Car Body Stiffness Optimization via Dynamic Simulation
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Solution Overview
Problem
Current car body construction optimization methods rely on static torsional stiffness calculation models, which fail to accurately consider local stiffness variations across different areas of the car body, leading to unreliable squeak & rattle performance and potential compromises in crashworthiness.
Innovation Solution
A method involving dynamic and equivalent static load simulation models to determine deformation values of selected car body elements, allowing for the optimization of car body construction by applying forces to a reduced model and verifying results against a fully trimmed model, ensuring desired deformation ranges are met without compromising crashworthiness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a stiff car body construction is used to reduce squeak and rattle, then NVH performance is improved, but crashworthiness deteriorates due to limited deformation capacity
Solution Approach 1:
The patent applies local quality by differentiating stiffness requirements across different car body areas. The method calculates and evaluates local stiffness characteristics of individual car body elements (such as pillars, roof, hood) separately, allowing optimization of each region's deformation behavior. This enables stiff regions to reduce squeak and rattle while permitting controlled deformation in crash-relevant areas, thus resolving the contradiction between NVH performance and crashworthiness.
2Device complexity
If static torsional stiffness calculation models are used to optimize car body construction, then optimization process is simplified, but measurement precision deteriorates due to inability to capture local stiffness variations
Solution Approach 1:
The patent implements segmentation by dividing the car body into multiple discrete elements (pillars, roof panels, hood, trunk lid, etc.) and calculating stiffness characteristics for each element separately. The method extracts local stiffness values from finite element models for individual components rather than relying on a single global torsional stiffness value. This segmentation approach maintains computational efficiency while significantly improving the precision of local stiffness assessment, enabling more accurate prediction of squeak and rattle behavior in specific car body regions.
Data Source
AI summary
A method for optimizing construction of a car body includes selecting body element(s) and obtaining first deformation values therefor from a fully-trimmed model of a first car body construction based on measured dynamic values or simulated dynamic data in a dynamic load simulation during a time period; determining force(s) to be applied to a reduced model of the first car body construction in an equivalent static load simulation model to achieve second deformation values of the element(s) for the reduced model, the second values correspond to the first values for the same element(s); applying in the equivalent static load simulation model, the determined force(s) to a reduced model of an alternative car body construction to achieve third deformation values of the element(s) for the reduced model of the second car body construction; determining if the third values are within a predetermined deformation range for the second car body construction.