Crashworthiness design and experimental validation of a novel collision post structure for subway cab cars

地铁车辆司机室新型防撞柱结构的耐撞性设计与试验验证

This paper proposes a novel collision post structure designed to improve the crashworthiness of subway cab cars.The structure provides two innovative features:1)a simpler connection between the post and the car roof,which gives a more reasonable load transfer path to reduce the stress concentration at the joint;and 2)a stiffness induction design that provides an ideal deformation model to protect the safe space of the cab cars.The novel collision post structure was evaluated with finite element analysis,and a prototype cab car was mechanically tested.The results demonstrate that the deformation response was stable and agreed well with the expected ideal mode.The maximum load was 874.17 kN and the responses remained well above the elastic design load of 334 kN as required by the design specification.In addition,there was no significant tearing failure during the whole test process.Therefore,the novel collision post structure proposed has met the requirements specified in new standard to improve the crashworthiness of subway cab cars.Finally,the energy absorption efficiency and light weight design highlights were also summarized and discussed.

为了改善地铁车辆司机室的耐撞性能,本文提出了一种新型的防撞柱结构设计方案。该结构的创新之处主要有两点:1)防撞柱体与车体顶部的连接更为简单,这使得力流分配更加合理,避免了关键连接部位的应力集中;2)防撞柱体内部结构采用了刚度诱导设计方案,使得其在承受压溃力时可以获得理想的变形模式,从而更好的保护司机室的安全空间。在本文中,对该新型防撞柱结构进行了碰撞场景的有限元分析和相应的原型车试验。结果表明,该结构的变形模式稳定且与预计的理想模式高度一致。试验时,最大载荷为874.17 kN,并且压溃过程中载荷全程高于弹性设计载荷334 kN。除此之外,试验中并未有明显的结构撕裂失效现象。因此,本文提出的新型防撞柱结构能够满足新标准的全部设计要求,有效改善地铁车辆司机室的耐撞性能。最后,本文对该结构的吸能效率以及轻量化设计方面的亮点同样进行了总结和讨论。