技术领域technical field
本发明涉及汽车设计领域，尤其涉及一种利用仿真技术布置安全系统传感器的方法。The invention relates to the field of automobile design, in particular to a method for arranging safety system sensors by using simulation technology.
背景技术Background technique
近年来，我国的新能源客车技术和客车产品在使用性能和产品质量上有很大的提高。客车技术标准也在逐渐与国际先进水平接轨。但由于我国客车产品的整体技术水平起步较晚，而单靠实验来进行新能源客车切氢切电安全系统设计其耗资巨大且设计周期漫长。因此利用CAE仿真技术代替实验来进行客车安全系统设计成为简单可行的方法，为减少新能源客车在碰撞事故中由于氢瓶，电池，燃料堆，高压线束，高压元器件接头短路泄露，电火花等伤害，迫切需要对新能源客车进行碰撞条件下的切氢切电安全系统设计。In recent years, my country's new energy bus technology and bus products have greatly improved in terms of performance and product quality. The technical standards of passenger cars are also gradually in line with the international advanced level. However, due to the late start of the overall technical level of passenger car products in my country, the design of the safety system of hydrogen and electricity cutting for new energy buses is costly and the design cycle is long. Therefore, using CAE simulation technology instead of experiments to design passenger car safety systems has become a simple and feasible method. In order to reduce the impact of new energy buses on collision accidents caused by hydrogen bottles, batteries, fuel stacks, high-voltage wiring harnesses, high-voltage component joints, short-circuit leakage, electric sparks, etc. There is an urgent need to design a safety system for cutting hydrogen and electricity under collision conditions for new energy buses.
然而目前新能源客车安全系统设计既缺乏相关的法规和技术规范也缺乏一种实用有效的方法，用传统的实车实验的方法进行安全系统设计既费时成本也非常高，缺少可操作性；However, the current safety system design of new energy buses lacks relevant regulations and technical specifications, and also lacks a practical and effective method. Using the traditional method of real vehicle experiments to design safety systems is time-consuming and costly, and lacks operability;
快速、准确的产品研发能力，才能缩短新产品的研发过程，领先市场地位。如何在整个产品的研发中缩短整个过程，提升产品研发效率，缩短产品上市的时间，且还能确保产品的安全性，已是目前汽车厂商所迫切需要解决的技术重点，有鉴于此，如今迫切需要设计一种新的方法，以便改进现有方法的上述缺陷。Rapid and accurate product R&D capabilities can shorten the R&D process of new products and lead the market. How to shorten the entire process of product development, improve the efficiency of product development, shorten the time to market, and ensure the safety of the product is an urgent technical focus for automobile manufacturers. In view of this, it is now urgent Need to design a kind of new method, so that improve above-mentioned defect of existing method.
发明内容Contents of the invention
本发明所要解决的技术问题是提供一种新能源客车切氢切电安全系统的传感器布置方法，该方法根据客车碰撞与安全仿真规范对所输入的产品设计模型、材料参数进行数值分析及仿真测试，对初始传感器的布置进行筛选，找出传感器的最佳布点位置，可大幅节省研发人员设计产品所需的时间，提高设计的效率，降低设计成本。The technical problem to be solved by the present invention is to provide a sensor layout method for the safety system of hydrogen-cutting and electricity-cutting for new energy buses. The method performs numerical analysis and simulation testing on the input product design model and material parameters according to the passenger car collision and safety simulation specifications. , to screen the initial sensor layout and find out the best sensor layout position, which can greatly save the time required for R&D personnel to design products, improve design efficiency, and reduce design costs.
本发明是这样实现的：一种新能源客车切氢切电安全系统的传感器布置方法，包括以下步骤：首先输入模块接收车辆的设计模型和车辆所用材料的性能参数；然后在车辆的设计模型内虚拟布置一组传感器作为信号输出，并设定传感器输出信号的边界条件；接着处理模块根据车辆的设计模型、机械性能参数、传感器的位置进行数值分析仿真测试，数值分析仿真测试包括前碰，整车各关键部位的侧碰，后碰测试分析，根据测试分析结果判断传感器的布置是否符合新能源客车切氢切电安全系统对输出信号的要求，不符合输出信号要求的传感器删除或调整位置，符合输出信号要求的传感器保留，并再次虚拟布置一组传感器进行数值分析仿真测试，直至有足够数量传感器能够满足输出信号的要求；最后输出传感器布置方案，完成新能源客车切氢切电安全系统的传感器布置。The present invention is realized in this way: a sensor layout method for a safety system of hydrogen and electricity cutting in new energy buses, comprising the following steps: firstly, the input module receives the design model of the vehicle and the performance parameters of the materials used in the vehicle; then, in the design model of the vehicle Virtually arrange a group of sensors as signal output, and set the boundary conditions of the sensor output signal; then the processing module conducts numerical analysis and simulation tests according to the design model of the vehicle, mechanical performance parameters, and the position of the sensors. Test and analyze the side impact and rear impact of each key part of the vehicle. According to the test and analysis results, it is judged whether the arrangement of the sensors meets the requirements of the output signal of the safety system for hydrogen and electricity cutting of new energy buses. The sensors that do not meet the requirements of the output signal are deleted or adjusted. The sensors that meet the output signal requirements are retained, and a group of sensors are virtually arranged again for numerical analysis and simulation testing, until a sufficient number of sensors can meet the output signal requirements; finally, the sensor layout plan is output to complete the new energy bus safety system for hydrogen and electricity cutting Sensor placement.
所述的车辆的设计模型为利用3D软件产生车辆轮廓，再将车辆轮廓生成为元素网格，然后将元素网格通过Hypermesh软件输出转换成含有节点、元素坐标相关位置的文字文件。The design model of the vehicle is to use 3D software to generate the vehicle outline, then generate the vehicle outline as an element grid, and then convert the element grid into a text file containing nodes and element coordinates through Hypermesh software output.
所述车辆所用材料的性能参数为该材料的机械性能参数包括材料的屈服极限、抗拉强度等、硬度、 弹性泊松比、塑性延伸率。The performance parameters of the material used in the vehicle are the mechanical performance parameters of the material, including the yield limit, tensile strength, etc., hardness, Poisson's ratio of elasticity, and plastic elongation of the material.
所述数值分析仿真测试利用动力分析程序LS-DYNA来实现。The numerical analysis simulation test is realized by using the dynamic analysis program LS-DYNA.
本发明新能源客车切氢切电安全系统的传感器布置方法利用客车传感器布点要求规范及判据，并根据客车碰撞与安全仿真规范对所输入的产品设计模型、材料参数进行数值分析及仿真测试，对初始传感器的布置进行筛选，找出传感器的最佳布点位置，可获取最符合设想的设计方案，方便设计人员对新能源客车切氢切电安全系统进行优化设计，可大幅节省研发人员设计产品所需的时间，提高设计的效率，降低设计成本，适用于燃料电池客车，油电混合动力客车，纯电动客车。The sensor arrangement method of the hydrogen-cutting electricity-cutting safety system of the new energy bus of the present invention utilizes the specification and criteria for the layout of the bus sensor, and performs numerical analysis and simulation testing on the input product design model and material parameters according to the bus collision and safety simulation specification, Screening the layout of the initial sensors to find out the best placement of the sensors can obtain the most conceived design scheme, which is convenient for designers to optimize the design of the safety system of hydrogen and electricity cutting for new energy buses, which can greatly save R&D personnel in designing products The required time is improved, the design efficiency is improved, and the design cost is reduced. It is suitable for fuel cell buses, gasoline-electric hybrid buses, and pure electric buses.
附图说明Description of drawings
图1为本发明新能源客车切氢切电安全系统的传感器布置方法的流程框图；Fig. 1 is the block flow diagram of the sensor arrangement method of the safety system of hydrogen cutting and electricity cutting of new energy passenger car of the present invention;
图2为本发明中新能源客车切氢切电安全系统的构架图；Fig. 2 is the frame diagram of the safety system of cutting hydrogen and electricity of new energy passenger car in the present invention;
图3为本发明实施例中的车辆轮廓元素网格图；Fig. 3 is a grid diagram of vehicle outline elements in an embodiment of the present invention;
图4为本发明实施例中的传感器布置示意图。Fig. 4 is a schematic diagram of sensor arrangement in an embodiment of the present invention.
图中：1第一传感器、2第二传感器、3第三传感器、4第四传感器、5第五传感器、6第六传感器、7第七传感器、8第八传感器。In the figure: 1 first sensor, 2 second sensor, 3 third sensor, 4 fourth sensor, 5 fifth sensor, 6 sixth sensor, 7 seventh sensor, 8 eighth sensor.
具体实施方式detailed description
下面结合具体实施例，进一步阐述本发明。应理解，这些实施例仅用于说明本发明而不用于限制本发明的范围。此外应理解，在阅读了本发明表述的内容之后，本领域技术人员可以对本发明作各种改动或修改，这些等价形式同样落于本申请所附权利要求书所限定的范围。Below in conjunction with specific embodiment, further illustrate the present invention. It should be understood that these examples are only used to illustrate the present invention and are not intended to limit the scope of the present invention. In addition, it should be understood that after reading the content of the present invention, those skilled in the art may make various changes or modifications to the present invention, and these equivalent forms also fall within the scope defined by the appended claims of the present application.
实施例1Example 1
如图1、2所示，一种新能源客车切氢切电安全系统的传感器布置方法，包括以下步骤：首先对车辆进行有限元建模，即输入模块接收车辆的设计模型和车辆所用材料的性能参数，所述的车辆的设计模型为利用3D软件产生车辆轮廓，车辆轮廓包括焊点及结构联接信息，再将车辆轮廓生成为元素网格，然后将元素网格通过Hypermesh软件输出转换成含有节点、元素坐标相关位置的文字文件；所述车辆所用材料的性能参数为该材料的机械性能参数包括材料的屈服极限、抗拉强度等、硬度、 弹性泊松比、塑性延伸率。As shown in Figures 1 and 2, a sensor layout method for a new energy bus safety system for hydrogen and electricity cuts includes the following steps: firstly, the finite element modeling of the vehicle is carried out, that is, the input module receives the design model of the vehicle and the materials used in the vehicle Performance parameters, the design model of the vehicle is to use 3D software to generate the vehicle outline, the vehicle outline includes welding points and structural connection information, and then the vehicle outline is generated as an element grid, and then the element grid is converted into an element grid through the Hypermesh software output. The text files of the relative positions of nodes and element coordinates; the performance parameters of the material used in the vehicle are the mechanical performance parameters of the material, including the yield limit, tensile strength, hardness, elastic Poisson’s ratio, and plastic elongation of the material.
然后在车辆的设计模型内虚拟布置一组传感器作为信号输出，并设定传感器输出信号的边界条件；Then a group of sensors are virtually arranged in the design model of the vehicle as signal output, and the boundary conditions of the sensor output signals are set;
接着处理模块根据车辆的设计模型、机械性能参数、传感器的位置进行数值分析仿真测试，所述数值分析仿真测试利用动力分析程序LS-DYNA来实现，数值分析仿真测试包括前碰，整车各关键部位的侧碰，后碰测试分析，根据测试分析结果判断传感器的布置是否符合新能源客车切氢切电安全系统对输出信号的要求，不符合输出信号要求的传感器删除或调整位置，符合输出信号要求的传感器保留，并再次虚拟布置一组传感器进行数值分析仿真测试，直至有足够数量的传感器能够满足输出信号的要求；Then the processing module performs numerical analysis simulation test according to the design model of the vehicle, mechanical performance parameters, and the position of the sensor. The numerical analysis simulation test is realized by using the dynamic analysis program LS-DYNA. The side impact and rear impact test analysis of the parts, according to the test and analysis results, judge whether the arrangement of the sensors meets the requirements of the output signal of the new energy bus safety system for cutting hydrogen and electricity, delete or adjust the position of the sensors that do not meet the requirements of the output signal, and meet the output signal The required sensors are retained, and a group of sensors is placed virtually again for numerical analysis and simulation testing until a sufficient number of sensors can meet the requirements of the output signal;
最后输出传感器布置方案，完成新能源客车切氢切电安全系统的传感器布置。Finally, output the sensor layout plan to complete the sensor layout of the hydrogen and electricity cutting safety system of the new energy bus.
以本公司一款新能源客车为例，首先对车辆进行有限元建模，即输入模块接收车辆的设计模型和车辆所用材料的性能参数，所述的车辆的设计模型为利用3D软件产生车辆轮廓，车辆轮廓包括焊点及结构联接信息，再将车辆轮廓生成为元素网格，然后将元素网格通过Hypermesh软件输出转换成含有节点、元素坐标相关位置的文字文件；所述车辆所用材料的性能参数为该材料的机械性能参数包括材料的屈服极限、抗拉强度等、硬度、 弹性泊松比、塑性延伸率，得到如图3所示的新能源客车网格模型示意图，在车辆的前中后部虚拟布置8个传感器，如图4所示，8个传感器分别独立编号，第一传感器1序号为3838429、第二传感器2序号为3712157，第三传感器3序号为3729812，第四传感器4序号为3704479，第五传感器5序号为3682007，第六传感器6序号为3700999，第七传感器7序号为3748909，第八传感器8序号为3807440。传感器触发条件：是否出现大于3个G的加速度信号。输出信号的要求：单个碰撞工况，在低速工况下传感器在10ms内加速度小于3个G不能触发信号，且在高速工况下传感器在10ms内加速度到达3个G触发信号为合格；高、低速工况都触发的传感器为不合格。允许单个碰撞工况合格的传感器在其他碰撞工况中，高、低速工况都不触发信号。最终要求有足够数量单个碰撞工况合格的传感器，覆盖满足每个碰撞工况，前碰，整车各关键部位的侧碰，后碰的触发要求。利用动力分析程序LS-DYNA得到各碰撞工况中高速和低速工况所有传感器加速度数值，绘制成加速度随时间变化曲线，根据传感器加速度数值的时间变化曲线得到如表1所示的传感器触发状况，得到测试结果，表1中，信号不触发用“O”、触发用“1”表示。根据数值分析仿真测试结果，按照触发要求，表1中“高速”列的数据为“1”，“低速”列的数据为“0”的传感器满足布置要求。根据表1归纳的计算结果，2号传感器满足除侧碰工况3与4之外所有碰撞工况的布置要求，8号传感器恰好满足了侧碰工况3与4的布置要求，两个传感器覆盖满足了每个碰撞工况的触发要求，最终选择第2、8号传感器为最终布置的传感器，完成该新能源客车切氢切电安全系统的传感器布置的设计。如果在本轮分析中，没有足够数量的传感器覆盖满足触发要求，则删除单一工况不合格的传感器，再次虚拟布置一组传感器进行数值分析仿真测试，直至有足够数量的传感器覆盖满足触发要求，完成传感器布置设计。Taking a new energy bus of our company as an example, firstly, the finite element modeling of the vehicle is carried out, that is, the input module receives the design model of the vehicle and the performance parameters of the materials used in the vehicle. The design model of the vehicle is to use 3D software to generate the vehicle outline , the vehicle outline includes welding points and structural connection information, and then the vehicle outline is generated as an element grid, and then the element grid is converted into a text file containing nodes and element coordinates through Hypermesh software output; the performance of the materials used in the vehicle The parameters are the mechanical performance parameters of the material, including the yield limit, tensile strength, hardness, elastic Poisson's ratio, and plastic elongation of the material. The schematic diagram of the grid model of the new energy bus is obtained as shown in Figure 3. Eight sensors are virtual arranged in the rear, as shown in Figure 4, the eight sensors are numbered independently, the serial number of the first sensor 1 is 3838429, the serial number of the second sensor 2 is 3712157, the serial number of the third sensor 3 is 3729812, and the serial number of the fourth sensor 4 The serial number of the fifth sensor 5 is 3682007, the serial number of the sixth sensor 6 is 3700999, the serial number of the seventh sensor 7 is 3748909, and the serial number of the eighth sensor 8 is 3807440. Sensor trigger condition: whether there is an acceleration signal greater than 3G. Requirements for the output signal: under single collision conditions, the sensor cannot trigger the signal when the acceleration is less than 3 G within 10ms under low-speed conditions, and the trigger signal is qualified if the sensor accelerates to 3 G within 10ms under high-speed conditions; Sensors that are triggered under low-speed conditions are unqualified. A sensor that is allowed to pass a single crash condition does not trigger a signal under high or low speed conditions in other crash conditions. Ultimately, it is required to have a sufficient number of sensors qualified for a single collision condition to cover and meet the trigger requirements of each collision condition, front collision, side collision and rear collision of key parts of the vehicle. The dynamic analysis program LS-DYNA is used to obtain the acceleration values of all sensors in the high-speed and low-speed conditions of each collision condition, and draw the acceleration versus time curve. According to the time-varying curve of the sensor acceleration value, the triggering status of the sensor is obtained as shown in Table 1. Get the test results, in Table 1, the signal is not triggered by "O", and the trigger is represented by "1". According to the simulation test results of numerical analysis, according to the trigger requirements, the sensors whose data in the "high speed" column is "1" and the data in the "low speed" column are "0" in Table 1 meet the layout requirements. According to the calculation results summarized in Table 1, sensor No. 2 meets the layout requirements of all collision conditions except side collision conditions 3 and 4, and sensor No. 8 just meets the layout requirements of side collision conditions 3 and 4. The two sensors The coverage meets the triggering requirements of each collision condition, and finally the No. 2 and No. 8 sensors are selected as the final sensors to complete the design of the sensor layout of the new energy bus safety system for hydrogen and electricity cut. If in this round of analysis, there is not enough sensor coverage to meet the triggering requirements, delete the unqualified sensors in a single working condition, and then arrange a group of sensors for numerical analysis and simulation testing until there are enough sensor coverage to meet the triggering requirements. Complete the sensor layout design.
表1传感器触发状况。Table 1 Sensor trigger conditions.
| Application Number | Priority Date | Filing Date | Title |
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| CN201310339492.2ACN103455663B (en) | 2013-08-01 | 2013-08-01 | Integral new-energy passenger is cut hydrogen and is cut the sensor arrangement method of electricity security system |
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| CN201310339492.2ACN103455663B (en) | 2013-08-01 | 2013-08-01 | Integral new-energy passenger is cut hydrogen and is cut the sensor arrangement method of electricity security system |
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