Vehicle Component Impact Testing via Simulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conducting crash tests on fully assembled vehicles to determine the integrity of individual components is costly and time-consuming, as it requires a comprehensive setup for each test.
Innovation Solution
A method involving computer-aided-design simulations to replicate the impact between a simulated wheel and vehicle component, determining the impact angle and energy absorption, and using a sled with adjusted mass and speed to test the component's integrity, allowing for targeted reinforcement and design updates without full vehicle assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If crash tests are conducted on fully assembled vehicles to determine component integrity, then measurement precision of component integrity is improved, but device complexity and cost increase
Solution Approach 1:
The patent segments the crash test system by separating the component of interest from the full vehicle assembly. Only the specific vehicle component under test is mounted on the test sled, while other vehicle systems are excluded. This segmentation maintains measurement precision for the target component while dramatically reducing device complexity and test cost.
Solution Approach 2:
The patent extracts the essential impact parameters from a full vehicle crash test and applies them directly to the isolated component test. By taking out only the necessary elements (impactor, sled, component mounting) and excluding unnecessary vehicle systems, the method achieves component integrity assessment without requiring complete vehicle assembly.
2Reliability
If crash tests are conducted on fully assembled vehicles, then reliability of component integrity data is improved, but loss of time increases
Solution Approach 1:
The patent performs preliminary computational simulations to determine optimal impact parameters (force, angle, velocity) before conducting physical component tests. This preliminary action allows the physical tests to be more efficient and targeted, reducing overall test time while maintaining data reliability through pre-validated test protocols.
Solution Approach 2:
The patent applies partial action by conducting only the specific impact tests necessary for the component under review, rather than performing comprehensive full-vehicle crash tests that examine all vehicle systems. This focused approach reduces time loss while maintaining reliability for the specific component integrity assessment.
3Productivity
If computational simulations are used to determine impact parameters, then productivity of test setup is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent creates a computational model that copies and simulates the physical crash scenario to determine optimal impact parameters. This virtual copying allows rapid iteration and optimization of test parameters without physical prototyping, improving productivity while the subsequent physical tests validate and refine the simulated parameters to achieve required precision.
Data Source
AI summary
A method includes simulating an impact between a simulated wheel and a simulated vehicle assembly, the simulated vehicle assembly including a simulated vehicle component that is a computer-aided-design model of a vehicle component. The method includes determining, based on the simulated impact, an impact angle between the simulated wheel and the simulated vehicle assembly. The method includes impacting an impactor with the vehicle component at the impact angle.