Method and apparatus for determining design parameters of range extender connecting mechanism mold

Abstract

This application discloses a method and apparatus for determining the design parameters of a mold for a range extender connecting mechanism. The method includes: acquiring a geometric model of the range extender; performing modal simulation on the range extender geometric model to obtain modal simulation results; performing frequency response simulation on the range extender geometric model to obtain frequency response simulation results; adjusting the structural attribute parameters and / or positional connection parameters of the connecting mechanism in the range extender geometric model based on the modal simulation results and frequency response simulation results; and adjusting the design parameters of the mold used to manufacture the connecting mechanism based on the adjusted parameters. According to the embodiments of this application, the precision of the mold for the range extender connecting mechanism can be improved.

Description

Technical Field

[0001] This application belongs to the field of vehicle powertrain design technology, and in particular relates to a method and device for determining the design parameters of a range extender connecting mechanism mold. Background Technology

[0002] This invention relates to a connection mechanism for range extender systems, such as an EGR (Exhaust Gas Recirculation) bracket assembly. Such connection mechanisms are typically manufactured using specialized molds, and the accuracy of their design directly determines the shape and structure of the mold, thereby affecting the quality and performance of the final parts.

[0003] In existing technologies, the design and mold development process for such connecting mechanisms typically involves the following steps: designers first create a three-dimensional digital model of the connecting mechanism itself, and then conduct preliminary simulation analyses of structural strength, modal characteristics, etc., based on this part model. Once the simulation results meet the design specifications, the part model is directly used for mold design and manufacturing.

[0004] However, the aforementioned existing technologies have a significant limitation. Because the simulation analysis during the design phase primarily targets isolated connection mechanism component models, there is a discrepancy between the simulated predicted mechanical behavior of the components and their actual performance after assembly. Molds developed based on these flawed component design models often fail to fully meet the performance requirements of complex actual working conditions, easily exhibiting problems such as vibration, abnormal noise, or insufficient durability. This issue arises because the design parameters of current molds have relatively low precision. Summary of the Invention

[0005] This application provides a method and apparatus for determining the design parameters of a range extender connecting mechanism mold, which can improve the precision of the range extender connecting mechanism mold.

[0006] On one hand, embodiments of this application provide a method for determining the design parameters of a mold for a range extender connection mechanism. The range extender includes: multiple range extender elements and a connection mechanism, the connection mechanism being used to connect the multiple range extender elements; the method includes: obtaining a geometric model of the range extender; Modal simulation was performed on the geometric model of the range extender to obtain the modal simulation results; Frequency response simulation was performed on the geometric model of the range extender to obtain the simulation results; Based on the modal simulation results and frequency response simulation results, adjust the structural property parameters and / or positional connection parameters of the connecting mechanism in the range extender's geometric model; Based on the adjusted parameters of the connecting mechanism, adjust the design parameters of the mold used to manufacture the connecting mechanism.

[0007] In some possible implementations, the modal simulation results include an energy density distribution map; modal simulation is performed on the range extender's geometric model to obtain the modal simulation results, including: Obtain the mode shape of the connecting mechanism in the range extender's geometric model; Based on the mode shape, determine the energy density distribution diagram of the range extender's geometric model.

[0008] In some possible implementations, the range extender element includes an engine, and the structural property parameters and / or positional connection parameters of the connecting mechanism in the range extender geometry are adjusted based on modal simulation results, including: Obtain the first-order frequency of the connecting mechanism in the range extender's geometric model; When the first-order frequency is less than a first preset threshold, the structural attribute parameters and / or positional connection parameters of the connecting mechanism in the range extender geometric model are adjusted according to the energy density distribution diagram; wherein, the first preset threshold is determined based on the engine speed.

[0009] In some possible implementations, the structural property parameters and / or positional connection parameters of the connecting mechanism in the range extender geometry model are adjusted according to the energy density distribution map, including: Based on the energy density distribution map, determine the energy concentration area; wherein, the energy concentration area includes areas with energy density greater than a second preset threshold; Based on the energy concentration region, the positional connection relationships of the connecting mechanisms in the range extender's geometric model are adjusted so that the adjusted energy density distribution map meets the first target condition.

[0010] In some possible implementations, adjusting the positional connection relationships of the connecting mechanism in the range extender geometry model includes at least one of the following: shortening the cantilever length or increasing the number of support fixing points.

[0011] In some possible implementations, multiple range-extending components include an exhaust gas recirculation (EGR) system and an engine. A connecting mechanism is used to connect the EGR and the engine. The positional connection relationships of the connecting mechanism in the range extender geometry are adjusted to ensure that the adjusted energy density distribution map meets a first target condition, including: Adjust the connection position between the EGR and the engine so that at least two support parts are provided along the length of the EGR.

[0012] In some possible implementations, the positional connection relationships of the connecting mechanisms in the range extender's geometric model are adjusted to ensure that the adjusted energy density distribution map meets the first target condition, including: Adjust the connection position between the EGR and the engine so that one end of the connection mechanism is connected to the engine and the other end is connected to at least two circumferential surfaces of the EGR; and the connection structure is integrally formed.

[0013] In some possible implementations, the frequency response simulation results include stress distribution diagrams; frequency response simulation is performed on the range extender's geometric model to obtain the following results: For the range extender geometric model, vibration excitations in the first direction, the second direction and the third direction are applied respectively. The frequency and amplitude of the vibration excitation are determined based on the engine operating conditions. The first direction, the second direction and the third direction are three mutually orthogonal spatial directions. For vibration excitation of the connecting mechanism in each direction, obtain the stress distribution diagram in the corresponding direction.

[0014] In some possible implementations, multiple range-extending components include an engine, an EGR, and a catalytic converter. The connecting mechanism includes a bracket and a bellows; the bracket connects the engine and EGR, and the bellows connects the catalytic converter and EGR. Based on frequency response simulation results, the structural property parameters and / or positional connection parameters of the connecting mechanism in the range extender's geometric model are adjusted, including: Identify at least one out-of-range region in the stress distribution map where the stress value exceeds the allowable stress threshold; If the area exceeding the standard includes the area where the support is located, the support in the connecting mechanism shall be subject to a first design adjustment; wherein, the first design adjustment includes at least one of the following: increasing the local thickness of the support in the area exceeding the standard, adjusting the material type of the support, and adjusting the manufacturing process to one-piece casting. If the area exceeding the standard includes the area where the corrugated pipe is located, a second design adjustment is made to the corrugated pipe in the connection mechanism; wherein, the second design adjustment includes at least one of the following: adjusting at least one parameter among the number of corrugations, the corrugation length, and the number of pipe layers.

[0015] Among some possible implementations, the method also includes: For the stress distribution in each direction, obtain the maximum stress value; If the maximum stress in a certain direction exceeds the maximum stress in any other direction by N times, the assembly relationship between the connecting mechanism and the engine is adjusted so that the adjusted stress distribution diagram meets the second target condition, where N is greater than or equal to 1.

[0016] On the other hand, embodiments of this application provide a device for determining the design parameters of a range extender connecting mechanism mold. The range extender includes: multiple range extender elements and a connecting mechanism, the connecting mechanism being used to connect the multiple range extender elements; the device includes: The model acquisition module is used to acquire the geometric model of the range extender; The modal simulation module is used to perform modal simulation on the range extender's geometric model and obtain the modal simulation results. The frequency response simulation module is used to perform frequency response simulation on the range extender's geometric model and obtain the frequency response simulation results. The parameter adjustment module is used to adjust the structural property parameters and / or position connection parameters of the connecting mechanism in the range extender geometric model based on the modal simulation results and frequency response simulation results. The mold adjustment module is used to adjust the design parameters of the mold used to manufacture the connecting mechanism based on the adjusted parameters of the connecting mechanism.

[0017] The method and apparatus for determining the design parameters of the range extender connecting mechanism mold in this application embodiment obtains an overall geometric model containing multiple range extender elements and multiple connecting mechanisms for joint simulation. This allows for a more realistic reflection of the mechanical behavior of the connecting mechanism under actual assembly constraints and dynamic coupling, thus making the simulation results more consistent with actual working conditions. Based on the simulation results, targeted adjustments are made to the connecting mechanism parameters, which can identify and avoid risks such as modal and frequency response anomalies in advance. Finally, the optimized connecting mechanism is mapped to the mold design parameters, so that the mold surface and structure accurately match the actual performance requirements of the connecting mechanism in integrated operation, thereby significantly improving the precision of the mold design and ensuring that the manufactured connecting mechanism meets the reliability requirements under complex working conditions. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments of this application will be briefly introduced below. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the structure of a range extender provided in one embodiment of this application; Figure 2 This is a flowchart illustrating a method for determining the design parameters of a range extender connection mechanism mold according to another embodiment of this application; Figure 3 This is a flowchart illustrating the method for determining the design parameters of the range extender connection mechanism mold according to another embodiment of this application; Figure 4 This is a flowchart illustrating the method for determining the design parameters of the range extender connection mechanism mold according to another embodiment of this application; Figure 5 This is a flowchart illustrating the method for determining the design parameters of the range extender connection mechanism mold according to another embodiment of this application; Figure 6 This is a schematic diagram of the design parameter determination device for the range extender connection mechanism mold provided in another embodiment of this application; Figure 7 This is a structural schematic diagram of a vehicle provided in another embodiment of this application. Detailed Implementation

[0020] The features and exemplary embodiments of various aspects of this application will be described in detail below. To make the objectives, technical solutions, and advantages of this application clearer, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are only intended to explain this application and not to limit it. For those skilled in the art, this application can be implemented without some of these specific details. The following description of the embodiments is merely to provide a better understanding of this application by illustrating examples.

[0021] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or vehicle that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or vehicle. Without further limitations, an element defined by the phrase "comprising..." does not exclude the presence of additional identical elements in the process, method, article, or vehicle that includes the element.

[0022] It should be noted that the acquisition, storage, use, and processing of data in this application embodiment all comply with the relevant provisions of national laws and regulations.

[0023] It should be noted that in the embodiments of this application, certain software, components, models and other existing solutions in the industry may be mentioned. These should be regarded as exemplary and are only intended to illustrate the feasibility of implementing the technical solution of this application. However, it does not mean that the applicant has used or necessarily used the solution.

[0024] In range extender systems, the EGR bracket assembly and other connecting mechanisms serve as critical components connecting the engine and exhaust system. Their structural design and mold development must closely match the mechanical performance requirements under actual assembly conditions. In existing technologies, the design and mold development process for connecting mechanisms is centered on isolated part models, conducting simulation analyses of structural strength and modal characteristics only for a single connecting mechanism. Once the simulation results meet preliminary requirements, mold design parameters are directly determined based on this isolated model. However, range extender systems are highly integrated, requiring the integration of multiple components such as the engine, exhaust system, and catalytic converter within a limited space. During actual operation, the connecting mechanisms must withstand complex loads, including engine excitation, exhaust system rigid constraints, and dynamic coupling between components. Their mechanical behavior is closely related to the assembly constraints and dynamic interactions of surrounding components.

[0025] The core flaw in existing technology lies in the fact that the preliminary simulation analysis did not incorporate the actual constraint boundaries of the connecting mechanism and the dynamic coupling relationship of multiple components in the actual assembly. This leads to a deviation between the constraint conditions used in the simulation and the actual working conditions, resulting in discrepancies between the predicted mechanical properties of the parts, such as modal frequencies and stress distribution, and their actual performance after assembly. The connecting mechanism model determined based on this biased simulation results fails to meet the actual requirements of complex assembly conditions in terms of its structural property parameters (such as bracket stiffness and bellows structural parameters) and positional connection parameters. Since the mold's surface and structural design parameters are directly based on this model, the mold design parameters inevitably lack sufficient precision. Ultimately, the connecting mechanism parts manufactured using this mold cannot effectively resist resonance caused by engine excitation and stress concentration caused by multi-directional loads in actual use, leading to vibration and abnormal noise, insufficient durability, and even failure phenomena such as cracking and air leakage.

[0026] The method for determining the design parameters of the range extender connecting mechanism mold in this application embodiment obtains an overall geometric model containing multiple range extender elements and multiple connecting mechanisms for joint simulation. This allows for a more realistic reflection of the mechanical behavior of the connecting mechanism under actual assembly constraints and dynamic coupling, thus making the simulation results more consistent with actual working conditions. Based on the simulation results, the connecting mechanism parameters are adjusted in a targeted manner, which can identify and avoid risks such as modal and frequency response anomalies in advance. Finally, the mold design parameters are mapped according to the optimized connecting mechanism, so that the mold surface and structure accurately match the actual performance requirements of the connecting mechanism in integrated operation, thereby significantly improving the precision of the mold design and ensuring that the manufactured connecting mechanism meets the reliability requirements under complex working conditions.

[0027] To address the problems in the prior art, this application provides a method and apparatus for determining the design parameters of a range extender connecting mechanism mold. The method for determining the design parameters of the range extender connecting mechanism mold provided in this application is described below.

[0028] Figure 1 A schematic diagram of the structure of a range extender provided in one embodiment of this application is shown. Figure 1As shown, the range extender includes multiple range-extending components such as an engine 101, an EGR 102, and a catalytic converter 103, as well as a connecting mechanism (specifically, an adapter bracket 104 and a bellows 105) for connecting these range-extending components. The engine 101 and EGR 102 are connected via the adapter bracket 104 in the connecting mechanism, while the EGR 102 and catalytic converter 103 are connected via the bellows 105 in the connecting mechanism. This structure is the physical embodiment of the range extender's geometric model. Based on this structure, modal simulation and frequency response simulation can be performed on the range extender's geometric model. The results of these simulations can support the adjustment of the structural attribute parameters and positional connection parameters of the connecting mechanism. Ultimately, based on the adjusted connecting mechanism, the design parameters of the mold used to manufacture the connecting mechanism can be adjusted.

[0029] Figure 2 A flowchart illustrating a method for determining the design parameters of a range extender connecting mechanism mold according to an embodiment of this application is shown. The range extender includes: multiple range extending elements and a connecting mechanism for connecting the multiple range extending elements. Figure 2 As shown, the method includes the following steps.

[0030] S201, Obtain the range extender geometric model.

[0031] As an example, the range extender geometry model can be a digital model that reflects the overall structural characteristics of the range extender, including multiple range extender components such as the engine, EGR, and catalytic converter, as well as connecting mechanisms such as brackets and bellows, accurately presenting the spatial layout, connection method, and actual constraint boundaries of each component.

[0032] Specifically, as an example, the structural data of all range-extending components and connecting mechanisms can be integrated according to the actual assembly structure of the range extender. The dimensions, assembly relationships and actual constraints of each component can be restored in detail, avoiding the loss of boundary information caused by modeling a single part. This ensures that the model can fully reflect the overall structural characteristics of the integrated parts and provide an accurate geometric basis for subsequent simulation analysis.

[0033] S202, Modal simulation is performed on the geometric model of the range extender to obtain the modal simulation results.

[0034] As an example, modal simulation can be a vibration characteristic analysis performed on the geometric model of a range extender to obtain the model's mode shapes, first-order frequencies, and energy density distribution.

[0035] As an example, modal simulation results can include mode shapes, first-order frequencies, and energy density distribution maps, with the energy density distribution map visually representing the energy distribution in different regions of the model.

[0036] As another implementation of S202, the modal simulation results include an energy density distribution map, and S202 may also include the following steps.

[0037] Obtain the mode shape of the connecting mechanism in the range extender's geometric model.

[0038] As an example, the mode shape can be the overall morphological characteristics of the connecting mechanism in the range extender's geometric model under vibration excitation, reflecting the vibration displacement law of each part of the connecting mechanism.

[0039] Specifically, as an example, a complete range extender geometric model can be used to fully consider the actual assembly constraints of each range extender component and the connecting mechanism, avoiding isolated analysis of the connecting mechanism. By applying excitations that conform to the engine's operating conditions using modal simulation tools, the displacement response of the connecting mechanism at different vibration orders can be captured, and the vibration amplitude and phase relationship of each part can be accurately recorded. This ensures that the obtained mode shapes can truly reflect the vibration state of the connecting mechanism in the integrated assembly, providing reliable data support for subsequent energy density analysis.

[0040] Based on the mode shape, determine the energy density distribution diagram of the range extender's geometric model.

[0041] As an example, the energy density distribution map can be a visualization result obtained by quantifying the mode shape data. It can be used to intuitively present the degree of energy accumulation in each region of the range extender's geometric model, identify the areas where energy is concentrated, and provide a direct basis for optimizing the connection mechanism.

[0042] Specifically, as an example, mode shape data can be combined with the material properties and structural parameters of the connecting mechanism to quantify the energy accumulation level in each region using specialized algorithms. During the calculation process, the support area of ​​the connecting mechanism should be given special attention to ensure that the energy quantification results accurately reflect actual working conditions. The energy density values ​​are then presented in a hierarchical manner to form an energy density distribution map, clearly identifying high-weight energy concentration areas. This provides a precise visual reference for subsequently dispersing support points and optimizing the energy distribution balance, preventing excessive energy concentration in a single area.

[0043] This application's embodiment describes a method for determining the design parameters of the range extender connecting mechanism mold. Modal simulation results include an energy density distribution map. By acquiring the vibration modes of the connecting mechanism and determining the energy density distribution map accordingly, the energy distribution characteristics of the connecting mechanism under vibration can be presented intuitively and accurately. This allows designers to clearly identify energy accumulation areas in the connecting mechanism, providing a clear target basis for subsequent parameter adjustments, avoiding blind optimization, improving the targeting and efficiency of parameter adjustments, and ultimately ensuring that the vibration characteristics of the connecting mechanism meet the operating requirements of the range extender, reducing the risk of resonance.

[0044] S203, perform frequency response simulation on the range extender geometric model to obtain the frequency response simulation results.

[0045] As an example, frequency response simulation can involve applying specific vibration excitation to the geometric model of a range extender and analyzing its response characteristics under vibration.

[0046] As an example, frequency response simulation results can include stress distribution maps and displacements under excitation in different directions. The stress distribution maps can reflect the stress levels in different regions of the connecting mechanism.

[0047] As another implementation of S203, the frequency response simulation results include stress distribution diagrams, and S203 may also include the following steps.

[0048] Vibration excitations in the first, second, and third directions are applied to the geometric model of the range extender. The frequency and amplitude of the vibration excitations are determined based on the engine operating conditions. The first, second, and third directions are three mutually orthogonal spatial directions.

[0049] As an example, vibration excitation can be a vibration load that simulates the engine's operation. Its frequency and amplitude are directly related to the engine's actual operating state and are the load conditions that trigger the vibration response of the range extender's geometric model.

[0050] As an example, the first, second, and third directions can be three mutually perpendicular dimensions in space, which can fully cover the vibration directions that the connecting mechanism may experience under actual working conditions.

[0051] As an example, engine operating conditions can be a set of operating parameters of the engine under different working conditions such as starting, idling, acceleration, and load changes, which is the basis for determining the key parameters of vibration excitation.

[0052] Specifically, as an example, vibration data of the engine under various typical operating conditions can be collected first to clarify the vibration frequency range and amplitude corresponding to different operating conditions, ensuring that the vibration excitation parameters are consistent with the actual use scenario. Based on the spatial structural characteristics of the range extender's geometric model, three mutually orthogonal vibration directions are set to comprehensively cover all dimensions of the connecting mechanism that may be subjected to forces. When applying excitation, the actual assembly constraints of each range extender component and connecting mechanism are fully considered to avoid deviating from the actual stress environment of the integrated assembly, ensuring that the excitation transmission conforms to the actual mechanical relationship, and providing a comprehensive and accurate load basis for subsequent stress analysis.

[0053] For vibration excitation of the connecting mechanism in each direction, obtain the stress distribution diagram in the corresponding direction.

[0054] As an example, a stress distribution diagram can be the output of a frequency response simulation, which can intuitively present the stress magnitude and distribution of the connecting mechanism in each region under vibration excitation in a specific direction, and can clearly identify areas of stress concentration or exceeding the standard.

[0055] As an example, the stress distribution map in the corresponding direction can be a stress visualization result that corresponds one-to-one with a single vibration direction, reflecting the specific influence of excitation in that direction on the stress state of the connecting mechanism.

[0056] Specifically, as an example, after vibration excitation is applied in each direction, simulation analysis tools are used to accurately capture stress response data of various parts of the connecting mechanism, focusing on key load-bearing components such as the support bellows. Combining the integrated features of the range extender with the structural characteristics of the connecting mechanism, the calculation accuracy for areas prone to stress concentration, such as the welded joints and bellows connections of the support, is enhanced. The collected stress data is converted into standardized stress distribution maps, clearly showing the differences in stress levels in different areas, identifying potential stress exceedance risks, and providing precise targeting for subsequent structural optimization of the connecting mechanism.

[0057] The method for determining the design parameters of the range extender connecting mechanism mold in this application applies vibration excitation in three mutually orthogonal directions to the range extender geometric model. The excitation parameters are determined based on the engine operating conditions, thereby obtaining stress distribution diagrams corresponding to each direction. This method can comprehensively simulate the multi-directional vibration loads that the connecting mechanism may bear in actual operation, fully presenting the stress distribution state of the connecting mechanism under different directional excitations, and avoiding incomplete stress analysis caused by single-direction simulation. Based on this comprehensive stress distribution data, the structural weak areas of the connecting mechanism can be more accurately identified, providing a comprehensive and reliable basis for subsequent parameter adjustments.

[0058] S204. Based on the modal simulation results and frequency response simulation results, adjust the structural attribute parameters and / or position connection parameters of the connecting mechanism in the range extender geometric model.

[0059] As an example, structural property parameters can be inherent structural characteristic parameters of the connecting mechanism, including the thickness, material type, and manufacturing process of the support, and the number of corrugations, length, number of layers, and stiffness of the corrugated pipe.

[0060] As an example, the position connection parameters can be the assembly parameters of the connection mechanism and the range extender element, which may include the installation orientation, the number and distribution of support fixing points.

[0061] As another implementation of S204, range extender components include engines, such as... Figure 3 As shown, S204 may also include the following steps.

[0062] S301, obtain the first-order frequency of the connecting mechanism in the range extender's geometric model.

[0063] As an example, the first-order frequency can be the first-order vibration frequency of the connecting mechanism in the range extender's geometric model. It is a core parameter that reflects the inherent vibration characteristics of the connecting mechanism. Its value is directly related to the matching relationship with the engine's excitation frequency and is a key indicator for judging the risk of resonance.

[0064] Specifically, as an example, analysis can be conducted based on a complete range extender geometry model that includes all range-extending components and connecting mechanisms. This fully considers the actual assembly constraints and dynamic interactions of each component, avoiding inaccurate constraint boundaries caused by modeling a single part. Vibration characteristics analysis can be performed on the integrated range extender geometry model using modal simulation tools to accurately extract the first-order vibration frequency data of the connecting mechanism. This ensures that the first-order frequency values ​​accurately reflect the vibration characteristics of the connecting mechanism in the actual assembly environment, providing a reliable basis for subsequent resonance risk assessment.

[0065] S302, when the first-order frequency is less than a first preset threshold, adjust the structural attribute parameters and / or position connection parameters of the connecting mechanism in the range extender geometric model according to the energy density distribution diagram; wherein, the first preset threshold is determined according to the engine speed.

[0066] As an example, the first preset threshold can refer to the modal evaluation critical value calculated based on engine speed, which is the criterion for determining whether the first-order frequency of the range extender meets the resonance prevention and control requirements.

[0067] As an example, an energy density distribution map can be a visualization of the degree of energy accumulation in each region of the quantified range extender geometry model, which can clearly identify the weighted areas of energy concentration and provide precise targeting for parameter adjustment.

[0068] Specifically, as an example, we can first obtain the engine's maximum speed, and then use the formula m The first preset threshold is determined by dividing the engine's maximum speed by 30, where m is set as an empirical safety factor greater than 1. The result of this calculation is used as the critical value for determining the first-order frequency. When the first-order frequency of the range extender's geometric model is determined to be less than the first preset threshold, the energy density distribution map of the range extender's geometric model is retrieved, and the areas where vibration energy is concentrated in the map are identified to determine the key parts of the connection mechanism with resonance risk. For these key parts, the structural attribute parameters of the connection mechanism, or the position connection parameters, or both types of parameters are adjusted. After adjustment, the first-order frequency of the range extender's geometric model is recalculated until the first-order frequency is not less than the first preset threshold, so that the first-order modal frequency of the range extender is higher than the recommended value, reducing the resonance effect and reducing the risk of noise and structural cracking.

[0069] As another implementation of S302, such as Figure 4 As shown, S302 may also include the following steps.

[0070] S401, Determine the energy concentration area based on the energy density distribution map; wherein, the energy concentration area includes areas where the energy density is greater than the second preset threshold.

[0071] As an example, the energy concentration area can be the region in the range extender geometry where the energy density value exceeds a preset threshold. It is a key part where vibration energy accumulates in the connecting mechanism, and its presence can easily lead to local stress concentration and resonance risks.

[0072] As an example, the second preset threshold can be the critical value of energy density determined based on the structural durability and NVH (Noise, Vibration, Harshness) performance requirements of the range extender, which is the core criterion for dividing the energy concentration area.

[0073] Specifically, as an example, energy density distribution maps obtained from modal simulations can be used to extract quantified energy density data for each region in the map. Combining the integrated structural features of the range extender and the load-bearing requirements of the connecting mechanism, and referencing the reliable operating energy density range of similar products, a reasonable preset threshold can be determined. The energy density data for each region is compared with the preset threshold, and regions exceeding the threshold are selected to pinpoint the specific locations of energy concentration. Particular attention can be paid to the support area of ​​the connecting mechanism, providing precise targeting for subsequent adjustments to the connection relationships.

[0074] S402, based on the energy concentration region, adjust the positional connection relationships of the connecting mechanisms in the range extender's geometric model to ensure that the adjusted energy density distribution map meets the first target condition. As an example, adjusting the positional connection relationships of the connecting mechanisms in the range extender's geometric model includes at least one of the following: shortening the cantilever length or increasing the number of support fixing points.

[0075] As an example, the first objective condition could be that the adjusted energy density distribution map shows a balanced energy distribution in each region with no obvious energy concentration areas, and the first-order frequency of the connecting mechanism is not less than the first preset threshold, thus meeting the structural durability and NVH performance requirements.

[0076] Specifically, as an example, the positional connections can be optimized based on the identified energy concentration areas, following the principle of minimizing cantilever length. If energy concentration stems from excessively long cantilever arms, shortening the cantilever length of the connecting mechanism reduces vibration energy accumulation. If insufficient support points lead to energy concentration, increasing the number of support fixing points disperses the support points, preventing any single area from bearing excessive energy weight. Through these adjustments, the energy density distribution map achieves the first target condition, reducing the risk of resonance and structural failure.

[0077] As another implementation of S402, multiple range extender components include an exhaust gas recirculation (EGR) system and an engine, and a connecting mechanism is used to connect the EGR and the engine. S402 may also include the following steps.

[0078] Adjust the connection position between the EGR and the engine so that at least two support parts are provided along the length of the EGR.

[0079] As an example, the connection position can be the spatial correspondence between the EGR and the engine to achieve assembly and fixation, which directly determines the assembly layout and support form of the two.

[0080] As an example, the support can be a structural component in the connection mechanism that provides rigid support for the EGR, and its distribution and quantity directly affect the energy transfer and vibration characteristics of the EGR.

[0081] As an example, the length direction of the EGR can be the axial direction of the EGR main structure.

[0082] Specifically, as an example, energy concentration areas can be identified by combining energy density distribution maps. Given the limited integration space of the range extender, assembly interference from other components can be avoided. Support positions are planned along different sections of the EGR's length, ensuring at least two supports are evenly distributed, covering critical areas where energy easily accumulates. The assembly correspondence between the EGR and the engine is adjusted to ensure precise alignment of the supports with the engine's mounting points, forming a multi-point support structure to avoid energy concentration caused by a single support. Through this adjustment, the vibration energy of the EGR is dispersed and transmitted along its length through multiple supports, optimizing the energy density distribution. This ensures the adjusted energy density distribution map meets the first target condition, improving the structural stiffness and anti-resonance capability of the connecting mechanism.

[0083] The method for determining the design parameters of the range extender connecting mechanism mold in this application involves adjusting the connection position between the EGR and the engine, and setting at least two support parts along the length of the EGR. This achieves multi-point support for the EGR by the connecting mechanism, effectively dispersing the vibration energy and stress of the EGR, avoiding local energy concentration and stress exceeding the limit caused by a single support, improving the stability of the connection between the EGR and the engine, reducing the vibration displacement of the EGR during operation, ensuring the normal operation of the EGR system, and thus improving the overall reliability of the range extender.

[0084] As another implementation of S402, S402 may also include the following steps.

[0085] Adjust the connection position between the EGR and the engine so that one end of the connection mechanism is connected to the engine and the other end is connected to at least two circumferential surfaces of the EGR; and the connection structure is integrally formed.

[0086] As an example, the circumferential direction can be the circumferential direction of the EGR main structure around its own axis, which is a key dimension for planning the contact range of the connecting mechanism.

[0087] As an example, one-piece molding can be a processing method in which the connecting mechanism is formed into a complete structure through a single manufacturing process, which can avoid structural weaknesses caused by splicing or welding.

[0088] Specifically, as an example, referring to the clearly defined energy concentration areas in the energy density distribution map, and considering the limited integration space of the range extender, assembly interference with other components is avoided. The docking points between the connecting mechanism and the engine are determined to ensure assembly stability. At least two relatively opposite or evenly distributed surfaces are selected circumferentially around the EGR as the other end contact area of ​​the connecting mechanism, forming a multi-faceted, enveloping support to avoid energy concentration caused by single-sided support. The connecting mechanism is manufactured using a one-piece manufacturing process, eliminating multi-level transitions or welding splices and enhancing the overall structural rigidity. Through this adjustment, the vibration energy of the EGR is evenly transferred to the engine through multi-faceted contact, optimizing the energy density distribution, meeting the first target condition, and simultaneously improving the structural durability and anti-resonance capability of the connecting mechanism.

[0089] The method for determining the design parameters of the range extender connecting mechanism mold in this application adjusts the connection position between the EGR and the engine, so that one end of the connecting mechanism is connected to the engine, and the other end is connected to at least two circumferential surfaces of the EGR, with the connecting structure integrally formed. This integrally formed connecting structure avoids structural weaknesses caused by splicing or welding, improving the overall rigidity and strength of the connecting mechanism. The connection to at least two circumferential surfaces of the EGR forms a multi-faceted, enveloping support, further optimizing the stress distribution and effectively dispersing energy and stress. This enhances the load-bearing capacity and vibration resistance of the connecting mechanism, reduces the risk of structural failure, and ensures the stability and durability of the connection between the EGR and the engine.

[0090] The method for determining the design parameters of the range extender connecting mechanism mold in this application embodiment identifies the energy concentration area based on the energy density distribution map, and adjusts the positional connection relationship of the connecting mechanism based on this area, so that the adjusted energy density distribution map meets the first target condition. This method can specifically solve the problem of energy concentration in the connecting mechanism, achieve balanced energy distribution by optimizing the positional connection relationship, avoid structural weakness caused by excessive local energy accumulation, improve the overall mechanical performance of the connecting mechanism, extend its service life, and ensure the long-term stable operation of the range extender.

[0091] The method for determining the design parameters of the range extender connecting mechanism mold in this application embodiment obtains the first-order frequency of the connecting mechanism and determines whether it is less than a first preset threshold determined by the engine speed. When the first-order frequency is less than the first preset threshold, relevant parameters are adjusted in conjunction with the energy density distribution map. This effectively avoids the overlap between the first-order frequency of the connecting mechanism and the engine excitation frequency, fundamentally reducing the probability of resonance and minimizing problems such as noise and structural cracking caused by resonance. Furthermore, the accuracy of the adjustment based on the energy density distribution map further improves the structural stability and durability of the connecting mechanism.

[0092] As another implementation of S204, multiple range extender components include an engine, EGR, and a catalytic converter. The connecting mechanism includes a bracket and a bellows; the bracket connects the engine and EGR, and the bellows connects the catalytic converter and EGR. Figure 5 As shown, S204 may also include the following steps.

[0093] S501, Identify at least one out-of-range region in the stress distribution map where the stress value exceeds the allowable stress threshold.

[0094] As an example, the area exceeding the standard can be a region in the stress distribution diagram where the stress value is higher than the allowable stress threshold, which is a critical part of the connection mechanism where there is a risk to structural strength.

[0095] As an example, the allowable stress threshold is a critical stress value determined based on the material properties of the support and bellows, structural durability requirements, and the operating conditions of the range extender. It is the core standard for determining whether a structure meets the usage requirements.

[0096] Specifically, as an example, stress distribution maps obtained from frequency response simulations in three directions can be compiled, and stress quantification data for each region can be extracted. Combining the material mechanical properties of the support and bellows, and the structural durability requirements for long-term operation of the range extender, a reasonable allowable stress threshold can be determined. Areas prone to stress concentration, such as support welds, transition points, and bellows connections, should be carefully examined. The stress data for each area should be compared with the allowable stress threshold one by one to accurately identify all areas exceeding the stress limit, clarifying the location and degree of exceedance, thus providing a basis for subsequent targeted adjustments.

[0097] S502, if the area exceeding the standard includes the area where the support is located, the support in the connection mechanism shall be subject to a first design adjustment; wherein, the first design adjustment includes at least one of the following: increasing the local thickness of the support in the area exceeding the standard, adjusting the material type of the support, and adjusting the manufacturing process to integral casting.

[0098] As an example, the first design adjustment could be an optimization measure for excessive stress in the support structure, with the aim of reducing the stress level of the support structure through structural, material or process improvements, thereby ensuring its structural strength and durability.

[0099] As an example, one-piece casting can be a processing method that forms a complete support structure through a single casting process, which can avoid the structural weaknesses caused by the patching design of multiple welded plates and improve the overall rigidity of the support.

[0100] Specifically, as an example, the extent and distribution of stress exceeding the standard in the affected area can be detected first. If the degree of exceedance is minor, the local thickness of the support in that area can be increased to enhance the local load-bearing capacity. If increasing the thickness of the sheet metal still cannot meet the requirements, the material type of the support can be adjusted, selecting a material with superior strength to suit the working conditions. Simultaneously, integrated assembly requirements can be considered to avoid multi-level transitions and single-sided supports. A one-piece casting process can be used to manufacture the support, improving the overall structural integrity and rigidity. This ensures that the stress value of the adjusted support is below the allowable stress threshold, meeting the durability and NVH performance requirements of the range extender structure.

[0101] S503, if the area exceeding the standard includes the area where the corrugated pipe is located, a second design adjustment is made to the corrugated pipe in the connection mechanism; wherein, the second design adjustment includes at least one of the following: adjusting at least one parameter among the number of corrugations, the corrugation length, and the number of pipe layers.

[0102] As an example, the second design adjustment can be an optimization measure for excessive stress in the bellows, which improves stiffness and stress state by adjusting its structural parameters and reduces the risk of vibration cracking.

[0103] As an example, the number of corrugations can be the number of corrugated structures on the corrugated pipe, the corrugation length can be the axial dimension of a single corrugation, and the number of pipe layers can be the number of stacked layers of the corrugated pipe. These three factors together determine the balance between the flexibility and rigidity of the corrugated pipe.

[0104] Specifically, as an example, the core reasons for excessive stress can be analyzed by combining the stress distribution characteristics of the bellows in frequency response simulation with the assembly span of the range extender. If stress concentration is caused by insufficient stiffness, the number of bellows or the number of pipe layers can be increased; if it is due to poor structural adaptability, the bellows length can be adjusted to optimize the connection compatibility with the EGR and catalytic converter. During the adjustment process, the semi-flexible connection characteristics of the bellows can be taken into account to ensure that the optimized bellows can reduce the stress level to below the allowable stress threshold while meeting the vibration compensation requirements between the engine and the exhaust system, thus avoiding cracking or leakage problems.

[0105] This application's embodiment describes a method for determining the design parameters of the range extender connecting mechanism mold. It identifies excessive areas in the stress distribution diagram, performs a first design adjustment for the excessive areas including the support frame, and a second design adjustment for the excessive areas including the bellows. This achieves targeted optimization of excessive stress in different components of the connecting mechanism. By increasing the local thickness of the support frame and adjusting materials or processes, the structural strength of the support frame can be effectively improved. By adjusting the bellows' corrugation parameters, its flexibility and rigidity balance can be optimized, reducing stress levels. These two design adjustments are adapted to the structural characteristics of the support frame and the bellows, respectively, improving the stress-bearing capacity of each component of the connecting mechanism and avoiding failures such as cracking and air leakage caused by excessive local stress, thus ensuring the overall service life of the connecting mechanism and the operational stability of the range extender.

[0106] S205, Based on the adjusted parameters of the connecting mechanism, adjust the design parameters of the mold used to manufacture the connecting mechanism.

[0107] As an example, the design parameters of a mold can be the mold parameters for manufacturing connecting mechanisms, including surface dimensions, structural layout, etc., which directly determine the mold processing accuracy and the quality of the final part.

[0108] Specifically, as an example, the design parameters such as the mold surface size and structural layout can be adjusted according to the structural characteristics of the connecting mechanism after parameter adjustment, to ensure that the mold surface is fully compatible with the adjusted connecting mechanism structure, the mold structure meets the manufacturing process requirements of the connecting mechanism, and the mold design adjustment is promoted in accordance with the simulation requirements to ensure that the manufactured connecting mechanism meets the structural durability and NVH performance standards.

[0109] This application's embodiment of the method for determining the design parameters of the range extender connecting mechanism mold involves acquiring a geometric model of the range extender that includes multiple range extender components and connecting mechanisms, avoiding the problem of inaccurate constraint boundaries caused by modeling a single part. Subsequently, modal simulation and frequency response simulation are used to comprehensively obtain the modal and frequency response characteristics of the connecting mechanism, providing precise data support for parameter adjustment. Then, based on the simulation results, the structural attribute parameters and / or positional connection parameters of the connecting mechanism are adjusted in a targeted manner to proactively avoid potential risks such as insufficient structural strength and abnormal vibration. Finally, based on the parameter-adjusted connecting mechanism, the mold design parameters are optimized to ensure a precise match between the mold design and the actual performance requirements of the connecting mechanism. This fundamentally solves problems such as part vibration and cracking caused by design deviations in the connecting mechanism, while ensuring that the connecting mechanism manufactured by the mold meets the reliability requirements of the integrated operation of the range extender. Based on the comprehensive and accurate data provided by simulation analysis, the adjustment of connecting mechanism parameters becomes more targeted, and the mold design parameters are directly anchored to the optimized connecting mechanism characteristics, further improving the precision of the mold.

[0110] As another implementation of this application, in order to improve the structural reliability and durability of the connection mechanism, the method may also include the following steps.

[0111] For the stress distribution in each direction, obtain the maximum stress value.

[0112] As an example, the maximum stress value can be the highest stress value in the stress distribution in a single direction, and it is a core indicator for measuring the degree of influence of excitation in that direction on the connecting mechanism.

[0113] Specifically, as an example, stress distribution maps corresponding to three mutually orthogonal spatial directions can be extracted. For the stress distribution in each direction, focus on key components such as supports and corrugated pipes, as well as areas prone to stress concentration such as welds and corrugated connections. Quantitative stress data for each area can be screened and extracted one by one to determine the peak data in the stress distribution of each direction, i.e., the maximum stress value, thus providing accurate data support for comparing stress levels in different directions.

[0114] If the maximum stress in a certain direction exceeds the maximum stress in any other direction by N times, the assembly relationship between the connecting mechanism and the engine is adjusted so that the adjusted stress distribution diagram meets the second target condition, where N is greater than or equal to 1.

[0115] As an example, the assembly relationship can be the installation orientation, connection point, and spatial arrangement between the connecting mechanism and the engine, which can directly affect the force balance of the connecting mechanism under excitation in all directions.

[0116] As an example, the second objective condition could be that the maximum stress values ​​in all directions tend to be balanced after adjustment, with no single direction stress exceeding the standard, and the overall stress level of the connecting mechanism meets the structural durability and NVH performance requirements, where N is a preset stress balance judgment coefficient and is not less than 1.

[0117] Specifically, as an example, the maximum stress values ​​in each direction can be compared pairwise to determine if the maximum stress value in one direction exceeds N times that in any other direction. If so, the installation orientation of the connecting mechanism and engine can be adjusted, and the distribution of support fixing points optimized, with reference to the integrated space of the range extender and the layout of surrounding components, to avoid excessive stress concentration in a single direction. By changing the placement orientation of the assembly, the integration of each component can be optimized, reducing the difference in the maximum stress values ​​in each direction after adjustment, thus achieving the second objective condition and reducing the risk of structural failure due to excessive stress in a single direction.

[0118] The method for determining the design parameters of the range extender connecting mechanism mold in this application involves obtaining the maximum stress values ​​in each direction. When the maximum stress value in one direction exceeds N times that in other directions, the assembly relationship between the connecting mechanism and the engine is adjusted. This effectively improves the stress balance of the connecting mechanism, avoids excessive stress concentration in a single direction, and makes the stress distribution in each direction more reasonable, achieving the second target condition. By optimizing the assembly relationship, the risk of local wear and fatigue failure of the connecting mechanism due to excessive unidirectional stress is reduced, further improving the structural reliability and durability of the connecting mechanism and ensuring the stable operation of the range extender under complex working conditions.

[0119] Based on the method for determining the design parameters of the range extender connecting mechanism mold provided in the above embodiments, this application also provides a specific implementation of the device for determining the design parameters of the range extender connecting mechanism mold. Please refer to the following embodiments.

[0120] First see Figure 6 The range extender includes: multiple range extender elements and a connecting mechanism. The connecting mechanism is used to connect the multiple range extender elements. The design parameter determination device 60 for the range extender connecting mechanism mold provided in this application embodiment includes the following modules: The model acquisition module 601 is used to acquire the geometric model of the range extender.

[0121] Modal simulation module 602 is used to perform modal simulation on the range extender geometric model and obtain modal simulation results.

[0122] In some embodiments, the modal simulation results include an energy density distribution map, and the modal simulation module 602 includes: The mode shape acquisition module is used to acquire the mode shape of the connecting mechanism in the range extender's geometric model; The energy distribution determination module is used to determine the energy density distribution map of the range extender's geometric model based on the mode shape.

[0123] The frequency response simulation module 603 is used to perform frequency response simulation on the range extender geometric model and obtain the frequency response simulation results.

[0124] In some embodiments, the frequency response simulation results include a stress distribution diagram; the frequency response simulation module 603 includes: The excitation application module is used to apply vibration excitation in a first direction, a second direction, and a third direction to the range extender geometric model, respectively. The frequency and amplitude of the vibration excitation are determined based on the engine operating conditions, and the first direction, the second direction, and the third direction are three mutually orthogonal spatial directions. The stress distribution acquisition module is used to acquire the stress distribution map in each direction for vibration excitation of the connecting mechanism.

[0125] The parameter adjustment module 604 is used to adjust the structural attribute parameters and / or position connection parameters of the connecting mechanism in the range extender geometric model based on the modal simulation results and frequency response simulation results.

[0126] In some embodiments, the parameter adjustment module 604 includes: The frequency acquisition module is used to acquire the first-order frequency of the connecting mechanism in the range extender's geometric model; The frequency determination and adjustment module is used to adjust the structural attribute parameters and / or position connection parameters of the connecting mechanism in the range extender geometric model according to the energy density distribution diagram when the first-order frequency is within the preset engine excitation frequency range.

[0127] In some embodiments, the frequency determination and adjustment module includes: The concentrated area determination module is used to determine the concentrated energy area based on the energy density distribution map; wherein, the concentrated energy area includes areas with energy density greater than a preset threshold; The connection relationship adjustment module is used to adjust the positional connection relationship of the connection mechanism in the range extender geometric model based on the energy concentration area, so that the adjusted energy density distribution map meets the first target condition.

[0128] In some embodiments, the connection adjustment module is used for at least one of the following: shortening the cantilever length and increasing the support fixing points.

[0129] In some embodiments, the multiple range extender components include an exhaust gas recirculation (EGR) system and an engine, and a connection mechanism is used to connect the EGR and the engine; the connection adjustment module includes: The support module is used to adjust the connection position between the EGR and the engine, so that at least two supports are provided along the length of the EGR.

[0130] In some embodiments, the connection relationship adjustment module includes: An integrated connection adjustment module is used to adjust the connection position between the EGR and the engine, so that one end of the connection mechanism is connected to the engine and the other end is connected to at least two circumferential surfaces of the EGR; and the connection structure is integrally formed.

[0131] In some embodiments, the plurality of range extender elements include an engine, an EGR, and a catalytic converter; the connection mechanism includes a bracket and a bellows, the bracket being used to connect the engine and the EGR, and the bellows being used to connect the catalytic converter and the EGR; the parameter adjustment module 604 includes: The out-of-range area identification module is used to identify at least one out-of-range area in the stress distribution map where the stress value exceeds the allowable stress threshold; The bracket adjustment module is used to make a first design adjustment to the bracket in the connection mechanism when the area exceeding the standard includes the area where the bracket is located; wherein, the first design adjustment includes at least one of the following: increasing the local thickness of the bracket in the area exceeding the standard, adjusting the material type of the bracket, and adjusting the manufacturing process to one-piece casting; A bellows adjustment module is used to perform a second design adjustment on the bellows in the connection mechanism when the area exceeding the standard includes the area where the bellows are located; wherein the second design adjustment includes at least one of the following: adjusting at least one parameter among the number of bellows, the length of the bellows, and the number of pipe layers.

[0132] The mold adjustment module 605 is used to adjust the design parameters of the mold used to manufacture the connecting mechanism according to the adjusted parameters of the connecting mechanism.

[0133] In some embodiments, the design parameter determination 60 for the range extender connection mechanism mold may further include the following modules: The stress extremum acquisition module is used to obtain the maximum stress value for each direction of stress distribution; The assembly relationship adjustment module is used to adjust the assembly relationship between the connecting mechanism and the engine when the maximum stress value in a certain direction exceeds N times the maximum stress value in any other direction, so that the adjusted stress distribution diagram meets the second target condition, where N is greater than or equal to 1.

[0134] Figure 7 A schematic diagram of the hardware structure of the vehicle provided in an embodiment of this application is shown.

[0135] The vehicle may include a processor 701 and a memory 702 storing computer program instructions.

[0136] Specifically, the processor 701 may include a central processing unit (CPU), an application-specific integrated circuit (ASIC), or one or more integrated circuits that can be configured to implement the embodiments of this application.

[0137] Memory 702 may include mass storage for data or instructions. For example, and not limitingly, memory 702 may include a hard disk drive (HDD), floppy disk drive, flash memory, optical disk, magneto-optical disk, magnetic tape, or Universal Serial Bus (USB) drive, or a combination of two or more of these. Where appropriate, memory 702 may include removable or non-removable (or fixed) media. Where appropriate, memory 702 may be internal or external to the integrated gateway disaster recovery device. In a particular embodiment, memory 702 is non-volatile solid-state memory.

[0138] Memory may include read-only memory (ROM), random access memory (RAM), disk storage media devices, optical storage media devices, flash memory devices, and electrical, optical, or other physical / tangible memory storage devices. Therefore, typically, memory includes one or more tangible (non-transitory) computer-readable storage media (e.g., memory devices) encoded with software including computer-executable instructions, and when the software is executed (e.g., by one or more processors), it is operable to perform the operations described with reference to the methods according to one aspect of this disclosure.

[0139] The processor 701 reads and executes computer program instructions stored in the memory 702 to implement any of the design parameter methods for the range extender connecting mechanism mold in the above embodiments.

[0140] In one example, the vehicle may also include a communication interface 703 and a bus 710. Wherein, as... Figure 7 As shown, the processor 701, memory 702, and communication interface 703 are connected through bus 710 and complete communication with each other.

[0141] The communication interface 703 is mainly used to realize communication between various modules, devices, units and / or vehicles in the embodiments of this application.

[0142] Bus 710 includes hardware, software, or both, that couples vehicle components together. For example, and not limitingly, the bus may include Accelerated Graphics Port (AGP) or other graphics buses, Enhanced Industry Standard Architecture (EISA) buses, Front Side Bus (FSB), HyperTransport (HT) interconnects, Industry Standard Architecture (ISA) buses, Infinite Bandwidth Interconnects, Low Pin Count (LPC) buses, memory buses, Microchannel Architecture (MCA) buses, Peripheral Component Interconnect (PCI) buses, PCI-Express (PCI-X) buses, Serial Advanced Technology Attachment (SATA) buses, Video Electronics Standards Association Local (VLB) buses, or other suitable buses, or combinations of two or more of these. Where appropriate, bus 710 may include one or more buses. Although specific buses are described and illustrated in embodiments of this application, this application contemplates any suitable bus or interconnect.

[0143] It should be clarified that this application is not limited to the specific configurations and processes described above and shown in the figures. For the sake of brevity, detailed descriptions of known methods are omitted here. In the above embodiments, several specific steps are described and shown as examples. However, the method process of this application is not limited to the specific steps described and shown. Those skilled in the art can make various changes, modifications, and additions, or change the order of steps, after understanding the spirit of this application.

[0144] The functional blocks shown in the above block diagram can be implemented as hardware, software, firmware, or a combination thereof. When implemented in hardware, they can be, for example, electronic circuits, application-specific integrated circuits (ASICs), appropriate firmware, plug-ins, function cards, etc. When implemented in software, the elements of this application are programs or code segments used to perform the required tasks. Programs or code segments can be stored on a machine-readable medium or transmitted over a transmission medium or communication link via data signals carried on a carrier wave. "Machine-readable medium" can include any medium capable of storing or transmitting information. Examples of machine-readable media include electronic circuits, semiconductor memory devices, ROM, flash memory, erasable ROM (EROM), floppy disks, CD-ROMs, optical disks, hard disks, fiber optic media, radio frequency (RF) links, etc. Code segments can be downloaded via computer networks such as the Internet, intranets, etc.

[0145] It should also be noted that the exemplary embodiments mentioned in this application describe methods or systems based on a series of steps or apparatus. However, this application is not limited to the order of the above steps; that is, the steps can be performed in the order mentioned in the embodiments, or in a different order, or several steps can be performed simultaneously.

[0146] The aspects of this disclosure have been described above with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this disclosure. It should be understood that each block in the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, or other programmable data processing apparatus to produce a machine such that these instructions, executable via the processor of the computer or other programmable data processing apparatus, enable the implementation of the functions / actions specified in one or more blocks of the flowchart illustrations and / or block diagrams. Such a processor can be, but is not limited to, a general-purpose processor, a special-purpose processor, a special application processor, or a field-programmable logic circuit. It is also understood that each block in the block diagrams and / or flowcharts, and combinations of blocks in the block diagrams and / or flowcharts, can also be implemented by special-purpose hardware performing the specified functions or actions, or can be implemented by a combination of special-purpose hardware and computer instructions.

[0147] The above are merely specific embodiments of this application. Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the systems, modules, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here. It should be understood that the protection scope of this application is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this application, and these modifications or substitutions should all be covered within the protection scope of this application.

Claims

1. A method for determining the design parameters of a range extender connecting mechanism mold, characterized in that, The range extender includes: a plurality of range extender elements and a connecting mechanism, the connecting mechanism being used to connect the plurality of range extender elements; the method includes: Obtain the range extender geometric model; Modal simulation was performed on the geometric model of the range extender to obtain the modal simulation results; Frequency response simulation was performed on the geometric model of the range extender to obtain the simulation results; Based on the modal simulation results and frequency response simulation results, adjust the structural attribute parameters and / or positional connection parameters of the connecting mechanism in the range extender geometric model; Based on the adjusted parameters of the connecting mechanism, the design parameters of the mold used to manufacture the connecting mechanism are adjusted.

2. The method according to claim 1, characterized in that, The modal simulation results include an energy density distribution map; the modal simulation of the range extender's geometric model to obtain modal simulation results includes: Obtain the mode shape of the connecting mechanism in the range extender geometry model; Based on the vibration mode, determine the energy density distribution diagram of the range extender geometric model.

3. The method according to claim 2, characterized in that, The range extender component includes an engine. Adjusting the structural attribute parameters and / or positional connection parameters of the connecting mechanism in the range extender's geometric model based on the modal simulation results includes: Obtain the first-order frequency of the connecting mechanism in the range extender geometry model; When the first-order frequency is less than a first preset threshold, the structural attribute parameters and / or position connection parameters of the connecting mechanism in the range extender geometric model are adjusted according to the energy density distribution map; wherein, the first preset threshold is determined based on the engine speed.

4. The method according to claim 3, characterized in that, The step of adjusting the structural attribute parameters and / or positional connection parameters of the connecting mechanism in the range extender geometric model according to the energy density distribution map includes: Based on the energy density distribution map, energy concentration areas are determined; wherein, the energy concentration areas include areas with energy density greater than a second preset threshold. Based on the energy concentration region, the positional connection relationships of the connecting mechanisms in the range extender geometric model are adjusted so that the adjusted energy density distribution map meets the first target condition.

5. The method according to claim 4, characterized in that, The adjustment of the positional connection relationship of the connecting mechanism in the range extender geometric model includes at least one of the following: shortening the cantilever length and increasing the support fixing points.

6. The method according to claim 4, characterized in that, The plurality of range-extending components include an exhaust gas recirculation (EGR) system and an engine. The connecting mechanism is used to connect the EGR and the engine. Adjusting the positional connection relationship of the connecting mechanism in the range extender's geometric model to achieve the first target condition in the adjusted energy density distribution map includes: Adjust the connection position between the EGR and the engine so that at least two support parts are provided along the length direction of the EGR.

7. The method according to claim 6, characterized in that, The adjustment of the positional connection relationships of the connecting mechanisms in the range extender's geometric model to ensure that the adjusted energy density distribution map meets the first target condition includes: Adjust the connection position between the EGR and the engine so that one end of the connection mechanism is connected to the engine and the other end is connected to at least two circumferential surfaces of the EGR; and the connection structure is integrally formed.

8. The method according to claim 1, characterized in that, The frequency response simulation results include a stress distribution diagram; the frequency response simulation of the range extender geometric model to obtain the frequency response simulation results includes: Vibration excitations in a first direction, a second direction, and a third direction are applied to the geometric model of the range extender, wherein the frequency and amplitude of the vibration excitations are determined based on the engine operating conditions, and the first direction, the second direction, and the third direction are three mutually orthogonal spatial directions. For the vibration excitation of the connecting mechanism in each direction, obtain the stress distribution map of the corresponding direction.

9. The method according to claim 8, characterized in that, The plurality of range extender components include an engine, an EGR and a catalyst, and the connection mechanism includes a bracket and a bellows, the bracket being used to connect the engine and the EGR, and the bellows being used to connect the catalyst and the EGR; The step of adjusting the structural attribute parameters and / or positional connection parameters of the connecting mechanism in the range extender geometric model based on the frequency response simulation results includes: Identify at least one out-of-range region in the stress distribution map where the stress value exceeds the allowable stress threshold; If the area exceeding the standard includes the area where the bracket is located, a first design adjustment is made to the bracket in the connecting mechanism; wherein, the first design adjustment includes at least one of the following: increasing the local thickness of the bracket in the area exceeding the standard, adjusting the material type of the bracket, and adjusting the manufacturing process to one-piece casting; If the area exceeding the standard includes the area where the corrugated pipe is located, a second design adjustment is made to the corrugated pipe in the connection mechanism; wherein, the second design adjustment includes at least one of the following: adjusting at least one parameter among the number of corrugations, the corrugation length, and the number of pipe layers of the corrugated pipe.

10. The method according to claim 9, characterized in that, The method further includes: For the stress distribution described in each direction, obtain the maximum stress value; If the maximum stress value in a certain direction exceeds the maximum stress value in any other direction by N times, the assembly relationship between the connecting mechanism and the engine is adjusted so that the adjusted stress distribution diagram meets the second target condition, where N is greater than or equal to 1.

11. A device for determining the design parameters of a range extender connecting mechanism mold, characterized in that, The range extender includes: a plurality of range extender elements and a connecting mechanism, the connecting mechanism being used to connect the plurality of range extender elements; the device includes: The model acquisition module is used to acquire the geometric model of the range extender; The modal simulation module is used to perform modal simulation on the geometric model of the range extender and obtain the modal simulation results; The frequency response simulation module is used to perform frequency response simulation on the geometric model of the range extender and obtain the frequency response simulation results. The parameter adjustment module is used to adjust the structural attribute parameters and / or position connection parameters of the connecting mechanism in the range extender geometric model according to the modal simulation results and frequency response simulation results. The mold adjustment module is used to adjust the design parameters of the mold used to manufacture the connecting mechanism according to the adjusted parameters of the connecting mechanism.

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