CAD Crashworthiness Analytics Using Response Surface Models
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Solution Overview
Problem
Current computer-aided design (CAD) systems lack efficient and understandable methods for providing crashworthiness analytics during the conceptual design phase of vehicle development, as existing finite element models are computationally intensive and require significant trial-and-error in assigning parameters to vehicle frame components, which is impractical due to the complexity of vehicle structures and limited simulation expertise among design engineers.
Innovation Solution
A CAD system that includes a graphical user interface for configuring section dimensions of vehicle frame members, utilizing pre-computed response surface models to predict crash resistances, allowing design engineers to evaluate and optimize section parameters for improved crashworthiness without needing deep simulation knowledge or running extensive simulations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If finite element models are used for crash analysis during conceptual design phase, then measurement precision of crash behavior is improved, but productivity is worsened due to computational intensity and time consumption
Solution Approach 1:
The system pre-computes response surface models during an offline phase using finite element analysis, storing the results in a lookup table. During the conceptual design phase, engineers can quickly query pre-computed results based on section dimensions without running new simulations, thus achieving fast predictions with acceptable accuracy.
Solution Approach 2:
The system creates simplified representations of complex finite element models by generating response surface models that approximate crash behavior. These response surfaces serve as lightweight copies that can be evaluated instantly compared to the computationally intensive original FE models.
2Manufacturing precision
If trial-and-error method is used to assign parameters to frame components, then manufacturing precision of crash performance is improved, but loss of time is worsened due to extensive testing required
Solution Approach 1:
The system provides immediate feedback by querying pre-computed response surface models with proposed section dimensions and returning predicted crash behavior. This allows designers to iteratively optimize parameters by observing immediate results without waiting for time-consuming simulations, significantly reducing the optimization cycle time.
3Measurement precision
If detailed simulation analysis is performed on each section member, then measurement precision of crash resistance is improved, but device complexity is worsened due to number of components requiring analysis
Solution Approach 1:
The system divides the vehicle frame into discrete section members with standardized cross-sectional dimensions. Each section type has its own pre-computed response surface model, allowing independent analysis and optimization of individual members without analyzing the entire vehicle structure, thus simplifying the overall complexity.
4Reliability
If finite element simulations are run for each design iteration, then reliability of crash analysis is improved, but productivity is worsened due to computational requirements
Solution Approach 1:
The system performs comprehensive finite element simulations in advance to build response surface models covering a range of section dimensions and crash scenarios. These pre-computed models capture the essential physics and can be queried instantly during design iterations, maintaining reliability while enabling rapid exploration of design alternatives.
Data Source
AI summary
A computer-aided design system includes a display device, a memory storing a plurality of response surface models, and a processor configured to: (a) display a graphical user interface that includes a model of a vehicle frame; (b) display a section configuration panel that includes one or more section dimension values for one or more section dimensions of a first section member of the plurality of section members; (c) retrieve a first response surface model based on values of the one or more section dimensions for the first section member; (d) determine one or more predicted values associated with the first section member based on the values of the section dimensions, the predicted values include one or more predicted crash resistances for the section member; and (e) display the predicted values, thereby allowing the user to evaluate the predicted values for suitability in vehicle design.