Truck bogie side frame / swing bolster CAD / CAE (computer-aided design / computer-aided engineering) integration method and system

Abstract

The invention discloses a truck bogie side frame / swing bolster CAD / CAE (computer-aided design / computer-aided engineering) integration method and a truck bogie side frame / swing bolster CAD / CAE integration system, and belongs to the technical field of rail transit equipment design. The truck bogie side frame / swing bolster CAD / CAE integration method comprises the following steps: preprocessing an original CAD model, and converting input parameter data into ANSYS software recognizable format; constructing a CAE (Computer Aided Engineering) template on the basis of ANSYS Workbench and intelligent mapping; and carrying out CAE simulation analysis by utilizing the recognizable parameter data and constructing a CAE template, and automatically generating a simulation analysis report. A CAE (computer aided engineering) simulation analysis template is established by utilizing CAD (computer aided design) geometric modeling, so that full-process automatic analysis under the working conditions of static load and static strength stipulated by TB / T 3549.2 is realized, and the design efficiency and reliability of the side frame / swing bolster of the truck bogie are remarkably improved.

Description

Technical Field

[0001] The present invention belongs to the technical field of rail transportation equipment design, and in particular relates to a CAD / CAE integration method and system for a freight car bogie sideframe / bolster. Background Art

[0002] As key components of freight car bogies, sideframes and bolsters play a vital role in load-bearing and force transmission in rail transit. During operation, these components withstand complex loads from the track and vehicle body, which can easily lead to fatigue damage, compromising bogie reliability and even causing serious accidents. Therefore, developing efficient and reliable sideframe and bolster design methods is crucial for improving freight car bogie design efficiency and ensuring operational safety.

[0003] With the rapid development of heavy-haul railways, sideframe / bolster design has become a key technology for improving train performance. However, traditional sideframe / bolster design methods face the following key challenges: A fragmented CAD / CAE process leads to low design efficiency, making it difficult to achieve multi-dimensional performance optimization and, even more so, to balance performance and cost. The relationship between design parameters and performance indicators is unclear, limiting the application of empirical formulas and resulting in design cycles as long as 3-6 months. Existing methods struggle to achieve multidisciplinary collaborative optimization and rely on manual experience, which can easily introduce design errors. Summary of the Invention

[0004] The purpose of the present invention is to overcome the shortcomings of the existing technology and provide a CAD / CAE integration method and system for freight car bogie sideframes / bolsters. By utilizing CAD (computer-aided design) geometric modeling and establishing a CAE (computer-aided engineering) simulation analysis template, the method realizes full-process automated analysis under the static load and static strength conditions specified in TB / T 3549.2, significantly improving the design efficiency and reliability of freight car bogie sideframes / bolsters.

[0005] To achieve the above-mentioned purpose, the present invention is implemented by adopting the following technical solutions.

[0006] In one aspect, the present invention provides a CAD / CAE integration method for a freight car bogie sideframe / bolster, comprising: Pre-process the original CAD model and convert the input parameter data into a format that can be recognized by ANSYS software; Build CAE templates based on ANSYS Workbench and intelligent mapping; Utilize identifiable parameter data and build CAE templates to perform CAE simulation analysis and automatically generate simulation analysis reports.

[0007] Furthermore, the pre-processing of the original CAD model includes: Convert the original CAD model via intermediate STEP / IGES files; Use VMoveCAD to extract key geometric features and compress unnecessary data; Check topological integrity and perform geometry cleanup to remove small features and repair gaps.

[0008] Furthermore, the input parameter data is converted into a load boundary condition file in a format that can be recognized by ANSYS Workbench software, including: Input the load spectrum / material parameters according to TB / T 3549.2 specification through the VB interface, convert the input data into a format recognizable by ANSYS Workbench, and verify the data validity through the ANSYS Workbench parameter manager.

[0009] Furthermore, CAE templates are built based on ANSYS Workbench and intelligent mapping, including a bidirectional parameter-driven multi-condition coupling analysis template in ANSYS Workbench, which associates load data, material library and mesh parameters through the intelligent mapping system, and synchronizes the positioning features and version information of the CAD model.

[0010] Furthermore, it also includes maintaining two-way parameter linkage between CAD models and CAE analysis, integrating pre-processing templates for static load / static strength / fatigue strength conditions, and implementing parameter updates and template configuration through APDL / Jscript.

[0011] Furthermore, it also includes establishing mapping rules between load files, material libraries, and mesh parameters, retaining the positioning features of the datum plane / coordinate system of the CAD model, and synchronizing the model version with the analysis template through the PDM interface.

[0012] Furthermore, CAE simulation analysis is performed using identifiable parameter data and constructed CAE templates, including the use of distributed computing for collaborative solution of multiple physical fields, real-time monitoring of convergence, and structured storage of simulation analysis result data in text, graphic and table formats, and automatic classification and archiving based on metadata.

[0013] Furthermore, it also includes: allocating multi-physics field tasks through the ANSYS Workbench HPC module, displaying the solution progress and convergence status on the VB interface, and establishing an associated index between the solution log and input parameters.

[0014] In another aspect, the present invention provides a freight car bogie sideframe / bolster CAD / CAE integrated system, comprising: The basic data input layer is configured to pre-process the original CAD model and convert the input parameter data into a format that can be recognized by the ANSYS Workbench software; CAE template production layer, configured to build CAE templates based on ANSYS Workbench and intelligent mapping; A CAE simulation analysis layer configured to perform CAE simulation analysis using identifiable parameter data and building CAE templates; The analysis report generation layer is configured to automatically generate simulation analysis reports.

[0015] Furthermore, the basic data input layer includes a CAD model preprocessing module and a load boundary condition determination module; The CAE template production layer includes a template construction module based on ANSYS Workbench and an intelligent mapping system module; The CAE simulation analysis layer includes a collaborative solution module and a result management module; The analysis report generation layer includes an automated document construction module and a collaborative review module.

[0016] Compared with the prior art, the present invention achieves the following beneficial effects: The CAD / CAE integration method and system for freight car bogie sideframes / bolsters provided by the present invention, through model preprocessing, data parameter format conversion, CAE template construction, CAE simulation analysis, and report generation, simultaneously utilizes the ANSYS Workbench platform and its script commands to compile and call the load data file generated by the TB / T3549.2 load condition determination module, the material data file generated by the material parameter input module, and the CAE analysis template, completes CAE simulation analysis of the freight car bogie sideframes / bolsters, and saves the text, table, and graphical analysis results required in the analysis report template. Based on the Visual Basic platform, a CAE analysis overall interface is developed, and a freight car bogie sideframe / bolster analysis report is generated by executing the analysis report automatic generation command.

[0017] The CAD / CAE integration method and system for freight car bogie side frames / rockers provided by the present invention improve efficiency, optimize performance, and reduce costs. This is mainly reflected in the following aspects: 1) The CAD model, CAE analysis template, and analysis report template save the development cost of the integration platform, realize the automation of CAE analysis and report generation, significantly reduce manual intervention, shorten the design cycle by more than 20%, and effectively improve design efficiency. 2) Comprehensively consider the load conditions and boundary conditions specified in TB / T 3549.2 to achieve a comprehensive consideration of the maximum deflection, permanent deformation, and strength of the freight car bogie side frames / rockers, and achieve an overall performance improvement. 3) Through CAD / CAE integrated design, the design reliability is significantly improved. It effectively reduces the rework cost and material waste caused by design errors, and reduces the test investment cost by 10%. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1A flow chart of the CAD / CAE integration method for freight car bogie sideframes / bolsters provided in an embodiment of the present invention.

[0019] Figure 2 This is the CAD / CAE integrated design flow chart of the present invention.

[0020] Figure 3 This is the login interface of the present invention.

[0021] Figure 4 An interface is provided for the material of the present invention.

[0022] Figure 5 It is the main interface of the CAD / CAE integrated design of the present invention.

[0023] Figure 6 This is an ANSYS Workbench script example of the present invention.

[0024] Figure 7 This is the CAE simulation analysis process of the present invention.

[0025] Figure 8 This is the bolster mesh and analysis results of the present invention.

[0026] Figure 9 The side frame grid and analysis results of the present invention. DETAILED DESCRIPTION

[0027] The present invention will be further described below in conjunction with the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solutions of the present invention and are not intended to limit the scope of protection of the present invention.

[0028] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, features defined as "first", "second", etc. may explicitly or implicitly include one or more of the features. In the description of the present invention, unless otherwise specified, "multiple" means two or more.

[0029] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integral connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances. Example

[0030] like Figure 1 As shown, an embodiment of the present invention provides a CAD / CAE integration method for a freight car bogie sideframe / bolster, which is characterized by comprising: Step S1: pre-processing the original CAD model and converting the input parameter data into a format recognizable by ANSYS Workbench software; Step S2: Building a CAE template based on ANSYS Workbench and intelligent mapping; Step S3: Perform CAE simulation analysis using the identifiable parameter data and constructing a CAE template and automatically generate a simulation analysis report.

[0031] like Figure 2 As shown in the figure, according to the contents of the CAD / CAE integrated design flow chart, the side frame / bolster CAD / CAE integrated design interface is developed based on the Visual Basic platform. Figures 3 to 5 Develop CAE analysis module script based on ANSYS Workbench platform, see the example Figure 6 . Then according to Figure 7 The CAE analysis process shown in the figure is used to carry out CAE analysis and the corresponding analysis results are shown in Figure 8 and Figure 9 Through deep CAD / CAE integration, the design cycle is shortened by more than 20% and the test cost is reduced by 10%.

[0032] The specific analysis process of the CAD / CAE integration method for the freight car bogie sideframe / bolster provided in the embodiment of the present invention is described as follows.

[0033] In step S1, a basic data input layer is constructed, including a CAD model preprocessing module and a load boundary condition determination module. The CAD model preprocessing module performs geometric standardization, lightweighting, and verification on the original model. Based on the TB / T 3549.2 specification, the load spectrum and material parameters are input to generate a load boundary condition file that can be recognized by ANSYS Workbench.

[0034] CAD model preprocessing is performed in the basic data input layer, including geometry standardization, model lightweighting and model verification.

[0035] During the geometric standardization process, preliminary 3D modeling of the side frames and bolsters was completed using CAD software such as SolidWorks. The models were then exported in STEP format and imported into VMoveCAD for geometric standardization. This corrected issues such as discontinuous faces and overlapping lines in the model, ensuring the integrity of the geometric data.

[0036] During the model lightweighting process, VMoveCAD was used to extract key geometric features, such as the side frame support structure and the rocker connection holes, to compress non-essential data, reducing the model data volume by approximately 35%, significantly improving the efficiency of subsequent CAE analysis.

[0037] During the model verification process, the lightweight model was imported into the Meshing module of ANSYS Workbench to check the topological structure integrity, delete small features (such as chamfers and fillets less than 0.1mm), and repair gaps (such as gaps less than 0.05mm). Ultimately, a high-quality geometric model that meets CAE analysis requirements was generated.

[0038] The load boundary condition determination module in the basic data input layer determines the load boundary conditions, including standard data entry, parameterized mapping and data verification.

[0039] Standard data entry involves inputting load spectra and material parameters according to TB / T 3549.2 through a Visual Basic-based user interface. For example, the vertical and lateral loads on the truck sideframe and bolster, along with their application points, are entered, along with material parameters such as elastic modulus, Poisson's ratio, and yield strength.

[0040] Parametric mapping uses the VB interface backend code to convert the input load and material parameters into a format recognizable by ANSYS Workbench, such as converting the load magnitude and direction into the Force command parameters in the Mechanical module and converting the material parameters into the Material command parameters.

[0041] Data Verification: Utilize the ANSYS Workbench parameter manager to verify the validity of the mapped data, ensuring that the load magnitude is within a reasonable range and that the material parameters conform to physical laws. If the data is invalid, the user is prompted to re-enter the data to ensure its accuracy.

[0042] In step S2, the CAE template creation layer includes an ANSYS Workbench-based template construction module and an intelligent mapping system module. A bidirectional parameter-driven, multi-condition coupling analysis template is constructed in ANSYS Workbench. The intelligent mapping system associates load data, material libraries, and mesh parameters, and synchronizes the CAD model's positioning features and version information.

[0043] Template construction based on ANSYS Workbench includes bidirectional parameter drive, multi-case coupling and automated scripts.

[0044] Import the pre-processed CAD model into ANSYS Workbench, and use parametric modeling to establish a parametric linkage between the CAD model and CAE analysis. For example, the thickness of the side frame and the length of the bolster can be set as variable parameters. When these parameters are modified, the model geometry and meshing are automatically updated.

[0045] Multi-condition coupling integrates pre-processing templates for various conditions, including static load, static strength, and fatigue strength. For example, you can set load boundary conditions for the static load condition, add stress and strain extraction settings for the static strength condition, and configure fatigue life calculation parameters for the fatigue strength condition, allowing you to analyze multiple conditions using a single template.

[0046] Automation scripts are written using APDL and Jscript. When the user modifies the load parameters in the VB interface, the script automatically calls the API interface of ANSYS Workbench, updates the load settings in the template, re-divides the grid and configures the solution parameters to achieve automatic configuration of the template.

[0047] The intelligent mapping system includes automatic data association, feature inheritance mechanism, and version control.

[0048] Automatic Data Association: Establish mapping rules between load files, material libraries, and mesh parameters in ANSYS Workbench. For example, when you select a specific load file, the system automatically associates the corresponding material properties and meshing parameters, reducing the manual effort of setting parameters.

[0049] The feature inheritance mechanism needs to retain the CAD model's datum plane, coordinate system and other positioning features to ensure that these features can be automatically inherited when the model is updated, avoiding analysis errors caused by inconsistent datum planes or coordinate systems.

[0050] Version control uses the PDM interface to synchronize model versions and analysis templates. When the CAD model version is updated, the PDM system automatically notifies ANSYS Workbench to update the corresponding analysis template, ensuring that the model and template versions are consistent.

[0051] In step S3, distributed computing is used to perform collaborative multi-physics solutions, monitor convergence in real time, and structuredly store result data in text (CSV), graphic (VPJ), and table (XML) formats. The data is automatically categorized and archived based on metadata. The CAE simulation analysis layer includes a collaborative solution module and a result management module.

[0052] In the collaborative solving module, collaborative solving includes distributed computing, real-time monitoring and error tracing.

[0053] Distributed computing leverages the HPC module of ANSYS Workbench to distribute multi-physics tasks to different computing nodes. For example, static load analysis can be assigned to one high-performance workstation, while fatigue strength analysis can be assigned to another. This improves solution efficiency through distributed computing.

[0054] Real-time monitoring displays the solution progress and convergence status in real time in the VB interface, showing the solution progress in the form of a progress bar and the convergence curve in the form of a graph. If convergence problems occur during the solution process, the user will be prompted to make adjustments in a timely manner.

[0055] Error tracing is to establish an index that associates the solution log with the input parameters. When the solution fails, the index can be used to quickly locate the input parameters that caused the error, such as excessive load or poor mesh quality, making it easier for users to troubleshoot and correct the problem.

[0056] Result management includes structured storage and intelligent classification. Structured storage organizes simulation results into different types. Text data (such as maximum stress and deformation) is stored in CSV format, graphical data (such as cloud maps and vector diagrams) is stored in VPJ format, and tabular data (such as parameter change history) is recorded in XML format. These data are automatically archived based on analysis type and timestamp. Intelligent classification automatically archives result data based on metadata (analysis type and timestamp), making it easier for users to find and use result data.

[0057] In step S3, simulation results are inserted into a Word template via dynamic bookmarks, embedded with an interactive 3D cloud map, and generated as a web report in HTML5 format, supporting cross-platform collaborative review and annotation linkage. The analysis report generation layer includes an automated document construction module and a collaborative review module.

[0058] Automated document construction includes template-driven, 3D reporting, version traceability, and annotation synchronization.

[0059] Template-driven development is an automated document construction module based on the Word API. It uses dynamic bookmarks to locate results according to preset report templates. For example, result data such as maximum stress and deformation contours can be automatically inserted into the corresponding position of the report template.

[0060] The three-dimensional report uses VCollab software to generate interactive 3D cloud charts and embed them into the report, allowing users to intuitively view the analysis results.

[0061] Version traceability ensures the integrity and traceability of reports by automatically generating change records and approval signature columns.

[0062] Publish the report in HTML5 format to the company's internal review platform, supporting cross-platform viewing, making it convenient for design teams, reviewers, and management to view the report anytime, anywhere.

[0063] The Redline function links comments with model positioning. Reviewers can annotate directly in the report, and relevant annotations are automatically linked to the corresponding model locations, making it easier for the design team to quickly locate problems and make modifications.

[0064] In terms of data security, a lightweight format is used to strip core geometric data to ensure the security of corporate intellectual property.

[0065] To address the problems of low design efficiency caused by the disconnection between CAD geometric design and CAE performance analysis in the prior art, an embodiment of the present invention provides a CAD / CAE integrated system for freight car bogie sideframes / bolsters, including a basic data input layer, a CAE template production layer, a CAE simulation analysis layer, and an analysis report generation layer, completing a three-end collaborative architecture and realizing deep integration of CAD / CAE / document processing systems.

[0066] The basic data input layer is configured to pre-process the original CAD model and convert the input parameter data into a format that can be recognized by the ANSYS software; CAE template production layer, configured to build CAE templates based on ANSYS Workbench and intelligent mapping; A CAE simulation analysis layer configured to perform CAE simulation analysis using identifiable parameter data and building CAE templates; The analysis report generation layer is configured to automatically generate simulation analysis reports.

[0067] In some embodiments, the present invention further provides a freight car bogie sideframe / bolster CAD / CAE integration system capable of executing the above-mentioned freight car bogie sideframe / bolster CAD / CAE integration method, the system mainly comprising: ANSYS Workbench platform: used for CAE template construction, simulation solution and result output; Visual Basic development interface: integrated data input, monitoring and report generation functions; PDM system interface: realizes the synchronous management of model versions and analysis templates.

[0068] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the technical principles of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A CAD / CAE integration method for freight car bogie sideframe / bolster, characterized in that: include: Pre-process the original CAD model and convert the input parameter data into a format recognizable by ANSYS Workbench software; Build CAE templates based on ANSYS Workbench and intelligent mapping; Utilize identifiable parameter data and build CAE templates to perform CAE simulation analysis and automatically generate simulation analysis reports.

2. The CAD / CAE integration method for freight car bogie sideframe / bolster according to claim 1, characterized in that: Preprocessing of the original CAD model includes: Convert the original CAD model via intermediate STEP / IGES files; Use VMoveCAD to extract key geometric features and compress unnecessary data; Check topological integrity and perform geometry cleanup to remove small features and repair gaps.

3. The CAD / CAE integration method for freight car bogie sideframe / bolster according to claim 1, characterized in that: Convert the input parameter data into a load boundary condition file in a format that can be recognized by ANSYS software, including: Input the load spectrum / material parameters according to TB / T 3549.2 through the VB interface, convert the input data into a format recognizable by ANSYS, and verify the data validity through the ANSYS Workbench parameter manager.

4. The CAD / CAE integration method for freight car bogie sideframe / bolster according to claim 1, characterized in that: Build CAE templates based on ANSYS Workbench and intelligent mapping, including building a bidirectional parameter-driven multi-condition coupling analysis template in ANSYS Workbench, associating load data, material libraries and mesh parameters through the intelligent mapping system, and synchronizing the positioning features and version information of the CAD model.

5. The CAD / CAE integration method for freight car bogie sideframe / bolster according to claim 4, characterized in that: It also includes maintaining bidirectional parameter linkage between CAD models and CAE analysis, integrating pre-processing templates for static load / static strength / fatigue strength conditions, and implementing parameter updates and template configuration through APDL / Jscript.

6. The CAD / CAE integration method for freight car bogie sideframe / bolster according to claim 4, characterized in that: It also includes establishing mapping rules between load files, material libraries, and mesh parameters, retaining the positioning features of the datum plane / coordinate system of the CAD model, and synchronizing the model version with the analysis template through the PDM interface.

7. The CAD / CAE integration method for freight car bogie sideframe / bolster according to claim 1, characterized in that: CAE simulation analysis is performed using identifiable parameter data and constructed CAE templates, including the use of distributed computing for collaborative multi-physics field solutions, real-time convergence monitoring, and structured storage of simulation analysis result data in text, graphic, and tabular formats, with automatic classification and archiving based on metadata.

8. The CAD / CAE integration method for freight car bogie sideframe / bolster according to claim 7, characterized in that: Also includes: Multi-physics tasks are assigned through the ANSYS Workbench HPC module, the solution progress and convergence status are displayed on the VB interface, and an index is established to associate the solution log with the input parameters.

9. A freight car bogie sideframe / bolster CAD / CAE integrated system, characterized in that: include: The basic data input layer is configured to pre-process the original CAD model and convert the input parameter data into a format that can be recognized by the ANSYS software; CAE template production layer, configured to build CAE templates based on ANSYS Workbench and intelligent mapping; A CAE simulation analysis layer configured to perform CAE simulation analysis using identifiable parameter data and building CAE templates; The analysis report generation layer is configured to automatically generate simulation analysis reports.

10. The freight car bogie sideframe / bolster CAD / CAE integrated system according to claim 9, characterized in that: The basic data input layer includes a CAD model preprocessing module and a load boundary condition determination module; The CAE template production layer includes a template construction module based on ANSYS Workbench and an intelligent mapping system module; The CAE simulation analysis layer includes a collaborative solution module and a result management module; The analysis report generation layer includes an automated document construction module and a collaborative review module.

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