电动汽车直形收缩梁的轻量化设计与耐撞性分析

Design of straight-retractable energy-absorbing beam for electric cars and its crashworthiness analysis

电动车续航里程过短是影响推广应用的主要瓶颈因素之一,而电动汽车车身结构的轻量化是提高续航里程的有效途径。该文提出了两款新型梁——直形收缩梁和锥形收缩梁,对某款电动汽车原吸能部件,进行轻量化设计。建立了电动汽车正面碰撞结构模型,运用Hypermesh和LS-DYNA软件,对新型吸能梁和原吸能梁进行低速(16km/h)碰撞和高速(50km/h)碰撞模拟,研究了其碰撞能量吸收、刚性墙撞击力、车身加速度等碰撞行为。仿真计算结果表明:新型直形收缩梁在高速碰撞时吸能提高了18.0%,同时吸能部件的质量减轻了23.6%,兼顾了电动汽车零部件的轻量化和耐撞性。

The insufficient mileage is one of the major bottleneck factors which affect the promotion and application of electric cars. To reduce the electric vehicle body mass is an effective way to improve the mileage of an electric vehicle. Two kinds of contraction beams, straight retractable （SR） and tapered retractable （TR） beams, were designed to lighten the electric car mass. A frontal crash model was established by using the Hypermesh and LS-DYNA to study the frontal structural component crashworthiness of an electric car during collisions at a low-speed of 16 km/h and a high-speed of 50 km/h. The collision energy absorption, the impact force, and the body acceleration, when using new energy-absorbing beams, were analyzed and compared with those when using the original energy-absorbing beam. Simulation results demonstrate that the straight retractable beam can absorb more crash energy by 18.0% at the high-speed collision and reduce the mass by 23.6%, which optimizes both the light mass and the crashworthiness of an electric car.