Engine oil pans optimization within a vehicle crash scenario
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Engine oil pans optimization within a vehicle crash scenario

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    Engine oil pans optimization within a vehicle crash scenario Engine oil pans optimization within a vehicle crash scenario Presentation Transcript

    • Engine oil pans optimizationwithin a vehicle crash scenarioB.Charlet6th European Altair Technology Conference - 2013
    • AbstractTitle:Engine oil pans optimization within a vehicle crash scenarioAuthor:• Bernard Charlet• PSA Peugeot Citroën, La Garenne, France• +33156477407• bernard.charlet@mpsa.comAbstractEngine downsizing is a strong trend in automotive industry. Engines are getting lighter and smaller and are installed inbigger cars. As a consequence the integrity of the engine to vehicle crash, either for compliance to safety rules ordifferent Euro NCAPs crash tests, is no longer guaranteed. It becomes necessary to maintain impact resistance whileoptimizing engine mass. PSA initiated a collaborative work with Altair, in order to test latest optimizationdevelopments.Topological optimization is a powerful way to achieve minimum mass within geometrical constraints. The challengehere was to work with variable load and strongly non-linear behaviour. In our case the specifications were a set oftime-dependant forces applied on the engine. These forces were extracted from a complete crash analysis. The aimwas to avoid engine collapse during crash time. The ESLM method was first tested but convergence issues weredetected. Then manual samplings of the loads were done and several section patterns were tested: samplings of thetime step and peaks load to take into account. Eventually, a new geometry that reaches the goal was identified, thatallows a gain of 50% resistance with 10% of additional mass.26th European Altair Technology Conference - 2013
    • 3IntroductionPSA PEUGEOT CITROËN3,500,000 vehicles sold worldwide (2011)Europe’s number two carmaker with a 13 % share of the marketInnovations and new technologies to reduce CO2 emissionsDownsizing policy to reduce engine capacity without reducing powerThe protection of the occupants of the vehicles, is a priority topic of R & D for PSAPeugeot Citroën, most of recent models reach 5 stars at crash-tests Euro NCAP.6th European Altair Technology Conference - 2013
    • 4Problem DefinitionImplication of the engine in the scenarioDepending of the country, the semi barrier of EuroNcap’s test is :• Either on the left when steering wheel is on the left.• Or on the right when steering wheel is on the right.In PSA vehicle, gear boxes are on the left side and engine on the right side.• When semi barrier is on the left the gear box is part of the crash scenario.• When semi barrier is on the right, it’s the engine which then play an important roleDownsizing: New and lighter engine in vehicleLower parts (Oilpans) being mainly aluminum shellsSpecification from the vehicule are forces with time duration6th European Altair Technology Conference - 2013
    • Definition of SpecificationsNeedsTransfert of forces toward the lower part ofcar’s bodyLimitation of the intrusion of the engine in thefront body panelPoints of impactImpact from the transmission bar to the oilpanthrough an impactorImpact of subframe on the lower part ofimpactorSpecificationsLoads vs time on the enginefrom crash simulations56th European Altair Technology Conference - 2013
    • 6Initial crash analysisCurrent StatePerformances to be achievedIn this case, a collision happens between the subframe and the engine blockand between the transmission rod and the engine block. Loads target aremeasured with Times Histories (TH).This Times Histories allow us to observe the behavior of the system anddefine the performance to be achieved.6th European Altair Technology Conference - 2013
    • Objectives of the studyDevelop a method to optimize an engine oil pan within its environment witha crash type scenario in order to improve its behavior.Proposal of new oilpan definition, based on this method, with respect to theperformances below :Increases the strength of the oil panDelays breakingMinimizes the mass added to the global system76th European Altair Technology Conference - 2013
    • 6th European Altair Technology Conference - 2013 8Setting up of the studyPSAALTAIRengineering• Selecting the type of optimization• Find the most appropriate method toperform this optimization• Writing methodological manuallinearization for topology optimizationof a crash type loading in OptiStructDefine :• The current problems and goals• The kinematics of the crash scenario• The sensors to observeRole of the two company during the project :
    • 9Optimization ProcessCrash analysisCrash analysisLinearization of crash loadingLinearization of crash loadingSub-model & Subcases for optimizationSub-model & Subcases for optimizationTopology optimizationTopology optimizationIntegration of the optimization results in a crashanalysis to validate the concept obtainedIntegration of the optimization results in a crashanalysis to validate the concept obtained6th European Altair Technology Conference - 2013
    • A new crash analysis must be performed using a model that contains thedesign space and TH output to retrieved loads for Optimization (Contactsforces, External forces… ).The TH (Loads vs time) of this new analysis will be used to identify theinstants to take into account for the linearization.10Model setup for crash analysis6th European Altair Technology Conference - 2013
    • 6th European Altair Technology Conference - 2013 11Model setup for optimizationLinearization of crash loadingProblems: how to represent crash behavior withsimple static loadcases (forces)?No rules for linearization of crash loading. This isbased on experience and testsAssumption selected for optimization : find peaksand scanning around these peaksCreation of the sub-model for optimization.Optimization can be done on a sub-modelThe efforts of the dynamic analysis must berecovered at the limits of the sub-model
    • 12OptimizationSubcase setup for optimizationThe calculated equivalent static loads from thecrash analysis are considered as separate loadcases, and these multiple load cases are usedin the linear response optimization.Optimization formulationVariables : Element density of each element inthe design space.Objective : Minimize weighted complianceConstraints : % Fraction of design volumeOptimization is performed on a submodelFaster convergence of the optimization6th European Altair Technology Conference - 2013
    • 13OptimizationOptimization resultsQuick validationThe validation method is independent of theCADNew model is obtained by directlyintegrating the results of the optimization inthe initial crash simulationWe retain only the elements which thedensity is higher than 0,66th European Altair Technology Conference - 2013
    • 14Validation resultsCrash analysisGlobal observationsImproved behavior of the oilpanPerformances improved by 78%6 % more weight6th European Altair Technology Conference - 2013
    • 15Optimization Process : SummaryOriginal partInitial crashsimulationCrash simulationwith DSlinearizationOptimizationValidationInterpretation6th European Altair Technology Conference - 2013
    • ProspectOn the path to integration…A new part is drawn:• Base on result of optimization• Including already some of the processrequirementPerformance:• 10 % more weight• Fulfillment of specifications16The effective use of topological otimization in strongly non-linear loadsOptimization is used here to tell the designer how the part will be reinforce6th European Altair Technology Conference - 2013
    • 17Thank you for your attention6th European Altair Technology Conference - 2013