Nonlinear Optimization of a Child Head Impact Using HyperStudy
Robert Raulf, HBPO
HBPO GmbH is a joint venture operated by the world-wide innovation
and market leaders for lighting and electronics (Hella KGaA
Hueck & Co.), vehicle air-conditioning and engine cooling
(Behr GmbH & Co. KG) and painted mounted parts and plastic
systems (Plastic Omnium Auto Exterior S.A.S). An integrated
operations the company develops, manufactures and distributes
intelligent front-end modules for vehicle manufacturers.
At present HBPO production takes place in sixteen JIS (Just-In-Sequence)
-assembly plants in Europe, North America and Asia with an
annual volume of approx. 2.8 million front-end modules. In
addition HBPO is represented in Europe, North America and
Asia with a total of 5 tech centers.
The development of a front-end module is characterised by
the coordination of a number of development partners. Usually,
up to ten different sub-suppliers, a large number of specialist
departments at the OEM as well as tool manufacturers and test
service providers have to be managed in a compact organisational
form by the partner responsible for the module.
Newest requirements like Pedestrian Safety, R-Car or AZT
leads to an optimization focused on component and module requirements.
To support this optimization HBPO developed his on processes.
One Example is the optimization of a Headlamp for Child Head
Impact. This Study shows a principal optimization and a DOE
of a Child head impact to understand the main Effects of the
physics.
The nonlinear optimization was made with HyperStudy and PamCrash.
21 design variables (see Figure 1 Design variables of the
Cover Lens) were set up to perform this optimization. Without
a significant design change the HIC Value could be reduced
by 22%.
To understand the physical Effects and the dependency of
the geometrical conditions a DOE was perform. The main result
is that the position of the projector module is one of the
key Influences. Once there is a proper Gap between cover and
projector module the Design of the Cover Lens is influencing
the HIC.
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