汽车工程学报2025，Vol.15Issue(3)：419-426,8.DOI:10.3969/j.issn.2095-1469.2025.03.14
汽车零面差车门系统数值模拟及优化
Numerical Simulation and Optimization of an Automotive Zero-Flush Door System
摘要
Abstract
Taking the zero-flush door system of a certain vehicle model as the research object,a finite element model of the glass guide seal is developed.Using MSC.Marc,the compression load of the seal is calculated under varying gaps between the sliding and fixed glass.Simulation results show that when the gap value decreases by 1.2 mm from the design value,the compression will sharply increases from 6.7 N/dm to 28.9 N/dm,which leads to jamming during glass lifting and lowering.Therefore,the critical gap tolerance threshold is determined to be±1.2 mm.A tolerance model of the zero-flush door system is constructed using the tolerance analysis software 3DCS,and 20 000 virtual assembly simulations are conducted using the Monte Carlo method.It is found that the tolerance fluctuation range of the gap between the sliding glass and the fixed glass is±1.39 mm,with a 0.89％probability of exceeding the critical value of±1.2 mm.After optimizing the structure of the zero-flush door system and re-evaluating the tolerance,the fluctuation range is reduced to±1.1 mm,and the probability of exceeding the critical value is reduced to zero.During the small-batch trial production phase of a specific vehicle model,data were collected from 30 randomly selected samples.The results showed that the gap fluctuation range was±1.08 mm,and no jamming or sticking occurred during the lifting or lowering of the glass,indicating that the design objectives were achieved.The deep integration of finite element analysis and dimensional tolerance evaluation provides important guidance for the structural design and performance simulation of flexible systems,ensuring a high level of consistency between simulation and real-world performance.关键词
零面差车门系统/玻璃导槽密封条/尺寸公差/数值模拟/结构优化Key words
zero-flush door system/glass guide seal/dimensional tolerance/numerical simulation/structure optimization分类
机械工程引用本文复制引用
贺志瑛,郑耀凯,张玉成,田顺,徐茂林,梁腾伟,邹利..汽车零面差车门系统数值模拟及优化[J].汽车工程学报,2025,15(3):419-426,8.基金项目
陕西省自然科学基础研究计划项目(2022JQ-007) （2022JQ-007）
