Real-time, dynamic simulation and optimization design of brake hoses, efficiently assessing the possible static or dynamic risks of brake hoses, comprehensive monitoring of interference, pulling, over-bending and fatigue damage.
• There is small space for tube layout in the engine compartment(especially PHEV), and there is relative motion between the tubes due to the vibration of the engine or the jitter caused by the extreme driving conditions. In order to avoid the risks such as interference friction or unplugging , the following three methods are generally used to avoid the previous risks ：
1、Length safety margin ,total length of profiled tube / straight line distance between two joints;
2、Gap safety margin ,large static gap between hoses；
3、Envelope check , static calibration using the engine envelope;The above method effectively assesses the risk of the moving tubes and does not allow for a rapid optimization of the powertrain tubes.
• In the development process of powertrain tubes, the advanced flexible cables simulation tool IPS Cable Simulation was introduced, the whole process development of powertrain tubes layout, simulation verification and optimization design were carried out under the same platform, and the design goals in different stages of the vehicle development process were completed :
1、Concept stage： Preliminary modeling, layout, and simulation of tubes to provide early design reference for powertrain tubes layout and integration. This stage mainly considers the aesthetics of powertrain tubes layout;
2、 Detailed design stage ： Detailed simulation design and optimization of powertrain tubes , comprehensive risks assessment and avoidance, this stage focuses on the reliability of the powertrain tubes;
3、 Trial or real vehicle test stage (non-essential): Re-simulation of individual risky powertrain tubes to find the cause of the risks and further provide an optimization solution. This stage focuses on powertrain tubes material, manufacturing process and assembly problems, making a diagnosis and control.
• Using IPS Cable Simulation for powertrain tubes layout, simulation verification and optimization design, engineers do not have to switch between design platform and simulation platform. That greatly improve powertrain tubes layout efficiency. The advantages and characteristics as follows:
•With powertrain tubes modeling capabilities and simulation capabilities ;
•Considering the influence of the powertrain tubes own gravity and the material properties on the space shape ;
•The simulation is real-time, no need to draw a grid, no waiting, and the optimization results are presented in real time;
•Comprehensive control of multiple risks, including interference, excessive force, severe torsion and too small bending radius;
•Suitable for modeling and simulation of various types of tubes such as ordinary tubes, preformed tube, bellows and pressure tubes;
•Supporting static, dynamic and durability analysis, can effectively simulate the dynamic response of tubes under high frequency vibration;