Multi System Level Driving Scenarious Based Topology Optimization of Bracket Design for 2 DoF Vehicle Simulator

Abstract

This article presents a topology optimization of the motor mounting bracket in a 2-degree-of-freedom (2 DoF) vehicle simulator that is enhanced by the driving scenari-os. Firstly, a 14 DoF passenger reference application model is determined in the Sim-ulink environment. Then, common driving scenarios (Constant Radius, Double Lane Change, Fishhook, Increasing Steer, Sine with Dwell and Swept Sine) are run on 14 DoF vehicle models to test the dynamic performance of the vehicle. During the anal-ysis, accelerations in the XYZ axes are logged, and the minimum and maximum ac-celeration values on each axis are grouped separately for each driving scenario. Next, the concept design of 2 DoF vehicle simulators is created. The obtained accelerations from the driving scenarios are then run on 2 DoF vehicle simulator in the Solidworks simulation environment, and stress and deformation on the 2 DoF vehicle simulator are analyzed. During this analysis, linear actuator and axis forces are calculated ac-cording to the reaction forces on the vehicle simulator. Under the determined axial forces, the brackets are subjected to topology optimization. The obtained generative design of the bracket is reshaped by post-processing for sustainable production. The shape-optimized bracket is run again on the 2 DoF vehicle simulator with the ob-tained acceleration values from the driving scenarios, and the study is completed by performing stress and deformation analysis.

Keywords

• Generative design
• topology optimization
• dynamic analysis
• driving scenarios

References

1. [1] Bang KH. Development of dynamics modeling in the vehicle simulator for road safety analysis. SICE Annual Conference 2007; 649-653. doi: 10.1109/SICE.2007.4421062.
2. [2] Reddy GN. An EV-simulator for Electric Vehicle Education. International Conference on Engineering Education (ICEED) 2009; 131-137. doi: 10.1109/ICEED.2009.5490597.
3. [3] Peng J, Zhenjun S. Improvement of driving simulator for real-time vehicle dynamic collision simulation. 2nd IEEE Interna-tional Conference on Computer Science and Information Tech-nology 2009; 590-593. doi: 10.1109/ICCSIT.2009.5234631.
4. [4] Zhao Y, et al. Integrated Traffic-Driving-Networking Simulator: A Unique R&D Tool for Connected Vehicles. International Conference on Connected Vehicles and Expo (ICCVE) 2012; 203-204. doi: 10.1109/ICCVE.2012.45.
5. [5] Weiss E, Gerdes JC. High Speed Emulation in a Vehicle-in-the-Loop Driving Simulator. IEEE Transactions on Intelligent Vehi-cles 2022; doi: 10.1109/TIV.2022.3162549.
6. [6] Jianjun H, Hehong G, Zhelong W. Solving the forward kine-matics problem of six-DOF Stewart platform using multi-task Gaussian process. Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical Engineering Science 2013; 227: 161-169. doi: 10.1177/0954406212444508.
7. [7] Kim KD, Kim MS, Moon YG, Lee MC. Application of Vehicle Driving simulator Using New Washout Algorithm and Robust Control. SICE-ICASE International Joint Conference 2006; 2121-2126. doi: 10.1109/SICE.2006.315563.
8. [8] Kulothungan S, Anirudh RV, Sivashankar K, Dash AK. Design and Development of a Vehicle Dynamics Model for a Drive Simulator.3rd International Conference on Communication and Electronics Systems (ICCES) 2018; 153-156. doi: 10.1109/CESYS.2018.8723987.

9. [9] Shuxian X, Linxuan Z. Simulating driving feel for virtual driv-ing simulator based on semi-physical simulation. 34th Chinese Control Conference (CCC) 2015; 8882-8887. doi: 10.1109/ChiCC.2015.7261043.
10. [10] Patel Y, George P. Parallel Manipulators Applications—A Survey. Modern Mechanical Engineering 2012; 2(3):57-64. doi: 10.4236/mme.2012.23008.
11. [11] Hernández A, Urízar M, Macho E, Petuya V. Parallel Manipulators: Practical Applications and Kinematic Design Cri-teria. Towards the Modular Reconfigurable Robots. Mecha-nisms, Transmissions and Applications. Mechanisms and Ma-chine Science 2017; 52. doi:10.1007/978-3-319-60702-3_14
12. [12] Gökdağ İ, Acar E. Application of a modular topology optimization framework to an aerospace bracket design. Mate-rials Testing 2022; 64(7): 1090-1102. doi: 10.1515/mt-2021-2148
13. [13] Arıcı BB, Armağan A, Yılmaz M, Serap G, Yücel SC. Microstructural and mechanical properties of friction and MIAB welded carbon steel tubes and forging bracket joints. Materials Testing 2018; 60(3): 273-282. doi:10.3139/120.111144
14. [14] Korkmaz FF, Subran M, Yıldız AR. Optimal design of aerospace structures using recent meta-heuristic algorithms. Ma-terials Testing 2021; 63(11): 1025-1031. doi:10.1515/mt-2021-0024
15. [15] Liu XJ, Wang QM, Wang J. Kinematics, dynamics and dimensional synthesis of a novel 2-DoF translational manipula-tor. J. Intell. Robot. Syst. 2005; 41(4): 205–224. doi: 10.1007/s10846-005-3507-z.
16. [16] Zhao TS, Huang Z. A Novel Three-DOF Translational Platform. Mechanism and its Kinematics 2000; 517–522. doi: 10.1115/DETC2000/MECH-14101.
17. [17] Ganesh SS, Rao ABK. Kinematic and Dynamic Optimi-zation of a 2-DOF Parallel Kinematic Mechanism. Procedia Comput. Sci. 2018; 133: 576–584. doi:10.1016/j.procs.2018.07.086.
18. [18] Karlsson A. Test Procedures and Evaluation Tools for Passenger Vehicle Dynamics. Computer Science. 2014.
19. [19] SAE International. J266: Steady-State Directional Con-trol Test Procedures for Passenger Cars and Light Trucks 2018;4970(724)
20. [20] ISO 3833:1977 - Road vehicles — Types — Terms and definitions., 2022.
21. [21] Bosch Automotive Handbook, 9th Edition. 2014. doi: 10.4271/0768081521.
22. [22] Rozvany GIN, Zhou M, Birker T. Generalized shape optimization without homogenization. Struct. Optim. 1992; 4(3-4): 250–252. doi: 10.1007/bf01742754.
23. [23] Bendsoe P, Kikuchi N. Generating optimal topologies in structural design using a homogenization method. Comput. Methods Appl. Mech. Eng. 1988; 71(2): 197–224. doi: 10.1016/0045-7825(88)90086-2.
24. [24] Isik M, et al. Topology Optimization and Manufacturing of Engine Bracket using Electron Beam Melting. J. Addit. Man-uf. Technol. 2021.
25. [25] Shi G, Guan C, Quan D, Wu D, Tang L, Gao T. An aero-space bracket designed by thermo-elastic topology optimization and manufactured by additive manufacturing. Chinese J. Aero-naut. 2020;33(4): 1252–1259. doi: 10.1016/j.cja.2019.09.006.
26. [26] Chen Y, et al. Topology optimization design and exper-imental research of a 3d-printed metal aerospace bracket con-sidering fatigue performance. Appl. Sci. 2021; 11(15). doi: 10.3390/app11156671.