A vehicle crash energy absorption box and design method

Abstract

The application discloses a kind of vehicle collision energy absorption box and design method, energy absorption box includes collapse part and the outer frame connected between vehicle crash beam and longitudinal beam, collapse part is set in outer frame;Outer frame includes front mounting plate and rear mounting plate, the front side of collapse part is connected with front mounting plate, the rear side of collapse part is connected with rear mounting plate;Collapse part includes N collapse units, each collapse unit includes first collapse piece and second collapse piece, first collapse piece and second collapse piece are connected with intersection, and intersection angle is opposite with front mounting plate and rear mounting plate, N collapse units are connected with transverse stack from front mounting plate to rear mounting plate, N is greater than or equal to 1.The energy absorption box has the characteristics of simple structure, good energy absorption effect, and the energy absorption box structure can be designed completely parameterized, so that the design difficulty is greatly reduced.

Description

Technical Field

[0001] This invention relates to the field of anti-collision buffer energy absorption equipment technology, and in particular to a vehicle collision energy absorption box and its design method. Background Technology

[0002] The automotive energy-absorbing box is one of the important safety components of a car. It connects the anti-collision beam and the longitudinal beam. Currently, this part is usually made of steel plate by stamping and is flat in shape.

[0003] However, existing energy-absorbing boxes have the following drawbacks: complicated manufacturing processes, time-consuming installation, and impact on overall vehicle assembly time; complex structures and high costs; and when a collision occurs, the force on the bumper is transferred to the longitudinal beams through the connecting parts, causing deformation of the longitudinal beams that is difficult to repair. Therefore, there is an urgent need to design an automotive energy-absorbing box structure that is simple in structure, reliable in performance, and effectively absorbs the energy of a vehicle collision on the longitudinal beams. Summary of the Invention

[0004] This application provides a vehicle collision energy-absorbing box and its design method. The energy-absorbing box has the characteristics of simple structure and good energy absorption effect. Moreover, the structure of the energy-absorbing box can be designed with full parametric parameters, which greatly reduces the design difficulty.

[0005] In a first aspect, the present invention provides the following technical solution through an embodiment of the present invention:

[0006] A vehicle collision energy-absorbing box includes a crumple zone and an outer frame connected between a vehicle anti-collision beam and a longitudinal beam. The crumple zone is disposed within the outer frame. The outer frame includes a front mounting plate and a rear mounting plate. The front side of the crumple zone is connected to the front mounting plate, and the rear side of the crumple zone is connected to the rear mounting plate. The crumple zone includes N crumple units, each crumple unit including a first crumple member and a second crumple member. The first crumple member and the second crumple member are cross-connected, and the cross angle is opposite to the front mounting plate and the rear mounting plate. The N crumple units are laterally stacked from the front mounting plate to the rear mounting plate, and N is greater than or equal to 1.

[0007] Preferably, the collapsible portion includes three collapsible units.

[0008] Preferably, the angles of the intersections of the N collapse units are all between 90 and 120 degrees.

[0009] Secondly, through an embodiment of the present invention, the present invention provides the following technical solution:

[0010] A design method for a vehicle collision energy-absorbing box, wherein the energy-absorbing box has the structure described in any one of the first aspects above, the design method comprising: determining a predetermined length, lateral width, height of the front mounting plate of the energy-absorbing box, and predetermined height of the rear mounting plate of the energy-absorbing box according to the vehicle's predetermined layout requirements, and performing the following design steps: determining the calculated length of the first crumple zone in the energy-absorbing box according to the lateral width, height of the front mounting plate, predetermined height of the rear mounting plate, angle of the predetermined first crumple zone intersection angle, and predetermined first calculation model; determining the calculated length of the first crumple zone intersection angle according to the predetermined length, angle of the first crumple zone intersection angle, and predetermined first calculation model; and determining the calculated length of the first crumple zone intersection angle according to the predetermined length, angle of the front mounting plate, angle of the front mounting plate, and predetermined height of the rear mounting plate, angle of the predetermined first crumple zone intersection angle, and predetermined height of the rear mounting plate, and performing the following design steps: determining the calculated length of the first crumple zone intersection angle, the calculated length of the first crumple zone intersection angle, and predetermined height of the rear mounting plate, according to the predetermined length, angle of the front mounting plate, angle of the front mounting plate, angle of the rear mounting plate, angle of the predetermined first crumple zone intersection angle, and predetermined height of the rear mounting plate, according to the predetermined length ... angle of the rear mounting plate, angle of the rear mounting plate, angle of the rear mounting plate, angle of the rear mounting plate, The first calculated height of the rear mounting plate of the energy-absorbing box is determined by the calculated length, the height of the front mounting plate, the set height of the rear mounting plate, and the preset second calculation model. If the calculated length of the first collapse unit is greater than or equal to the set length, the calculated length of the first collapse unit is determined as the target length of the energy-absorbing box, and the first calculated height of the rear mounting plate of the energy-absorbing box is determined as the target height of the rear mounting plate. The energy-absorbing box is designed based on the target length, the height of the front mounting plate, the lateral width, the target height of the rear mounting plate, and the angle of the preset first collapse unit intersection angle.

[0011] Preferably, if the calculated length of the first collapse unit is less than the set length, then the calculated length of the second collapse unit in the energy-absorbing box is determined based on the first calculated height of the rear mounting plate, the set height of the rear mounting plate, the height of the front mounting plate, the set length, the angle of the preset second collapse unit intersection angle, and the preset first calculation model; the second calculated height of the rear mounting plate of the energy-absorbing box is determined based on the set length, the calculated length of the second collapse unit, the height of the front mounting plate, the set height of the rear mounting plate, the first calculated height of the rear mounting plate, and the preset second calculation model; if the sum of the calculated lengths of the first collapse unit and the second collapse unit is greater than or equal to the set length, then the calculated length of the first collapse unit is determined as the target length of the energy-absorbing box, the first calculated height of the rear mounting plate of the energy-absorbing box is determined as the target height of the rear mounting plate, and the energy-absorbing box is designed based on the target length, the height of the front mounting plate, the lateral width, the target height of the rear mounting plate, and the angle of the preset first collapse unit intersection angle.

[0012] Preferably, if the sum of the calculated lengths of the first and second collapse units is less than the set length, then the calculated length of the third collapse unit in the energy-absorbing box is determined based on the second calculated height of the rear mounting plate, the set height of the rear mounting plate, the height of the front mounting plate, the set length, the angle of the preset third collapse unit intersection angle, and the preset first calculation model; the rear mounting length of the energy-absorbing box is determined based on the set length, the calculated length of the third collapse unit, the height of the front mounting plate, the set height of the rear mounting plate, the second calculated height of the rear mounting plate, and the preset second calculation model. The third calculated height of the plate; if the sum of the calculated lengths of the first collapse unit, the second collapse unit, and the third collapse unit is greater than or equal to the set length, then the sum of the calculated lengths of the first collapse unit and the second collapse unit is determined as the target length of the energy-absorbing box, and the second calculated height of the rear mounting plate of the energy-absorbing box is the target height of the rear mounting plate. The energy-absorbing box is designed based on the target length, the height of the front mounting plate, the lateral width, the target height of the rear mounting plate, the angle of the preset first collapse unit intersection angle, and the angle of the preset second collapse unit intersection angle.

[0013] Preferably, if the sum of the calculated lengths of the first, second, and third collapse units is less than the set length, then the sum of the calculated lengths of the first, second, and third collapse units is determined to be the target length of the energy-absorbing box, and the third calculated height is the target height of the rear mounting plate; the energy-absorbing box is designed based on the target length, the height of the front mounting plate, the lateral width, the target height of the rear mounting plate, the angle of the preset first, second, and third collapse unit intersection angles.

[0014] Preferably, after designing the energy-absorbing box, the following performance optimization steps are further performed: performing performance simulation analysis on the vehicle to obtain the actual load-bearing capacity of the designed energy-absorbing box; determining whether the designed energy-absorbing box meets the design target based on the actual load-bearing capacity and the set load-bearing capacity; if the actual load-bearing capacity is less than the set load-bearing capacity, reducing the angle of the intersection of the first crumple zone; redesigning the energy-absorbing box after reducing the angle based on the design steps, and performing the performance optimization steps on the redesigned energy-absorbing box until the energy-absorbing box meets the design target.

[0015] Preferably, before reducing the angle of the intersection of the first collapse unit, the method further includes: determining whether the angle of the intersection of the first collapse unit is less than or equal to 90 degrees; if so, increasing the material thickness of the first collapse member and the second collapse member according to a preset thickness step; and repeating the performance optimization step on the energy-absorbing box after increasing the material thickness until the energy-absorbing box meets the design target.

[0016] Preferably, if the actual bearing capacity is greater than the set bearing capacity, the material thickness of the first and second collapse members is reduced according to a preset thickness step; the performance optimization steps are repeated on the energy-absorbing box after the material thickness is reduced until the energy-absorbing box meets the design target.

[0017] One or more technical solutions provided in the embodiments of this application have at least the following technical effects or advantages:

[0018] This invention provides a vehicle collision energy-absorbing box, which includes a crumple zone and an outer frame connected between the vehicle's anti-collision beam and longitudinal beams. The crumple zone is disposed within the outer frame. The crumple zone includes N crumple units, each of which includes a first crumple member and a second crumple member. The first and second crumple members are cross-connected, and the cross angle is opposite to the front mounting plate and the rear mounting plate. The N crumple units are laterally stacked from the front mounting plate to the rear mounting plate, where N is greater than or equal to 1. Because it uses cross-structured crumple units as the crumple zone, and the number of crumple units can be designed according to actual needs, this energy-absorbing box has the characteristics of simple structure and good energy absorption effect. Furthermore, the structure of this energy-absorbing box can be designed using complete parametric design, which greatly reduces the design difficulty while improving the vehicle's collision performance. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the outer frame in an embodiment of the present invention;

[0021] Figure 2 This is a schematic diagram of the structure of the collapsible portion in an embodiment of the present invention;

[0022] Figure 3 This is a schematic diagram of the vehicle collision energy absorption box in an embodiment of the present invention;

[0023] Figure 4 This is a schematic diagram of the design method of the vehicle collision energy absorption box in an embodiment of the present invention;

[0024] Figure 5 This is a schematic diagram of the structural design parameters of the energy-absorbing box in an embodiment of the present invention. Detailed Implementation

[0025] This application provides a vehicle collision energy-absorbing box and its design method. The energy-absorbing box has the characteristics of simple structure and good energy absorption effect. Moreover, the structure of the energy-absorbing box can be designed with full parametric parameters, which greatly reduces the design difficulty.

[0026] The technical solution of this application embodiment is to solve the above-mentioned technical problems, and the general idea is as follows:

[0027] A vehicle collision energy-absorbing box includes a crumple zone and an outer frame connected between a vehicle anti-collision beam and a longitudinal beam. The crumple zone is disposed within the outer frame. The outer frame includes a front mounting plate and a rear mounting plate. The front side of the crumple zone is connected to the front mounting plate, and the rear side of the crumple zone is connected to the rear mounting plate. The crumple zone includes N crumple units. Each crumple unit includes a first crumple member and a second crumple member. The first crumple member and the second crumple member are cross-connected, and the cross angle is opposite to the front mounting plate and the rear mounting plate. The N crumple units are laterally stacked from the front mounting plate to the rear mounting plate, and N is greater than or equal to 1.

[0028] To better understand the above technical solutions, the following will provide a detailed explanation of the technical solutions in conjunction with the accompanying drawings and specific implementation methods.

[0029] In a first aspect, the vehicle collision energy-absorbing box provided in the embodiments of the present invention specifically includes, for example... Figures 1-3 As shown, the energy-absorbing box includes a crumple zone 20 and an outer frame 10 connected between the vehicle's anti-collision beam and the longitudinal beam. The crumple zone 20 is disposed inside the outer frame 10.

[0030] The outer frame 10 includes a front mounting plate 101 and a rear mounting plate 102. The front side of the collapsible portion is connected to the front mounting plate 101, and the rear side of the collapsible portion is connected to the rear mounting plate 102.

[0031] In a specific embodiment, in order to make the structure of the energy-absorbing box more stable, the outer frame 10 may also include: a top plate 103 and a bottom plate 104, a front mounting plate 101 and a rear mounting plate 102 connected to the two sides of the top plate 103 and the bottom plate 104, the bottom of the collapsible part connected to the bottom plate 104, and the top of the collapsible part connected to the bottom plate 104.

[0032] like Figure 2As shown, the collapsible section includes N collapsible units. Each collapsible unit includes a first collapsible component 201 and a second collapsible component 202. The first collapsible component 201 and the second collapsible component 202 are cross-connected, and the cross angle α is opposite to the front mounting plate 101 and the rear mounting plate 102. The N collapsible units are horizontally stacked from the front mounting plate 101 to the rear mounting plate 102, and N is greater than or equal to 1.

[0033] Optionally, the angles of the intersections of the N collapse units can all be between 90 and 120 degrees. For example, the angles of the intersections of the N collapse units can all be 100 degrees.

[0034] Optionally, the crumple zone may include 1 to 6 crumple units, for example, such as Figure 2 As shown, the collapse section may include three collapse units, namely, the collapse units that are horizontally stacked and connected from the front mounting plate 101 to the rear mounting plate 102 are, in sequence, a first collapse unit, a second collapse unit, and a third collapse unit. Correspondingly, the collapse section includes the intersection angle α1 of the first collapse unit, the intersection angle α2 of the second collapse unit, and the intersection angle α3 of the third collapse unit.

[0035] In one application scenario, the height of the front mounting plate 101 is less than the height of the rear mounting plate 102, such that the height of the laterally stacked collapsible units increases sequentially from the front mounting plate 101 to the rear mounting plate 102, ensuring that the top of the collapsible unit is connected to the top plate 103 of the outer frame, and the bottom of the collapsible unit is connected to the bottom plate 104 of the outer frame. Of course, in other application scenarios, the height of the front mounting plate 101 can also be equal to or greater than the height of the rear mounting plate 102, and this application does not impose any limitations.

[0036] Optionally, a certain amount of slack can be reserved at both the upper and lower ends of the front mounting plate 101 and the upper and lower ends of the rear mounting plate 102, and mounting holes can be provided at the reserved positions for fixing the front mounting plate 101 and the rear mounting plate 102. It should be noted that the size of the reserved positions depends on the dimensions of the mounting and mating structure.

[0037] Secondly, the present invention provides a design method for a vehicle collision energy-absorbing box, specifically, as follows: Figure 4 As shown, the method includes the following steps S101 to S104:

[0038] Step S101: Based on the vehicle's preset layout requirements, determine the set length, lateral width, height of the front mounting plate of the energy-absorbing box, and set height of the rear mounting plate of the energy-absorbing box, and perform the following design steps:

[0039] Step S102: Determine the calculated length of the first collapse unit in the energy-absorbing box based on the horizontal width, the height of the front mounting plate, the set height of the rear mounting plate, the angle of the preset first collapse unit intersection angle, and the preset first calculation model.

[0040] Step S103: Based on the set length, the calculated length of the first collapse unit, the height of the front mounting plate, the set height of the rear mounting plate, and the preset second calculation model, determine the first calculated height of the rear mounting plate of the energy-absorbing box.

[0041] Step S104: If the calculated length of the first collapse unit is greater than or equal to the set length, then the calculated length of the first collapse unit is determined to be the target length of the energy-absorbing box, the first calculated height of the rear mounting plate of the energy-absorbing box is the target height of the rear mounting plate, and the energy-absorbing box is designed according to the target length, the height of the front mounting plate, the lateral width, the target height of the rear mounting plate, and the angle of the preset first collapse unit intersection angle.

[0042] In a specific embodiment, the predetermined length, lateral width, height of the front mounting plate, and predetermined height of the rear mounting plate of the energy-absorbing box are determined according to the vehicle's preset layout requirements. This may include: determining the predetermined length L of the energy-absorbing box based on the overall internal layout of the vehicle; determining the lateral width W of the energy-absorbing box based on the lateral width of the vehicle's longitudinal beams; determining the height H1 of the front mounting plate of the energy-absorbing box based on the vertical (Z) height of the vehicle's anti-collision beam cross-section; and determining the predetermined height H2 of the rear mounting plate of the energy-absorbing box based on the vertical (Z) height (fixed in the Z direction) or the Y width (fixed in the Y direction) of the vehicle's longitudinal beam cross-section.

[0043] Next, based on the lateral width W, the height H1 of the front mounting plate, the set height H2 of the rear mounting plate, the angle α1 of the preset first collapse unit intersection, and the preset first calculation model, the calculated length L1 of the first collapse unit in the energy-absorbing box is determined, i.e., as shown below. Figure 5 The length of the first collapse unit shown.

[0044] The angle of the first collapse unit cross angle α1 can be set as needed, for example, the angle of the first collapse unit cross angle α1 is between 90 and 120 degrees.

[0045] Specifically, by substituting the lateral width W, the height H1 of the front mounting plate, the set height H2 of the rear mounting plate, and the angle α1 of the preset first collapse unit intersection into the preset first calculation model, we obtain Formula 1:

[0046]

[0047] The calculated length L1 of the first collapse unit is calculated according to Formula 1.

[0048] Next, based on the set length L, the calculated length L1 of the first collapse unit, the height H1 of the front mounting plate, the set height H2 of the rear mounting plate, and the preset second calculation model, the first calculated height H3 of the rear mounting plate of the energy absorption box is determined.

[0049] Specifically, by substituting the lateral width W, the height H1 of the front mounting plate, the set height H2 of the rear mounting plate, and the angle α1 of the preset first collapse unit intersection into the preset second calculation model, we obtain Formula 2:

[0050]

[0051] The first calculated height H3 of the rear mounting plate is calculated according to Formula 2.

[0052] The difference between the calculated length L1 of the first collapse unit and the set length L is determined. If the calculated length L1 of the first collapse unit is greater than or equal to the set length L, that is, L1≥L, it indicates that only one collapse unit can be set under the set length L. Therefore, it is determined that there is one collapse unit in the energy absorption box.

[0053] The calculated length L1 of the first collapse unit is determined as the target length of the energy-absorbing box, i.e., L1 = L. The first calculated height H3 of the rear mounting plate of the energy-absorbing box is determined as the target height of the rear mounting plate, i.e., H3 = H2. Based on the target length, the height H1 of the front mounting plate, the lateral width W, the target height of the rear mounting plate, and the preset angle α1 of the first collapse unit intersection angle, the energy-absorbing box is designed. The angle of the intersection angle of the collapse units in the designed energy-absorbing box is the preset angle α1 of the first collapse unit intersection angle.

[0054] If the calculated length L1 of the first collapse unit is less than the set length L, i.e., L1 < L, then the calculated length L2 of the second collapse unit in the energy absorption box is determined based on the first calculated height H3 of the rear mounting plate, the set height H2 of the rear mounting plate, the height H1 of the front mounting plate, the set length L, the angle of the preset second collapse unit intersection angle α2, and the preset first calculation model.

[0055] The angle of the second collapse unit cross angle α2 can be set as needed, for example, the angle of the second collapse unit cross angle α2 is between 90 and 120 degrees.

[0056] Specifically, by substituting the first calculated height H3 of the rear mounting plate, the set height H2 of the rear mounting plate, the height H1 of the front mounting plate, the set length L, and the angle α2 of the preset second collapse unit into the preset first calculation model, we obtain Formula 3:

[0057]

[0058] The calculated length L2 of the second collapse unit is calculated according to Formula 3.

[0059] Next, based on the set length L, the calculated length L2 of the second collapse unit, the height H1 of the front mounting plate, the set height H2 of the rear mounting plate, the first calculated height H3 of the rear mounting plate, and the preset second calculation model, the second calculated height H4 of the energy absorption box's rear mounting plate is determined.

[0060] Specifically, by substituting the set length L, the calculated length L2 of the second collapse unit, the height H1 of the front mounting plate, the set height H2 of the rear mounting plate, and the first calculated height H3 of the rear mounting plate into the preset second calculation model, we obtain Formula 4:

[0061]

[0062] The second calculated height H4 of the rear mounting plate is calculated according to Formula 4.

[0063] Next, the sum of the calculated length L1 of the first collapse unit and the calculated length L2 of the second collapse unit is compared with the set length L. If L1 + L2 ≥ L, it indicates that only one collapse unit can be set under the set length L. Therefore, it is determined that there is one collapse unit in the energy absorption box.

[0064] The calculated length L1 of the first collapse unit is determined as the target length of the energy-absorbing box, i.e., L1 = L. The first calculated height H3 of the rear mounting plate of the energy-absorbing box is determined as the target height of the rear mounting plate, i.e., H3 = H2. Based on the target length, the height H1 of the front mounting plate, the lateral width W, the target height of the rear mounting plate, and the preset angle α1 of the first collapse unit intersection angle, the energy-absorbing box is designed. The angle of the intersection angle of the collapse units in the designed energy-absorbing box is the preset angle α1 of the first collapse unit intersection angle.

[0065] If the sum of the calculated length L1 of the first collapse unit and the calculated length L2 of the second collapse unit is less than the set length L, i.e., L1 + L2 < L, it indicates that two collapse units can be set at the set length L. Therefore, it is determined that there are two collapse units in the energy absorption box. Further, based on the second calculated height H4 of the rear mounting plate, the set height H2 of the rear mounting plate, the height H1 of the front mounting plate, the set length L, the angle of the preset third collapse unit intersection angle α3, and the preset first calculation model, the calculated length L3 of the third collapse unit in the energy absorption box is determined.

[0066] The angle of the third collapse unit cross angle α3 can be set as needed, for example, the angle of the third collapse unit cross angle α3 is between 90 and 120 degrees.

[0067] Specifically, by substituting the second calculated height H4 of the rear mounting plate, the set height H2 of the rear mounting plate, the height H1 of the front mounting plate, the set length L, and the angle α3 of the preset third collapse unit crossover angle into the preset first calculation model, we obtain Formula 5:

[0068]

[0069] Formula 5 is used to calculate the calculated length L3 of the third collapse unit.

[0070] Next, based on the set length L, the calculated length L3 of the third collapse unit, the height H1 of the front mounting plate, the set height H2 of the rear mounting plate, the second calculated height H4 of the rear mounting plate, and the preset second calculation model, the third calculated height H5 of the rear mounting plate of the energy absorption box is determined.

[0071] Specifically, by substituting the set length L, the calculated length L3 of the third collapse unit, the height H1 of the front mounting plate, the set height H2 of the rear mounting plate, and the second calculated height H4 of the rear mounting plate into the preset second calculation model, we obtain Formula Six:

[0072]

[0073] Formula 6 is used to calculate the third calculated height H5 of the mounting plate.

[0074] Next, the sum of the calculated length L1 of the first collapse unit, the calculated length L2 of the second collapse unit, and the calculated length L3 of the third collapse unit is compared with the set length L. If L1 + L2 + L3 ≥ L, it indicates that two collapse units can be set under the set length L. Therefore, it is determined that there are 2 collapse units in the energy absorption box.

[0075] The calculated length L1 of the first collapse unit and the calculated length L2 of the second collapse unit are determined to be the target length of the energy-absorbing box, i.e., L = L1 + L2, L2 = L - L1. The second calculated height H4 of the rear mounting plate of the energy-absorbing box is the target height of the rear mounting plate, i.e., H4 = H2. The energy-absorbing box is designed based on the target length, the height H1 of the front mounting plate, the lateral width W, the target height of the rear mounting plate, the angle of the preset first collapse unit intersection angle α1, and the angle of the preset second collapse unit intersection angle α2.

[0076] The designed energy-absorbing box contains two collapse units. The angle of the intersection of the first collapse unit is the preset angle α1 of the first collapse unit, and the angle of the intersection of the second collapse unit is the preset angle α2 of the second collapse unit.

[0077] If the sum of the calculated length L1 of the first collapse unit, the calculated length L2 of the second collapse unit, and the calculated length L3 of the third collapse unit is less than the set length L, i.e., L1+L2+L3<L, it indicates that three collapse units can be set under the set length L. Therefore, it is determined that there are 3 collapse units in the energy absorption box.

[0078] The calculated lengths L1, L2, and L3 of the first, second, and third collapse units are combined to determine the target length of the energy-absorbing box, i.e., L = L1 + L2 + L3, L3 = L - L1 - L2. The third calculated height is the target height of the rear mounting plate, i.e., H5 = H2. Based on the target length, the height H1 of the front mounting plate, the lateral width W, the target height of the rear mounting plate, and the preset angles α1, α2, and α3 of the first, second, and third collapse units, the energy-absorbing box is designed.

[0079] The designed energy-absorbing box contains three collapse units. The angle of the intersection of the first collapse unit is the preset angle α1, the angle of the intersection of the second collapse unit is the preset angle α2, and the angle of the intersection of the third collapse unit is the preset angle α3.

[0080] Furthermore, to ensure that the designed performance box has good performance, after designing the energy-absorbing box, the following performance optimization steps S201-S204 are also performed:

[0081] Step S201: Perform performance simulation analysis on the vehicle to obtain the actual load-bearing capacity F1 of the designed energy-absorbing box;

[0082] Step S202: Based on the actual load-bearing capacity F1 and the set load-bearing capacity F0, determine whether the designed energy-absorbing box meets the design target, wherein the set load-bearing capacity F0 is determined based on the decomposition of the vehicle collision performance target;

[0083] Step S203: If the actual bearing capacity F1 is less than the set bearing capacity F0, then reduce the angle of the intersection of the first collapse unit.

[0084] Step S204: Based on the design steps, redesign the energy-absorbing box after reducing the angle, and perform the performance optimization steps on the redesigned energy-absorbing box until the energy-absorbing box meets the design objectives.

[0085] In practical implementation, the vehicle's performance is simulated and analyzed to determine the actual load-bearing capacity F1 of the designed energy-absorbing box. This may include: performing finite element modeling of the energy-absorbing box and the vehicle, and conducting calculation and simulation analysis of frontal and offset collisions to determine the actual load-bearing capacity F1 of the energy-absorbing box.

[0086] Then, based on the actual load-bearing capacity F1 and the set load-bearing capacity F0, it is determined whether the designed energy-absorbing box meets the design objectives. The set load-bearing capacity F0 is determined based on the decomposition of the vehicle's collision performance objectives. Specifically, by decomposing the vehicle's collision performance objectives, the set load-bearing capacity F0 of the energy-absorbing box can be determined, which is the calculated load-bearing capacity.

[0087] In one embodiment, if the actual bearing capacity F1 is within the range of (100±10%)F0, then the designed scheme is determined to meet the design objective. Of course, in other embodiments, it is also possible that the actual bearing capacity F1 is within the range of (100±5%)F0, and the designed scheme is determined to meet the design objective. This application does not limit this.

[0088] If the actual bearing capacity F1 is less than the set bearing capacity F0, then the angle of the first collapse unit intersection angle α1 is reduced. Specifically, reducing the angle of the first collapse unit intersection angle α1 can include reducing the angle of the first collapse unit intersection angle α1 by a preset angle step. For example, the preset angle step can be between 1 and 5 degrees, such as a preset angle step of 2.5 degrees.

[0089] Specifically, determining whether the actual bearing capacity F1 is less than the set bearing capacity F0 can include: determining whether F1 < 90% * F0; if so, then the actual bearing capacity F1 is determined to be less than the set bearing capacity F0. Of course, in other embodiments, it can also be directly determined whether F1 < F0.

[0090] Then, based on the design steps, the energy-absorbing box with the reduced angle is redesigned, and the performance of the redesigned energy-absorbing box is optimized until the energy-absorbing box meets the design objectives.

[0091] Specifically, the angle of the first collapse unit cross angle a1 can be reduced by 2.5 degrees. Then, the design process can be completed again according to the aforementioned design steps. The performance optimization steps of the redesigned energy-absorbing box can be performed again until the energy-absorbing box meets the design objectives.

[0092] Furthermore, in order to ensure that the energy-absorbing box has a stable structure and good performance, before reducing the angle of the first collapse unit cross angle a1, it may also include: determining whether the angle of the first collapse unit cross angle a1 is less than or equal to 90 degrees; if so, increasing the material thickness of the first collapse member and the second collapse member according to the preset thickness step; and performing the performance optimization step again on the energy-absorbing box after increasing the material thickness until the energy-absorbing box meets the design target.

[0093] The preset thickness step can be between 0.1 and 0.3 mm, for example, a preset thickness step of 0.1 mm. It should be noted that the material thickness here refers to the thickness values ​​of the first and second collapsing parts in the collapsing section.

[0094] Specifically, such as Figure 5 As shown, assuming the collapsible section includes three collapsible units, namely the first collapsible unit, the second collapsible unit, and the third collapsible unit, if a1≤90 degrees, the energy-absorbing box still cannot meet the design target requirements. Therefore, the material thickness t1 of the first and second collapsible components of the first collapsible unit is increased in 0.1mm increments, the material thickness t2 of the first and second collapsible components of the second collapsible unit is increased in 0.1mm increments, and the material thickness t3 of the first and second collapsible components of the third collapsible unit is increased in 0.1mm increments.

[0095] The energy-absorbing box with increased material thickness underwent a performance optimization process again until it met the design objectives. The a1 value corresponding to the maximum actual load-bearing capacity F1 was not recorded as the final design angle.

[0096] In one application scenario, the material thicknesses (t1, t2, and t3) of the first, second, and third collapse units are equal.

[0097] If the actual load-bearing capacity F1 is greater than the set load-bearing capacity F0, the material thickness of the first and second collapse components is reduced according to the preset thickness step. The aforementioned performance optimization steps are then repeated on the energy-absorbing box after the material thickness is reduced until the energy-absorbing box meets the design target. This allows the energy-absorbing box to maintain good performance while having a lighter structure. The preset thickness step can be between 0.1 and 0.3 mm.

[0098] Specifically, determining whether the actual bearing capacity F1 is greater than the set bearing capacity F0 can include: determining whether F1 > 110% * F0; if so, then the actual bearing capacity F1 is determined to be greater than the set bearing capacity F0. Of course, in other embodiments, it can also be directly determined whether F1 > F0.

[0099] In this embodiment, if the actual load-bearing capacity F1 is greater than the set load-bearing capacity F0, the material thickness of the first and second collapsing components is reduced in increments of 0.1 mm. The energy-absorbing box with reduced material thickness is then subjected to a performance optimization process again until the energy-absorbing box meets the design target. In one application scenario, the material thickness of the first, second, and third collapsing units is equal.

[0100] In summary, the vehicle collision energy-absorbing box design method provided by this invention allows for a fully parametric design of the energy-absorbing box structure, significantly reducing design complexity while improving vehicle collision performance. Compared to traditional energy-absorbing boxes, which rely heavily on experience and competitor analysis, lacking efficient parametric design and performance optimization based on parameters, this invention proposes a novel energy-absorbing box and constructs a parametric performance optimization method, providing a standardized and parametric design approach for energy-absorbing box design. Therefore, the parameter-driven design optimization method proposed in this application greatly reduces the difficulty of performance design and improves the efficiency of performance optimization.

[0101] Although preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including both the preferred embodiments and all changes and modifications falling within the scope of the invention.

[0102] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A design method for a vehicle collision energy-absorbing box, characterized in that, The energy-absorbing box includes a crumple zone and an outer frame connecting the vehicle's anti-collision beam and longitudinal beam. The crumple zone is disposed within the outer frame. The outer frame includes a front mounting plate and a rear mounting plate. The crumple zone includes N crumple units, each crumple unit including a first crumple member and a second crumple member that are cross-connected, with the cross angle opposite to the front mounting plate and the rear mounting plate. The N crumple units are laterally stacked from the front mounting plate to the rear mounting plate. The design method includes: Based on the vehicle's pre-defined layout requirements, determine the set length, lateral width, height of the front mounting plate of the energy-absorbing box, and set height of the rear mounting plate of the energy-absorbing box, and then perform the following design steps: The calculated length of the first collapse unit in the energy-absorbing box is determined based on the horizontal width, the height of the front mounting plate, the set height of the rear mounting plate, the angle of the preset first collapse unit intersection angle, and the preset first calculation model. Based on the set length, the calculated length of the first collapse unit, the height of the front mounting plate, the set height of the rear mounting plate, and the preset second calculation model, the first calculated height of the rear mounting plate of the energy-absorbing box is determined. If the calculated length of the first collapse unit is greater than or equal to the set length, then the calculated length of the first collapse unit is determined as the target length of the energy-absorbing box, the first calculated height of the rear mounting plate of the energy-absorbing box is the target height of the rear mounting plate, and the energy-absorbing box is designed according to the target length, the height of the front mounting plate, the lateral width, the target height of the rear mounting plate, and the angle of the preset first collapse unit intersection angle. Wherein, the preset first calculation model is L is the set length, and L1 is the calculated length of the first collapse unit. This refers to the height of the front mounting plate. The set height of the rear mounting plate, α1 is the angle of the preset first collapse unit intersection angle; the preset second calculation model is H3=H1+L1× , This is the first calculated height for the rear mounting plate.

2. The design method as described in claim 1, characterized in that, include: If the calculated length of the first collapse unit is less than the set length, then the calculated length of the second collapse unit in the energy-absorbing box is determined based on the first calculated height of the rear mounting plate, the set height of the rear mounting plate, the height of the front mounting plate, the set length, the angle of the preset second collapse unit intersection angle, and the preset first calculation model. The second calculated height of the energy-absorbing box's rear mounting plate is determined based on the set length, the calculated length of the second collapse unit, the height of the front mounting plate, the set height of the rear mounting plate, the first calculated height of the rear mounting plate, and the preset second calculation model. If the sum of the calculated length of the first collapse unit and the calculated length of the second collapse unit is greater than or equal to the set length, then the calculated length of the first collapse unit is determined as the target length of the energy-absorbing box, the first calculated height of the rear mounting plate of the energy-absorbing box is the target height of the rear mounting plate, and the energy-absorbing box is designed according to the target length, the height of the front mounting plate, the lateral width, the target height of the rear mounting plate, and the angle of the preset first collapse unit intersection angle.

3. The design method as described in claim 2, characterized in that, If the sum of the calculated length of the first collapse unit and the calculated length of the second collapse unit is less than the set length, then the calculated length of the third collapse unit in the energy absorption box is determined based on the second calculated height of the rear mounting plate, the set height of the rear mounting plate, the height of the front mounting plate, the set length, the angle of the preset third collapse unit intersection angle, and the preset first calculation model. The third calculated height of the energy-absorbing box's rear mounting plate is determined based on the set length, the calculated length of the third collapse unit, the height of the front mounting plate, the set height of the rear mounting plate, the second calculated height of the rear mounting plate, and the preset second calculation model. If the sum of the calculated lengths of the first, second, and third collapse units is greater than or equal to the set length, then the sum of the calculated lengths of the first and second collapse units is determined to be the target length of the energy-absorbing box, and the second calculated height of the rear mounting plate of the energy-absorbing box is determined to be the target height of the rear mounting plate. The energy-absorbing box is designed based on the target length, the height of the front mounting plate, the lateral width, the target height of the rear mounting plate, the angle of the preset first collapse unit intersection angle, and the angle of the preset second collapse unit intersection angle.

4. The design method as described in claim 3, characterized in that, If the sum of the calculated lengths of the first collapse unit, the second collapse unit, and the third collapse unit is less than the set length, then the sum of the calculated lengths of the first collapse unit, the second collapse unit, and the third collapse unit is determined to be the target length of the energy-absorbing box, and the third calculated height is the target height of the rear mounting plate. The energy-absorbing box is designed based on the target length, the height and lateral width of the front mounting plate, the target height of the rear mounting plate, the angle of the preset first crumple unit intersection angle, the angle of the preset second crumple unit intersection angle, and the angle of the preset third crumple unit intersection angle.

5. The design method as described in claim 1, characterized in that, After designing the energy-absorbing box, the following performance optimization steps are also included: The vehicle's performance was simulated and analyzed to determine the actual load-bearing capacity of the designed energy-absorbing box. Based on the actual load-bearing capacity and the set load-bearing capacity, determine whether the designed energy-absorbing box meets the design objectives; If the actual bearing capacity is less than the set bearing capacity, then reduce the angle of the intersection of the first collapse unit; Based on the design steps described above, the energy-absorbing box with the reduced angle is redesigned, and the performance optimization steps described above are performed on the redesigned energy-absorbing box until the energy-absorbing box meets the design objectives.

6. The design method as described in claim 5, characterized in that, Before reducing the angle of the intersection of the first collapse unit, the method further includes: Determine whether the angle of the intersection of the first collapse unit is less than or equal to 90 degrees. If so, increase the material thickness of the first collapse component and the second collapse component according to the preset thickness step. The performance optimization steps are repeated for the energy-absorbing box with increased material thickness until the energy-absorbing box meets the design goals.

7. The design method as described in claim 5, characterized in that, If the actual bearing capacity is greater than the set bearing capacity, then the material thickness of the first and second collapsing components is reduced according to the preset thickness step. The performance optimization steps are repeated for the energy-absorbing box after the material thickness is reduced until the energy-absorbing box meets the design goals.

8. The design method as described in claim 1, characterized in that, The collapsible section includes three collapsible units.

9. The design method as described in claim 1, characterized in that, The angles of the intersections of the N collapse units are all between 90 and 120 degrees.

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