Bus Air Conditioner Sheet Metal Major Structure Finite Element Analysis And Optimization Design

Usually, bus air-conditioner is installed on top of bus. As the road situation is complex,the bus body vibration coming from the road will directly transfer to the air-conditionerwhich installed on the bus top.Therefore bus air-conditioner runs usually under thecomplex and irregular vibration environment. Vibration failure is common failure modehappened in bus air-conditioner, so during product structure designing, the structurestrength analysis is design key point. Paper with a company bus air-conditioner mainstructure as research object and for the failure modes happened during the actual running,process finite element analysis and propose improved design scheme. The main workcontent as below:1) For the occurrence of sheet metal frame fracture failure about bus air-conditioner inone company, firstly analyze the sheet metal material and mechanical property.Find thatthe material and mechanical property can’t meet the standard requirement. Secondlyintroduce and analyze the original design scheme of this structure and utilize Pro/Engineerto create3D model, then process stress analysis by means of finite element analysissoftware ANSYS, then find the maximum stress and stress concentration positions. Themaximum stress and the stress concentration positions are totally the same with thefracture positions.On this basis, proposes improvement methods for the fracture frame.Themaximum stress of the improved frame has been decreased sharply compared with theoriginal frame. The maximum decreasing amplitude is92%。The Stress concentrations ofthe fracture positions are resolved at the same time. 2) For the bus air-conditioner lifting eye fell off during lifting operation, firstly create3D solid model of the lifting eye and installation beam according to the original designscheme, then analyze the stress, find that the original design lifting eye and installationbeam strength can’t meet the requirement. On this basis, propose improvement designscheme and analyze,the maximum stress of the improved frame has been decreased sharplycompared with the original frame. The maximum decreasing amplitude is63%。3) In laboratory vibration platform, firstly test the original design scheme sample tosimulate the filed fracture failure mode, and at the same time, to verify the feasibility of thetest input condition. Then use the same test input condition to test the improved designscheme sample, the test result shows that there are no failure mode happened on theimproved design sample.