Abstract:

According to the ECE R66, the structure of bus body was optimized for lightweight based on the tube filling method herein. Uniform design method was used to set the experimental scheme on the side pillars and roof crossbeams of bus body with different thicknesses of steel tube and lengths of filler in the tube, simultaneously a series of simulation studies on bus rollover safety were conducted. Based on the regression analysis of the simulation results, the regression functions were established by SAS software, the design variables were optimized by MATLAB software. The results show that, under the conditions of bus body meeting ECE R66 for living space, the total weight of optimized side pillar and roof crossbeam structures is decreased by 23.7% and the lightweight design of bus body is realized.

Key words: tube filling, rollover safety, lightweight, simulation analysis

摘要：

按照欧洲ECE R66法规，基于管内填充方法，以车身轻量化为优化目标，对某客车的车身骨架结构进行了优化设计。采用均匀试验设计方法对车身侧围立柱和顶横梁的壁厚及管内填充长度等设计变量进行了仿真实验设计和侧翻碰撞仿真模拟，采用SAS软件对仿真结果进行回归分析并建立了回归函数，利用MATLAB软件对设计变量进行了优化。结果表明，客车车体在满足ECE R66法规对生存空间要求的情况下，侧围立柱和顶横梁优化后的结构比原结构质量减轻了23.7%，实现了车身结构轻量化。
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关键词: 管内填充, 侧翻安全性, 轻量化, 仿真分析