Simulation Analysis And Experimental Research For Occupant Safety Of Commercial Vehicle Cab

In recent years,with the promulgation and implementation of Chinese passive safety standards of passenger vehicle,domestic passenger vehicle passive safety design level of research and development has a significant upgrade; but the research work for commercial vehicle passive safety is just the beginning, relevant national standard has not yet implemented. Therefore, research of in-depth system simulation analysis and test of commercial vehicle cab passive safety has important theory significance and practical value in order to improve Chinese own-brand commercial vehicle passive safety technology level and enhance its competitiveness in the international market and improve the commercial vehicle occupants protection performance.This article is combined with the national 863 project"high quality heavy duty commercial vehicle integrated development advanced technology", some design structure problems were found concerning a commercial vehicle cab with regard to the export approval of front impact and roof strength test according to ECE R29-02, the cab of passive safety of finite element simulation analysis model is established, LS-DYNA software is used in accordance with the regulations test requirements for cab passive safety simulation analysis, having compared the result of virtual tests with real vehicle tests, the validity of the model had been verified. At the same time, topology optimization structure improvement design for broken cab front suspension brackets is done during the process of front crash,structure improvement design was completed for floor, front-wall and rear-wall, the feasibility of the improved design structure had been verified by real vehicle test.This article is further combined with the author's unit research project"a new generation of commercial vehicle planning", commercial vehicle which export to Europe should be pass new regulation ECE R29-03 test certification in five years, the cab having been passed according to ECE R29-02 was performed virtual test simulation analysis according to ECER29-03, studies were done concerning the whole cab structure strength, rigidity, the force transfer path and passive safety in the case of crash and load, after many cycles of simulation analysis and improvement of structure, the results show that cab surface skin(inner and outer panel) has little support act in the case of crash and load, otherwise, cab skeleton(transversel and longitudinal support beams ) is main support parts, reasonable skeleton structure design and force transfer path is key technology for cab to demand the requirements of passive safety technology.This article carried out in-depth system simulation analysis and test research of commercial vehicle cab passive safety,the main research work is as follows:1. Analysing international regulations difference for European, American and Swedish concerning the cab of a commercial vehicle passive safety test requirements, contrasting test requirements for exiting and new regulation of ECE R29, it provides a reference for China's commercial vehicle R & D and exports.2. Adopting OptiStruct software to perform topology optimization improvement design for broken cab front suspension brackets, the purpose was realized for effectively utilizing the CAE method to quickly resolve the problem of design structure.3. Combined finite element simulation with real vehicle test, it can effectively improve the cab rollover accident overall crashworthiness for overall skeleton structure of the cab and a reasonable force transfer path design.4. An energy-absorbing devices is adopted on cab front-end parts in order to absorb front impact energy. Its effective energy-absorbing function is verified by simulation analysis, it is an effective scheme for reducing cab structure deformation during frontal collision.5. A new method which fills with reinforced-bonding and increases section size for A-pillar was selected in order to solve cab A-pillar serious deformation during A-pillar impact test, an ideal way for the compatibility of cab weight reduction and crashworthiness was determined.6. Comparing simulation test result concerning three styles roof impactor crash concerning new regulation ECE R29-03, a simple and easy test method of commercial vehicle passive safety test is provided, it has some instruction function for the effective utilization of current test equipment and renovation.This article's research results provide the basis for Chinese independent research and development commercial vehicle passive safety to reach the international advanced level. It has a certain practical and reference value for commercial vehicle passive safety national standards to establish and perfect.