of the geometry reconstruction is only the regions that failed the verification. That is, the initial model that failed the verification is used as the current target model, and its regions that failed the verification are defined as the optimization region of the current target model.

[0134] When using Abaqus for performance verification, regions that pass the verification are those with a safety factor ≥ 1, while regions that fail are those with a safety factor < 1. Topology optimization calculations are performed on regions with a safety factor < 1, followed by geometric reconstruction. This iterative process yields a new initial optimized model, which is then subjected to performance verification until a satisfactory initial optimized model is obtained. This accelerates design iteration efficiency and allows for a faster acquisition of a vehicle component model 100 that meets performance requirements.

[0135] The specific steps for re-performing geometric reconstruction are as follows: re-import the initial optimized model (which failed the performance verification) into Inspire to meet the performance requirements; confirm the consistency of the printing material properties and the ultimate load under each working condition; analyze the motion trends under each working condition using analysis tools; and combine the above conclusions to perform geometric reconstruction on the areas with a safety factor < 1, i.e., the areas that failed the verification.

[0136] Understandably, in some other embodiments, the optimization region may not be divided, and topology optimization calculations may be performed directly on the original model or the initial optimization model that has not passed the verification, and geometric reconstruction may be performed accordingly.

[0137] Please refer to the following: Figure 14 In some embodiments, step S13, which is the step of calling finite element analysis software to perform topology optimization calculations on the optimization region of the current target model based on boundary conditions and obtaining the calculation results, includes:

[0138] S131. Determine the location information of the assembly holes within the maximum design space in the optimization area;

[0139] S133. Based on the assembly hole location information, the optimization area within the maximum design space is divided into a design domain and a non-design domain.

[0140] S135. Perform topology optimization calculations on the design domain based on the boundary conditions to obtain the calculation results.

[0141] Understandably, assembly holes are hole structures on the original model used for assembly. To avoid causing functional damage, such structures are not suitable for topology optimization. Therefore, the area where the assembly holes are located is defined as the non-design domain, and the remaining areas are the design domain. In the subsequent topology optimization calculations, only the design domain is calculated.

[0142] When using Inspire software, the specific steps for topology optimization calculations based on boundary conditions are as follows: Import the pre-determined maximum design space and printing material properties into Inspire. Divide the area containing the assembly holes in the maximum design space into a non-design domain, and the remaining areas into design domains. Then, apply the ultimate loads under each working condition, add symmetry shape control to the design domains, set the optimization objective to maximize stiffness, the mass objective to 30%, and the thickness constraint to the default value. Finally, run the calculation and export the results as an STL model.

[0143] Please refer to the following: Figure 15 In some embodiments, step S30, which is the step of splitting the vehicle component model 100 into the main part 10 and the supplementary part 30, includes:

[0144] S31. Obtain the maximum printing size of the 3D printing equipment;

[0145] S33. Match the maximum print size with the size of the vehicle part model 100 to determine the size of the overlapping area;

[0146] S35. The vehicle component model 100 located within the overlapping area size range is divided into the main part 10, and the vehicle component model 100 located outside the overlapping area size range is divided into the supplementary part 30.

[0147] The maximum printing size of a 3D printing machine is the maximum size of a product that the machine can print in a single print run. When the size of the vehicle part model 100 exceeds the maximum printing size of the 3D printing machine, it means that the vehicle part model 100 cannot be printed into a vehicle part in one run. Considering the large size of actual vehicle parts, it is difficult for common 3D printing machines to print vehicle parts within their maximum printing size. Therefore, the maximum area that the vehicle part model 100 can cover, limited by the maximum printing size of the 3D printing machine, is defined as the main part 10, and the remaining part is the supplementary part 30. The supplementary part 30 is printed after the main part 10 is printed. In this way, the printing difficulty caused by the limitations of the 3D printing machine is solved, and the printing quality of the vehicle part is guaranteed to the greatest extent.

[0148] In addition to considering the maximum printing size of the 3D printing equipment, the stress conditions of the vehicle components themselves in actual use can also be considered. Prioritize the critical stress areas of the entire vehicle component with high loads as the main structure, and the areas with low loads as supplementary structures. The corresponding model areas are the supplementary parts 30. For example, the lugs of the subframe are not part of the critical stress areas of the entire subframe, so they can be used as supplementary structures, and the rest of the subframe is used as the main part 10.

[0149] Understandably, in some other embodiments, the vehicle component model 100 can be split in other ways, such as cutting the vehicle component model 100 in the middle and dividing it into two equal parts. In this form, since the two parts are the same size or have a small difference in size, it is difficult to print based on one part, so they must be printed separately and then joined together by welding.

[0150] The aforementioned control method for producing vehicle components first involves topology optimization based on the original model. Specifically, the boundary conditions for topology optimization are first determined, and the boundary conditions and the original model are imported into finite element analysis software for topology optimization calculations to obtain the results. Based on the calculation results and the maximum design space, geometric reconstruction is performed to obtain an initial optimized model. The initial optimized model undergoes performance verification. If the initial optimized model passes the performance verification, it can be output and used as vehicle component model 100. If the initial optimized model fails the performance verification, the topology optimization calculation is performed again for the failed areas, and the geometric reconstruction is completed again to obtain a new initial optimized model. Performance verification is then performed on this new model until it passes the performance verification.

[0151] After obtaining the vehicle component model 100, based on the maximum size of the 3D printing equipment and the performance requirements of each part of the vehicle component, the vehicle component model 100 is divided into a main body part 10 and a supplementary part 30. The printing process for the main body part 10 is designed, auxiliary structures and machining allowances are added to obtain the main printed model, and 3D printing simulation software is used to perform a printing feasibility analysis on the main printed model. Main printed models that fail the printing feasibility analysis need to have their printing process redesigned; those that pass the feasibility analysis can be printed. Based on the main printed model, a semi-finished main body is obtained through SLM printing, followed by heat treatment and wire cutting to obtain the main structure. Then, based on the main structure, supplementary structures are printed according to supplementary part 30 and heat-treated to obtain the vehicle component composed of the main structure and supplementary structure. Finally, the vehicle component is machined and post-processed.

[0152] The aforementioned control method for producing vehicle components enables the completion of the lightweight design-to-production process in a shorter cycle, accelerating product iteration efficiency and allowing for the production of lightweight, structurally complex vehicle components via 3D printing. Furthermore, by using a split-printing method, it overcomes the size limitations of 3D printing equipment, enabling it to adapt to larger-scale production.

[0153] Based on the same concept, this application also provides an apparatus for producing vehicle components to implement the control method for producing vehicle components as described above. The solution provided by this apparatus is similar to the implementation described in the above method; therefore, specific limitations in one or more embodiments of the apparatus for producing vehicle components provided below can be found in the limitations of the method for producing vehicle components described above, and will not be repeated here.

[0154] Please see Figure 16 In some embodiments, the apparatus for producing vehicle parts includes a topology optimization module 301, a splitting module 303, a first printing module 305, and a second printing module 307, wherein:

[0155] The topology optimization module 301 is used to obtain the original model of the vehicle part to be produced, and call the topology optimization software to perform topology optimization based on the original model to obtain the optimized vehicle part model 100.

[0156] The splitting module 303 is used to split the vehicle component model 100 into a main part 10 and a supplementary part 30.

[0157] The first printing module 305 obtains the main structure of the vehicle component through 3D printing based on the main body 10;

[0158] The second printing module 307 obtains a supplementary structure based on the main structure through 3D printing according to the supplementary part 30, so as to obtain the vehicle part.

[0159] Each module in the aforementioned device for producing vehicle components can be implemented entirely or partially through software, hardware, or a combination thereof. These modules can be embedded in the processor of the terminal device in hardware form or independent of it, or stored in the memory of the terminal device in software form, so that the processor can call and execute the operations corresponding to each module.

[0160] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0161] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A control method for producing vehicle components, characterized in that, The control method for producing vehicle components includes: Obtain the original model of the vehicle component to be produced, and call the topology optimization software to perform topology optimization based on the original model to obtain the optimized vehicle component model (100). The vehicle component model (100) is divided into a main part (10) and a supplementary part (30). The main structure of the vehicle component is obtained by 3D printing based on the main body (10); The supplementary structure (30) is obtained by 3D printing based on the main structure to obtain the vehicle component; The process of obtaining the original model of the vehicle component to be produced, and then calling topology optimization software to perform topology optimization based on the original model to obtain an optimized vehicle component model (100), includes: obtaining the original model of the vehicle component to be produced, determining the original model as the current target model, and determining the optimization region of the current target model; obtaining the boundary conditions for topology optimization, the boundary conditions including the maximum design space; calling finite element analysis software to perform topology optimization calculations on the optimization region of the current target model according to the boundary conditions, and obtaining the calculation results; performing geometric reconstruction based on the calculation results and the maximum design space to obtain an initial optimized model; calling finite element simulation software to perform performance verification on the initial optimized model; and if the performance verification is passed, outputting the initial optimized model as the vehicle component model (100).

2. The control method for producing vehicle components according to claim 1, characterized in that, After calling finite element simulation software to perform performance verification on the initial optimized model, the following steps are also included: If the performance verification fails, the verification result is obtained; Based on the verification results and the current initial optimization model, the current target model and its optimization region are redefined, and the process returns to the step: according to the boundary conditions, the finite element analysis software is called to perform topology optimization calculations on the optimization region of the current target model to obtain the calculation results.

3. The control method for producing vehicle components according to claim 2, characterized in that, Based on the verification results and the current initial optimization model, the current target model and its optimization region are redefined, including: The initial optimization model is redefined as the current target model; Based on the verification results, the current target model is divided into regions that pass the verification and regions that fail the verification. The regions that failed the verification are redefined as the current optimization regions of the target model.

4. The control method for producing vehicle components according to claim 1, characterized in that, Based on the boundary conditions, the finite element analysis software is invoked to perform topology optimization calculations on the optimization region of the current target model, and the calculation results are obtained, including: Determine the location information of the assembly holes within the maximum design space in the optimized region; Based on the assembly hole location information, the optimized area located within the maximum design space is divided into a design domain and a non-design domain; The design domain is subjected to topology optimization calculation based on the boundary conditions to obtain the calculation results.

5. The control method for producing vehicle components according to any one of claims 1-4, characterized in that, The process of obtaining the main structure of the vehicle component by 3D printing based on the main body part (10) includes: The printing process of the main body (10) is designed to obtain the main body printing model; A 3D printing simulation software was used to perform a printing feasibility analysis on the main printing model. If the printing feasibility analysis is not passed, return to step: design the printing process for the main body (10); If the printing feasibility analysis is passed, the main semi-finished product can be obtained by SLM printing based on the main printing model; The main body semi-finished product is wire-cut using a wire cutting device to obtain the main body structure.

6. The control method for producing vehicle components according to claim 5, characterized in that, The process of obtaining a supplementary structure based on the main structure using 3D printing according to the supplementary part (30) includes: The supplementary structure is obtained by LSF printing based on the main structure according to the supplementary part (30); The supplementary structure is subjected to heat treatment using heat treatment equipment.

7. The control method for producing vehicle components according to claim 5, characterized in that, The step of designing the printing process for the main body (10) to obtain the main body printing model includes: Add auxiliary structures and machining allowances to the main body (10) to obtain the main body printing model; The auxiliary structure includes auxiliary reinforcing ribs (50), printing support (70), and process table (90).

8. The control method for producing vehicle components according to claim 5, characterized in that, After obtaining the semi-finished main body through SLM printing based on the main body printing model, the process further includes: The main semi-finished product is subjected to heat treatment using heat treatment equipment.

9. The control method for producing vehicle components according to claim 1, characterized in that, The process of splitting the vehicle component model (100) into a main part (10) and a supplementary part (30) includes: To obtain the maximum print size of the 3D printing equipment; The overlapping area size is determined by matching the maximum printing size with the size of the vehicle component model (100); The vehicle component model (100) located within the overlapping area size range is divided into the main body part (10), and the vehicle component model (100) located outside the overlapping area size range is divided into the supplementary part (30).

10. The control method for producing vehicle components according to claim 1, characterized in that, After obtaining the supplementary structure by 3D printing based on the main structure according to the supplementary part (30) to obtain the vehicle part, the method further includes: The vehicle components are machined and post-processed.

11. An apparatus for producing vehicle parts, characterized in that, The device employs the control method for producing vehicle components as described in any one of claims 1-10, and includes: The topology optimization module (301) is used to obtain the original model of the vehicle part to be produced, and call the topology optimization software to perform topology optimization based on the original model to obtain the optimized vehicle part model (100). The splitting module (303) is used to split the vehicle component model (100) into a main part (10) and a supplementary part (30). The first printing module (305) obtains the main structure of the vehicle component by 3D printing based on the main body part (10); and The second printing module (307) obtains the supplementary structure by 3D printing based on the main structure according to the supplementary part (30) to obtain the vehicle part.

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