CN111209705B - Three-dimensional flexible assembly tolerance prediction method for glass lifter based on finite element - Google Patents
Three-dimensional flexible assembly tolerance prediction method for glass lifter based on finite element Download PDFInfo
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Abstract
The invention relates to a three-dimensional flexible assembly tolerance prediction method of a glass lifter based on finite elements, which comprises the following steps: 1: establishing a glass lifter dynamics simulation analysis model to obtain lifting load; 2: based on the extracted lifting load, calculating the rigidity expression of the inner plate of the vehicle door under the action of the load, and obtaining the deformation of the upper mounting surface and the lower mounting surface of the glass lifter; 3: reconstructing lifter installation surface characteristics according to the obtained deformation result, and establishing a three-dimensional flexible assembly tolerance model of the glass lifter; 4: the ratio of the reduction amplitude of the super-differential rate and the tolerance shrink is defined as the gain ratio of the tolerance shrink, and the tolerance optimization design of the vehicle window lifting system is realized by using the gain ratio as an evaluation index. According to the invention, a method of combining finite elements and three-dimensional tolerance design is adopted, the influence of lifting load on the assembly relation is considered, the influence of sealing resistance and rigidity of the inner plate of the vehicle door on the assembly state of the lifter is revealed, and the assembly relation between glass and a sealing strip is ensured by optimizing the tolerance design, so that the lifting smoothness is improved.
Description
Technical Field
The invention relates to the technical field of digital design and manufacture of automobile power windows, in particular to a three-dimensional flexible assembly tolerance prediction method of a glass lifter based on finite elements.
Background
Tolerance design is one of the important factors for determining product quality, and traditional mechanical product tolerance modeling is assumed on the premise of rigid body. However, automotive body parts are assembled from sheet stampings by hierarchical welding, with the sheet material being relatively flexible. Deformation under the action of external load directly affects the transmission and accumulation of assembly deviation, and finally affects the assembly precision and the use function.
The power window lifting system reflects NVH performance of the vehicle door, and the lifting smoothness of the window glass has great influence on the evaluation of the quality of the whole vehicle. The lifting moment and the sealing resistance of the power window lifting system are complex. Meanwhile, the geometrical curved surface of the vehicle window and the rigidity of the inner plate of the vehicle door directly influence the final lifting track. These factors are coupled with each other and act together, so that unsmooth lifting, clamping stagnation, shaking, deviation and other unsmooth states of the vehicle window and even lifting failure are finally caused. The design and manufacturing accuracy of the product determines the final quality. In order to improve the lifting smoothness of the vehicle window with complex load working conditions and hidden constraint conditions, the lifting kinematics and the dynamics process of the vehicle window must be deeply analyzed based on the assembly characteristics of the flexible sheet of the vehicle door system, and the corresponding relation between manufacturing and assembly tolerances and lifting quality is established.
Disclosure of Invention
The invention aims to overcome the defects in the prior art and provide a three-dimensional flexible assembly tolerance prediction method for a glass lifter based on finite elements, which takes a rope wheel type single-guide rail electric glass lifter as a research object to research the influence relationship of key assembly dimensional accuracy of a vehicle door on performance. Aiming at the problems of jitter, clamping stagnation, insufficient rigidity of a vehicle door inner plate and the like of vehicle window glass in the lifting process, a method of combining finite element and three-dimensional tolerance design is adopted, the influence of lifting load on the assembly relation is considered, a three-dimensional assembly tolerance analysis model containing finite element deformation is established, the critical dimension tolerance transmission mechanism is analyzed, and the influence of lifting dynamic load, sealing resistance characteristics, glass lifting track, assembly tolerance and fluctuation on lifting quality is clarified.
The aim of the invention can be achieved by the following technical scheme:
A method for predicting three-dimensional flexible assembly tolerance of a glass lifter based on finite elements, comprising the following steps:
Step1: based on a multi-body dynamics analysis theory and a lifter working principle, a glass lifter dynamics simulation analysis model is established, and a lifting load of stable operation is obtained;
step 2: detecting the rigidity expression of an inner plate of the vehicle door under the load action of the closing process of the vehicle window based on the lifting load extracted by finite element analysis theory and dynamics analysis, and obtaining the deformation of the upper mounting surface and the lower mounting surface of the glass lifter;
Step 3: reconstructing the lifter installation surface characteristics according to the deformation result obtained by finite element analysis, and establishing a three-dimensional flexible assembly tolerance model of the glass lifter considering the installation surface deformation based on Vis VSA to obtain the assembly state of the glass and the sealing strip;
step 4: based on a principal component analysis and experimental design method, the ratio of the reduction range of the out-of-tolerance ratio to the tolerance tightening is defined as the gain ratio of the tolerance tightening, and the tolerance optimization design and prediction of the vehicle window lifting system considering the flexible deformation of the vehicle door inner plate are realized as evaluation indexes.
Further, the step 1 comprises the following sub-steps:
Step 11: establishing a glass lifter constraint condition;
step 12: acquiring corresponding installation positions and geometric attributes according to related technical parameters of the three-dimensional real object, and respectively establishing an upper section of steel wire rope transmission model and a lower section of steel wire rope transmission model based on Adams/Cable modules;
Step 13: winch Winch functions in the Adams/Cable module are used for simulating winch functions, winding and unwinding of the steel wire ropes are simulated, and lifting movement of the glass is achieved;
step 14: establishing nonlinear resistance functions of the window glass, front and rear guide groove sealing strips and inner and outer water cuts;
Step 15: and setting related simulation parameters according to the time of the actual lift of the glass, and running simulation operation to obtain the lifting load of the glass in stable operation.
Further, the nonlinear resistance function in the step 14 is described as:
Wherein f 3 is the friction resistance of the glass and the water-cut sealing strip, h is the lift, C f is the friction coefficient of the sealing strip, and C 1 is the compression load of the sealing strip.
Further, the step2 comprises the following sub-steps:
Step 21: modeling the finite element analysis pretreatment of the inner plate of the vehicle door;
Step 22: defining corresponding constraints and loads;
step 23: and (3) running simulation, analyzing rigidity characteristics of the lifter installation surface under the load action of the glass lifting process based on the lifting load extracted by the dynamics analysis in the step (1), and obtaining deformation of the lifter installation surface.
Further, the step 21 includes the following sub-steps:
step 211: simplifying characteristics, simulating a vehicle door inner plate by adopting a SHELL181 unit, matching grid types with quadrilateral units and triangular units, and carrying out encryption grid division at the position of a lifter installation hole site;
Step 212: and adopting a three-dimensional hexahedral unit to grid the hinge structure.
Further, the step 22 includes the following sub-steps:
Step 221: restricting the freedom degrees of the hinge mounting holes in multiple directions, and releasing the rotation freedom degrees around the Y-axis direction so as to simulate the connection of the vehicle door and the white vehicle body and the real rotation condition of the hinge;
step 222: constraining a plurality of translational degrees of freedom of a mounting point of the door lock to simulate a state of the door lock when the door lock is locked;
Step 223: and respectively taking the upper mounting surface and the lower mounting surface of the lifter as XY planes, taking the normal direction as a Z axis, taking the center of a mounting hole of the lifter as a coordinate origin, establishing a local coordinate system, and applying load force on the XY planes of the local coordinate systems.
Further, the step 3 comprises the following sub-steps:
Step 31: extracting deformation of point coordinates of assembly of the guide rail and the inner plate of the vehicle door by combining the finite element analysis result obtained in the step 2, and reconstructing the coordinates of the assembly characteristic points;
Step 32: establishing a reference, assembly characteristics and measurement characteristics of each part, defining an assembly relation, and completing three-dimensional tolerance analysis modeling;
step 33: according to the requirements of lifting smoothness on the matching state of the glass and the sealing strip, measuring points are respectively arranged at the front edge, the rear edge, the top end and the water cutting position of the glass, and a measuring relation is established;
Step 34: setting Monte Carlo simulation times, acquiring iterative calculation results of all measuring points, and outputting a process report and an influence factor report of relevant measurement of the assembly state of the final glass and the sealing strip.
Further, the step 4 includes the following sub-steps:
step 41: based on the principle component analysis idea, extracting the characteristics with the influence factor more than 10% in the step 3 as design variables;
Step 42: acquiring the influence trend of the variation of the tolerance value of the variable on the out-of-tolerance rate through experimental design;
step 43: defining a gain ratio with tight tolerance, and determining a feasible tolerance combination scheme;
Step 44: and (3) predicting other measuring points by using the tolerance combination scheme obtained in the step (43) and verifying whether the tolerance requirement of the lifting ride design is met.
Further, the benefit ratio in the step 43 is calculated as:
Where η i denotes the i-th group gain ratio, T i and T i+1 denote the i-th and i+1-th group shape and position tolerance values, respectively, and S i and S i+1 denote the i-th and i+1-th group super-differential rates, respectively.
Compared with the prior art, the invention has the following advantages:
(1) Based on the operation principle of the glass lifter and the assembly relation between the vehicle door and the lifter, the finite element analysis theory is combined with the tolerance design, so that the three-dimensional tolerance design of the glass by applying the finite element method is realized, and the smoothness design level of the glass lifter is improved.
(2) According to the invention, aiming at the problems of shaking, clamping stagnation, insufficient rigidity of the inner plate of the vehicle door and the like of the vehicle window glass in the lifting process, a method of combining finite elements and three-dimensional tolerance design is adopted, the influence of lifting load on the assembly relation is considered, a vehicle window lifting three-dimensional assembly tolerance analysis model containing deformation of the inner plate is established, the influence of sealing resistance and rigidity of the inner plate of the vehicle door on the assembly state of the lifter is revealed, and the assembly relation between the glass and the sealing strip is ensured through optimizing tolerance design, so that the lifting smoothness is improved.
Drawings
FIG. 1 is a schematic diagram of the method of the present invention;
FIG. 2 is a graph showing the force analysis of the glass during the ascending process in the implementation of the method of the present invention;
FIG. 3 is a graph showing the stress analysis of the glass falling process in the implementation of the method of the present invention;
FIG. 4 is a schematic diagram of the components of a simplified model of the kinetic analysis of a glass lifter during the implementation of the method of the present invention;
FIG. 5 is a schematic diagram of the front view of a simplified model of the kinetic analysis of a glass lifter during the implementation of the method of the present invention;
FIG. 6 is a schematic side view of a simplified model of glass lifter dynamics analysis in the implementation of the method of the present invention;
FIG. 7 is a schematic diagram of a wire rope drive and drive model during the practice of the method of the present invention;
FIG. 8 is a graph of the load of a glass lifting condition steel wire rope in the implementation of the method of the present invention;
FIG. 9 is a finite element analysis model of deformation of the inner door panel during the implementation of the method of the present invention;
FIG. 10 is a graph of the results of a finite element analysis of deformation of the inner door panel during the practice of the method of the present invention;
FIG. 11 is a view of a virtual assembly hierarchy of a glass lifter during the implementation of the method of the present invention;
FIG. 12 is a schematic view of a software interface for defining door inner panel features, benchmarks, tolerances, and assembly relationships during the implementation of the method of the present invention;
FIG. 13 is a schematic view of the distribution of glass measurement points in the implementation of the method of the present invention;
FIG. 14 is a schematic diagram of a three-dimensional analysis statistics reporting software interface in the implementation of the method of the present invention;
FIG. 15 is a schematic view of the software interface for reporting the impact factors of the compression amount of the sealing strip and the upper edge of the rear end of the glass in the implementation process of the method of the invention;
FIG. 16 is a graph showing the influence of the tolerance value variation of the profile of the matching surface of the guide rail and the bracket on the super-differential rate of the measuring points in the implementation process of the method of the invention;
FIG. 17 is a schematic diagram of the transmission of deformation deviations of the inner door panel during the implementation of the method of the present invention;
In the figure, 1 is glass, 2 is a bracket, 3 is a buckle, 4 is a guide rail, 5 is an upper guide wheel, 6 is a lower guide wheel, 7 is a spring, 8 is a wire winding drum, 9 is a first wire rope, 10 is a second wire rope, 11 is a connecting bolt, 12 is an inner lip, 13 is an outer lip, 14 is door glass, 15 is an inner water cutting strip, and 16 is an outer water cutting strip.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and fully with reference to the accompanying drawings, in which it is evident that the embodiments described are some, but not all embodiments of the invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the present invention without making any inventive effort, shall fall within the scope of the present invention.
The main contents of the method of the invention are as shown in figure 1:
1) Glass lifter dynamics modeling based on a multi-body dynamics simulation analysis platform (Adams): analyzing the motion principle of the glass lifter, and determining the constraint state among all the components of each lifter; aiming at dynamic contact friction resistance of vehicle window glass, front and rear guide groove sealing strips and internal and external water cutting, firstly combining actual operation conditions, constructing a piecewise function of the contact length and lift of the water cutting sealing strips and the glass, secondly applying a infinitesimal method, comprehensively considering irregular section characteristics and compression load characteristics of the sealing strips, and determining nonlinear friction resistance of a vehicle window sealing system and the groove entering force of the top sealing strip; constructing a lifter steel wire rope transmission model based on a rope (cable) module integrated by an Adams platform, and completing the construction of a driving module by winding and unwinding a simulated wire drum of a winch (Winch) functional simulated steel wire rope; and finally, taking a lifting speed of 110mm/s as an input, and extracting the stable running loads of the two sections of steel wire ropes to be 75N and 10N respectively.
2) Door modal and stiffness analysis based on universal finite element analysis software (ANSYS): based on a finite element analysis theory, the structure, the material property and the actual working state of the inner plate of the vehicle door are combined, and modeling of a finite element analysis model of the inner plate of the vehicle door is completed; and (3) based on lifting load extracted by the lifting dynamics model, examining the rigidity performance of the mounting surface of the inner plate guide rail of the vehicle door under the action of the lifting load of glass, wherein the deformation amounts of the upper mounting surface and the lower mounting surface are respectively 0.594mm and 0.393 mm.
3) Three-dimensional assembly tolerance analysis of glass lifter based on Vis VSA: combining the requirement of lifting smoothness on the matching of the glass and the sealing strip, decomposing the size target according to the lifting state of the glass, and finishing the arrangement of the measuring points; based on the deformation of the mounting surface of the door inner plate guide rail on the rising load, carrying out characteristic reconstruction on the door inner plate and the matching surface, and researching the influence of the load deformation on the assembly relation of the glass and the sealing strip; the iterative calculation result shows that the glass, the front and rear guide groove sealing strips and the water cutting sealing strips have the phenomenon of out-of-tolerance under the action of rising load, and the compression amount of the sealing strips reaches 3.2554mm at maximum when the worst working condition occurs when the window glass is about to enter the groove, and the out-of-tolerance rate is 6.0%.
4) Tolerance optimization based on experimental design: based on the three-dimensional tolerance analysis result of the glass lifter considering the finite element deformation, the main component analysis is applied to extract key influence factors: the guide rail-bracket mounting surface-surface profile and the glass-bracket mounting hole-position are used as design variables, and experimental design is adopted to obtain the influence trend of the variation of the variable tolerance value on the out-of-tolerance rate; defining the ratio of the out-of-tolerance rate change to the tolerance change as an evaluation index, and determining the optimal design scheme combination as follows: rail-carriage mounting face-face profile: 0.5mm, glass-bracket mounting hole-position was 0.9mm.
Practical embodiment
A three-dimensional flexible assembly tolerance prediction method of a glass lifter based on finite elements comprises the following steps:
S1: establishing a glass lifter dynamics simulation analysis model to obtain a steel wire rope load of stably rising glass;
S2: establishing a finite element analysis model of a vehicle door inner plate, and obtaining deformation of a mounting plane of a lifter of the vehicle door inner plate;
s3: establishing a three-dimensional assembly tolerance analysis model of the glass lifter considering the flexible deformation of the inner plate of the vehicle door, and obtaining the assembly state of the glass and the sealing strip;
s4: based on the principal component analysis and experimental design method, the ratio of the reduction amplitude of the out-of-tolerance ratio and the tolerance tightening is the gain ratio of the tolerance tightening, and the tolerance optimization design of the vehicle window lifting system considering the flexible deformation of the vehicle door inner plate is realized as an evaluation index.
The step S1 specifically comprises the steps of:
s11: establishing constraint conditions of the glass lifter;
S12: according to the related technical parameters of the three-dimensional real object, mounting positions and geometric attributes of a wire winding drum, an upper guide wheel, a lower guide wheel and the like are obtained, and an upper section of wire rope transmission model and a lower section of wire rope transmission model are respectively built based on an Adams/Cable module;
s13: as shown in fig. 7, winch functions are simulated by using winch (Winch) functions in an Adams/Cable module, so as to simulate the winding and unwinding of the steel wire rope and realize the lifting movement of the glass;
S14: establishing nonlinear resistance functions of the window glass, front and rear guide groove sealing strips and inner and outer water cuts;
S15: setting the simulation time to be 3.5s by referring to the time used by the actual lift of the glass, iterating the step length to be 0.01s, and running simulation operation to obtain the mechanical load of the steel wire rope in the glass lifting process, as shown in fig. 8;
S111: as shown in fig. 4, 5, 6 and 11, the lifter digital model is simplified, main parts such as glass, guide rails, brackets (sliding blocks) and the like are reserved, the main parts are assembled according to the assembly relation, and related material parameters are set.
S112: the corresponding kinematic pairs are abstracted according to the actual movement of the glass lifter and defined between the constructions.
The step S14 specifically includes the steps of:
s141: analyzing the force balance of the glass-handling system as shown in fig. 2 and 3, the equation can be found:
Wherein: g is the gravity of the glass; f 1 and f 2 are the resistances of the front and rear channel seals respectively; f 3 is an inner and outer water slitting friction resistance buckle; f 4 is the friction force between the bracket and the guide rail; and f q is the motion traction of the lifter.
S142: selecting a certain moment t in the ascending stage of the car window, and calculating the sealing resistance of the front guide groove and the rear guide groove at the moment:
Wherein: mu is the friction coefficient of the sealing strip; l 1、l2 is the contact length of the glass with the front and rear guide grooves; n in、Nout is the compression load of the inner and outer lips on the glass, respectively.
S143: defining the total travel H of the vehicle window glass, taking the travel (H-H0) of the front end of the glass entering the groove as a demarcation point, and establishing a functional relation between the friction resistance of the glass and the water cutting sealing strip and the lift (H):
Wherein f 3 is the friction resistance of the glass and the water-cut sealing strip, h is the lift, C f is the friction coefficient of the sealing strip, and C 1 is the compression load of the sealing strip.
S144: the glass run-in force was taken to be 150N.
The step S2 specifically includes the steps of:
s21: modeling the finite element analysis pretreatment of the inner door panel, as shown in fig. 9;
S22: defining constraints and loads;
s23: running simulation, analyzing rigidity characteristics of the lifter installation surface under the load action of the glass lifting process, and obtaining deformation of the lifter installation surface;
the step S21 specifically includes the steps of:
S211: features of holes below 10mm, rounded corners, bosses with depth less than 5mm and the like which do not affect the analysis result are ignored, and a model is simplified;
s212: as shown in fig. 10, a SHELL181 unit is adopted to simulate a vehicle door inner plate, the mesh size is controlled to be 5-10 mm, a quadrilateral unit is taken as a main material, triangle units are adopted to assist in some transitional areas, and proper encryption mesh division is carried out near a lifter installation hole site;
S213: the hinge structure is meshed with the three-dimensional hexahedral unit, and the mesh unit in the thickness direction is not less than two layers.
The step S22 specifically includes the steps of:
S221: restricting the freedom degrees of the hinge mounting holes in 5 directions, and releasing the rotation freedom degrees around the Y-axis direction so as to simulate the connection of the vehicle door and the white vehicle body and the real rotation condition of the hinge;
S222: restraining 3 translational degrees of freedom of a mounting point of the door lock so as to simulate the state of the door lock during locking;
S223: and respectively taking the upper mounting surface and the lower mounting surface of the lifter as XY planes, taking the normal direction as a Z axis, taking the center of a mounting hole of the lifter as a coordinate origin, establishing a local coordinate system, and applying load force on the XY planes of the local coordinate systems.
The step S3 specifically includes the steps of:
s31: extracting deformation of point coordinates of assembly of the guide rail and the inner plate of the vehicle door by combining S23 finite element analysis results, and reconstructing the coordinates of the assembly characteristic points;
s32: establishing the reference, assembly characteristics and measurement characteristics of each part, defining the mutual assembly relation, and completing three-dimensional tolerance analysis modeling as shown in fig. 12;
S33: according to the requirement of the lifting smoothness on the matching state of the glass and the sealing strip, measuring points are respectively arranged at the front edge, the rear edge, the top end and the water cutting position of the glass as shown in fig. 13, and a measuring relation is established;
S34: setting the Monte Carlo simulation times to 5000 times, acquiring iterative calculation results of each measuring point, and outputting a process report and an influence factor report of related measurement as shown in fig. 14 and 15; ,
The step S4 specifically includes the steps of:
s41: based on the principle component analysis idea, extracting the key features in the step S34, namely features with influence factors larger than 10%, as design variables;
S42: the influence trend of the variation of the tolerance value of the variable on the out-of-tolerance rate is obtained through experimental design, as shown in fig. 16;
S43: defining a tolerance shrink gain ratio, and determining a feasible tolerance combination scheme, as shown in fig. 17;
s44: and (3) verifying whether the tolerance requirements of the lifting ride design are met or not for other measuring points according to the scheme obtained in the step S43.
The step S42 specifically includes the steps of:
S421: the tolerance value of a single variable is selected as a unique variable by a control variable method, and the influence of the tolerance change of each influence factor on the fluctuation range of the glass measuring point deviation is obtained by Monte Carlo iterative calculation;
s422: the range of the tolerance zone of the profile of the matching surface of the guide rail and the bracket is 0.4-1.0 mm, monte Carlo simulation calculation is carried out, and the deviation fluctuation range and the super-difference rate of the measuring points are obtained;
S423: the tolerance of the position degree of the mounting hole of the glass bracket is 0.5-2.0 mm, monte Carlo simulation calculation is carried out, and the deviation fluctuation range and the super-difference rate of the measuring point are obtained;
The step S43 specifically includes the steps of:
s431: when defining the i-th group of form and position tolerance values as T i, calculating the super-difference rate S i, wherein the range of the super-difference rate reduction caused by the tight tolerance of each group is the benefit ratio:
Where η i denotes the i-th group gain ratio, T i and T i+1 denote the i-th and i+1-th group shape and position tolerance values, respectively, and S i and S i+1 denote the i-th and i+1-th group super-differential rates, respectively.
S432: and (3) summarizing the results obtained in the step S42, calculating a tolerance gain ratio, and selecting the gain ratio jumping points as possible scheme combinations.
While the invention has been described with reference to certain preferred embodiments, it will be understood by those skilled in the art that various changes and substitutions of equivalents may be made and equivalents will be apparent to those skilled in the art without departing from the scope of the invention. Therefore, the protection scope of the invention is subject to the protection scope of the claims.
Claims (5)
1. A method for predicting three-dimensional flexible assembly tolerance of a glass lifter based on finite elements, which is characterized by comprising the following steps:
step 1: based on a multi-body dynamics analysis theory and a lifter working principle, a glass lifter dynamics simulation analysis model is established, and a lifting load of stable operation is obtained, wherein the method comprises the following sub-steps:
Step 11: establishing a glass lifter constraint condition;
step 12: acquiring corresponding installation positions and geometric attributes according to related technical parameters of the three-dimensional real object, and respectively establishing an upper section of steel wire rope transmission model and a lower section of steel wire rope transmission model based on Adams/Cable modules;
Step 13: winch Winch functions in the Adams/Cable module are used for simulating winch functions, winding and unwinding of the steel wire ropes are simulated, and lifting movement of the glass is achieved;
step 14: establishing nonlinear resistance functions of the window glass, front and rear guide groove sealing strips and inner and outer water cuts;
Step 15: setting related simulation parameters according to the time of the actual lift of the glass, and running simulation operation to acquire the lifting load of the glass in stable operation;
Step 2: based on the lifting load extracted by finite element analysis theory and dynamics analysis, detecting the rigidity expression of the inner plate of the vehicle door under the load action of the vehicle window closing process, and obtaining the deformation of the upper mounting surface and the lower mounting surface of the glass lifter, wherein the method comprises the following sub-steps:
Step 21: modeling the finite element analysis pretreatment of the inner plate of the vehicle door;
Step 22: defining corresponding constraints and loads;
step 23: running simulation, analyzing rigidity characteristics of the lifter installation surface under the load action of the glass lifting process based on lifting loads extracted by dynamic analysis in the step 1, and obtaining deformation of the lifter installation surface;
Step 3: reconstructing lifter installation surface characteristics according to deformation results obtained by finite element analysis, establishing a three-dimensional flexible assembly tolerance model of the glass lifter considering installation surface deformation based on Vis VSA, and obtaining the assembly state of glass and a sealing strip, wherein the method comprises the following steps of:
Step 31: extracting deformation of point coordinates of assembly of the guide rail and the inner plate of the vehicle door by combining the finite element analysis result obtained in the step 2, and reconstructing the coordinates of the assembly characteristic points;
Step 32: establishing a reference, assembly characteristics and measurement characteristics of each part, defining an assembly relation, and completing three-dimensional tolerance analysis modeling;
step 33: according to the requirements of lifting smoothness on the matching state of the glass and the sealing strip, measuring points are respectively arranged at the front edge, the rear edge, the top end and the water cutting position of the glass, and a measuring relation is established;
Step 34: setting Monte Carlo simulation times, acquiring iterative calculation results of all measuring points, and outputting a process report and an influence factor report of relevant measurement of the assembly state of the final glass and the sealing strip;
Step 4: based on a principal component analysis and experimental design method, defining the ratio of the reduction range of the out-of-tolerance ratio to the tolerance tightening as the gain ratio of the tolerance tightening, and taking the gain ratio as an evaluation index to realize the optimal design and prediction of the tolerance of the vehicle window lifting system considering the flexible deformation of the inner plate of the vehicle door, wherein the method comprises the following steps of:
step 41: based on the principle component analysis idea, extracting the characteristics with the influence factor more than 10% in the step 3 as design variables;
Step 42: acquiring the influence trend of the variation of the tolerance value of the variable on the out-of-tolerance rate through experimental design;
step 43: defining a gain ratio with tight tolerance, and determining a feasible tolerance combination scheme;
Step 44: and (3) predicting other measuring points by using the tolerance combination scheme obtained in the step (43) and verifying whether the tolerance requirement of the lifting ride design is met.
2. The method for predicting three-dimensional flexible assembly tolerance of glass lifter based on finite element according to claim 1, wherein the nonlinear resistance function in the step 14 is described by the following formula:
Wherein f 3 is the friction resistance of the glass and the water-cut sealing strip, h is the lift, C f is the friction coefficient of the sealing strip, and C 1 is the compression load of the sealing strip.
3. The method for predicting three-dimensional flexible assembly tolerance of glass lifter based on finite element according to claim 1, wherein the step 21 comprises the following sub-steps:
step 211: simplifying characteristics, simulating a vehicle door inner plate by adopting a SHELL181 unit, matching grid types with quadrilateral units and triangular units, and carrying out encryption grid division at the position of a lifter installation hole site;
Step 212: and adopting a three-dimensional hexahedral unit to grid the hinge structure.
4. The method for predicting three-dimensional flexible assembly tolerance of glass lifter based on finite element according to claim 1, wherein the step 22 comprises the following sub-steps:
Step 221: restricting the freedom degrees of the hinge mounting holes in multiple directions, and releasing the rotation freedom degrees around the Y-axis direction so as to simulate the connection of the vehicle door and the white vehicle body and the real rotation condition of the hinge;
step 222: constraining a plurality of translational degrees of freedom of a mounting point of the door lock to simulate a state of the door lock when the door lock is locked;
Step 223: and respectively taking the upper mounting surface and the lower mounting surface of the lifter as XY planes, taking the normal direction as a Z axis, taking the center of a mounting hole of the lifter as a coordinate origin, establishing a local coordinate system, and applying load force on the XY planes of the local coordinate systems.
5. The method for predicting three-dimensional flexible assembly tolerance of glass lifter based on finite element according to claim 1, wherein the profit ratio in step 43 is calculated by the following formula:
Where η i denotes the i-th group gain ratio, T i and T i+1 denote the i-th and i+1-th group shape and position tolerance values, respectively, and S i and S i+1 denote the i-th and i+1-th group super-differential rates, respectively.
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