Disclosure of Invention
In view of the above, the present invention provides a foam structure optimization method and a controller to solve the problems of redundant foam materials and unreasonable structure in the prior art, and to design an optimal packaging structure with the least foam.
In order to achieve the purpose, the invention adopts the following technical scheme: a foam structure optimization method, comprising:
building a product finite element model;
according to the product finite element model, obtaining the load data of the foam through simulation analysis processing;
constructing a foam topological optimization mathematical model according to load data, a topological optimization principle and foam process processing requirements and in combination with performance requirements of packaging foam;
reconstructing a foam structure according to the foam topology optimization mathematical model;
verifying the reconstructed foam structure;
and after the verification is passed, replacing the reconstructed foam structure with the original foam structure.
Optionally, the building product finite element model includes:
building a finite element model for the product;
and (4) carrying out calibration correction on the finite element model by utilizing the actual drop test working condition of the product so as to enable the precision of the finite element model to meet the requirement.
Optionally, the obtaining of the load data of the foam through simulation analysis processing according to the product finite element model includes:
acquiring dynamic data capable of reflecting the stress condition and energy absorption condition of foam and the acceleration condition of a product under the standard working condition of a simulation experiment;
and performing dynamic load equivalence by using an equivalent static load method to aim at consistent displacement deformation to form a series of static load data.
Optionally, the constructing a foam topology optimization mathematical model according to the load data, the topology optimization principle and the foam process processing requirement in combination with the performance requirement of the packaging foam includes:
inputting the static load data as a load for topology optimization;
constructing a foam topological optimization mathematical model according to a topological optimization principle and foam process processing requirements and in combination with performance requirements of packaging foam;
and performing algorithm iteration on the foam topology optimization mathematical model according to the optimization constraint condition and the optimization target until convergence, and obtaining the foam topology optimization mathematical model meeting the optimization constraint condition and the target convergence.
Optionally, if the foam topology optimization mathematical model which does not satisfy the optimization constraint condition and the target convergence is not obtained after the algorithm iteration is performed on the foam topology optimization mathematical model, the foam topology optimization mathematical model and the optimization constraint condition are adjusted.
Optionally, reconstructing the foam structure according to the foam topology optimization mathematical model includes:
deleting redundant materials according to the foam topology optimization mathematical model, and reconstructing a foam structure;
and the foam topology optimization mathematical model meets optimization constraint conditions and the target is converged.
Optionally, the verifying the reconstructed foam structure includes:
carrying out finite element analysis on the reconstructed foam structure, comparing and optimizing various parameters of the foam and the protected product before and after the foam structure is reconstructed, and comprehensively evaluating the overall performance of the reconstructed foam structure;
when the overall performance of the reconstructed foam structure reaches the standard, performing a mold opening test;
and when the die sinking test is passed, the reconstructed foam structure is proved to be passed.
Optionally, the parameters of the foam and the protected product include:
foam energy absorption capacity, product acceleration, and product part stress and strain.
Optionally, the method further includes:
and when the reconstructed foam structure fails to be verified, reconstructing the foam topology optimization mathematical model again by using the topology optimization principle, and performing corresponding verification.
The invention also provides a controller for carrying out the foam structure optimization method of any one of the preceding claims.
By adopting the technical scheme, the foam structure optimization method comprises the following steps: building a product finite element model; according to the product finite element model, obtaining the load data of the foam through simulation analysis processing; constructing a foam topological optimization mathematical model according to load data, a topological optimization principle and foam process processing requirements and in combination with performance requirements of packaging foam; reconstructing a foam structure according to the foam topology optimization mathematical model; verifying the reconstructed foam structure; and after the verification is passed, replacing the reconstructed foam structure with the original foam structure. According to the optimization method, the foam structure is designed, so that the problems of redundant foam materials and unreasonable structure are solved, the optimal packaging structure is designed by using the least foam, and the production cost and the test waste are reduced.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the technical solutions of the present invention will be described in detail below. It is to be understood that the described embodiments are merely exemplary of the invention, and not restrictive of the full scope of the invention. All other embodiments, which can be derived by a person skilled in the art from the examples given herein without any inventive step, are within the scope of the present invention.
FIG. 1 is a schematic view of the overall process flow provided by a foam structure optimization method of the present invention.
As shown in fig. 1, the method for optimizing a foam structure according to this embodiment includes:
s11: building a product finite element model;
further, the building product finite element model comprises:
building a finite element model for the product;
and (4) carrying out calibration correction on the finite element model by utilizing the actual drop test working condition of the product so as to enable the precision of the finite element model to meet the requirement.
S12: according to the product finite element model, obtaining the load data of the foam through simulation analysis processing;
further, the obtaining of the load data of the foam through simulation analysis processing according to the product finite element model includes:
acquiring dynamic data capable of reflecting the stress condition and energy absorption condition of foam and the acceleration condition of a product under the standard working condition of a simulation experiment;
and performing dynamic load equivalence by using an equivalent static load method to aim at consistent displacement deformation to form a series of static load data.
S13: constructing a foam topological optimization mathematical model according to load data, a topological optimization principle and foam process processing requirements and in combination with performance requirements of packaging foam;
further, the step of constructing a foam topology optimization mathematical model according to the load data, the topology optimization principle and the foam process processing requirements and in combination with the performance requirements of packaging foam comprises the following steps:
inputting the static load data as a load for topology optimization;
constructing a foam topological optimization mathematical model according to a topological optimization principle and foam process processing requirements and in combination with performance requirements of packaging foam;
and performing algorithm iteration on the foam topology optimization mathematical model according to the optimization constraint condition and the optimization target until convergence, and obtaining the foam topology optimization mathematical model meeting the optimization constraint condition and the target convergence.
Further, if the foam topology optimization mathematical model which meets the optimization constraint condition and the target convergence cannot be obtained after algorithm iteration is carried out on the foam topology optimization mathematical model, the foam topology optimization mathematical model and the optimization constraint condition are adjusted.
S14: reconstructing a foam structure according to the foam topology optimization mathematical model;
further, the reconstructing the foam structure according to the foam topology optimization mathematical model includes:
deleting redundant materials according to the foam topology optimization mathematical model, and reconstructing a foam structure;
and the foam topology optimization mathematical model meets optimization constraint conditions and the target is converged.
S15: verifying the reconstructed foam structure;
further, the verifying the reconstructed foam structure includes:
carrying out finite element analysis on the reconstructed foam structure, comparing and optimizing various parameters of the foam and the protected product before and after the foam structure is reconstructed, and comprehensively evaluating the overall performance of the reconstructed foam structure;
when the overall performance of the reconstructed foam structure reaches the standard, performing a mold opening test;
and when the die sinking test is passed, the reconstructed foam structure is proved to be passed.
Further, the parameters of the foam and protected product include:
foam energy absorption capacity, product acceleration, and product part stress and strain.
S16: and after the verification is passed, replacing the reconstructed foam structure with the original foam structure.
Further, the method further comprises:
and when the reconstructed foam structure fails to be verified, reconstructing the foam topology optimization mathematical model again by using the topology optimization principle, and performing corresponding verification.
The invention provides a foam structure optimization method, which adopts a dynamic topology mode to carry out optimization, and the goal of topology optimization is to search an optimal layout meeting design conditions in the design domain of a structure so as to give full play to material performance.
When the method is actually executed, as shown in fig. 2, the method may include the following steps:
step 1, building a finite element model for a whole protected product, and correcting the standard of the finite element model and the actual working condition of a product drop test to ensure the accuracy of the finite element model;
step 2, acquiring dynamic data such as the stress condition of the foam, the energy absorption condition of the foam and the acceleration condition of the product under the standard working condition of the simulation experiment;
step 3, carrying out dynamic load equivalence by using an equivalent static load method to aim at consistent displacement deformation to form a series of static load data, and inputting the static load data as a load for topological optimization;
the processing flow of the equivalent dead load method is shown in fig. 3.In the formula: m, K are the mass matrix and stiffness matrix, respectively, both being the design variable and the displacement vector z
N(t);
is an acceleration vector;
is a velocity vector; the subscript N indicates that the response was obtained by nonlinear analysis; f (t) is the external load at the t-th moment; the subscript L indicates the linear analysis,
by means of a linear stiffness matrix K
L(b) And a displacement vector z
N(t) multiplication, and calculating the obtained displacement vector z
L(t) and displacement vector z
N(t) is equal at any time.
And 4, constructing a foam topological optimization mathematical model according to a topological optimization principle and foam process processing requirements and combining performance requirements of packaging foam, and performing algorithm iteration according to optimization constraint conditions and optimization targets until convergence.
fing:x=(x1,x2,x3,…xe)
The optimization constraint conditions are as follows:
V≤V*
0<xmin≤xe≤1
x1≤x2≤x3≤…≤xn
in the formula: x is the number of1,x2,x3,...,xeThe pseudo density of each unit after the structure finite element is dispersed; n is the direction of die drawingThe number of upper units; c (x) is the model total strain energy; k is a unit stiffness matrix; u is a unit deformation quantity; v is the volume after the structure optimization; v*Is the upper limit of volume; l is the equivalent characteristic size of the discrete boundary unit cavity; se is the external surface area of the boundary unit e; dQIs the average depth of the boundary void relative to the projection plane Q; m is the number of boundary discrete units; l is0Is the minimum member size, and is constant.
Step 5, after an optimization result is obtained through topology optimization, redundant materials are deleted according to the optimization result, and a foam structure is reconstructed;
step 6, carrying out finite element analysis on the reconstructed foam structure, comparing various parameters of the foam and the protected product before and after optimization, such as foam energy absorption capacity, product acceleration and stress and strain of product parts, comprehensively evaluating the overall performance of the reconstructed foam structure, and verifying whether the structure of the optimization scheme is reliable or not in a finite element analysis mode; when the method is reliable, the mold opening test is carried out (that is, the structural scheme is processed, and the actual test is carried out for comparison), and when the mold opening test passes, the reconstructed foam structure is verified to pass, so that the one-time pass rate of the test is greatly improved in the above process.
The verification object of the air duct machine product packaging foam as an optimization method is further explained below.
The ducted product is wrapped with the original foam structure as shown in figure 4. By using the optimization method, the load data of the foam (as shown in FIG. 5) is obtained through simulation analysis processing, and topology optimization design is carried out. Iteration is performed through a topological optimization mathematical model algorithm until convergence, and an optimization scheme of the foam is obtained, as shown in fig. 6.
And replacing the foam structure of the optimization scheme into a product finite element model for simulation verification, and as shown in fig. 7, knowing from the analysis result: the peak value of the acceleration of the product is reduced by 14% in the falling process, so that the foam structure of the optimized scheme is superior to the original foam structure in terms of the buffering performance.
According to the optimization method, the foam structure is designed, so that the problems of redundant foam materials and unreasonable structure are solved, the minimum foam is used, the optimal packaging structure is designed, and the production cost and the test waste are reduced.
The present invention also provides a controller for performing the foam structure optimization method described above.
It is understood that the same or similar parts in the above embodiments may be mutually referred to, and the same or similar parts in other embodiments may be referred to for the content which is not described in detail in some embodiments.
It should be noted that the terms "first," "second," and the like in the description of the present invention are used for descriptive purposes only and are not to be construed as indicating or implying relative importance. Further, in the description of the present invention, the meaning of "a plurality" means at least two unless otherwise specified.
Any process or method descriptions in flow charts or otherwise described herein may be understood as representing modules, segments, or portions of code which include one or more executable instructions for implementing specific logical functions or steps of the process, and alternate implementations are included within the scope of the preferred embodiment of the present invention in which functions may be executed out of order from that shown or discussed, including substantially concurrently or in reverse order, depending on the functionality involved, as would be understood by those reasonably skilled in the art of the present invention.
It should be understood that portions of the present invention may be implemented in hardware, software, firmware, or a combination thereof. In the above embodiments, the various steps or methods may be implemented in software or firmware stored in memory and executed by a suitable instruction execution system. For example, if implemented in hardware, as in another embodiment, any one or combination of the following techniques, which are known in the art, may be used: a discrete logic circuit having a logic gate circuit for implementing a logic function on a data signal, an application specific integrated circuit having an appropriate combinational logic gate circuit, a Programmable Gate Array (PGA), a Field Programmable Gate Array (FPGA), or the like.
It will be understood by those skilled in the art that all or part of the steps carried by the method for implementing the above embodiments may be implemented by hardware related to instructions of a program, which may be stored in a computer readable storage medium, and when the program is executed, the program includes one or a combination of the steps of the method embodiments.
In addition, functional units in the embodiments of the present invention may be integrated into one processing module, or each unit may exist alone physically, or two or more units are integrated into one module. The integrated module can be realized in a hardware mode, and can also be realized in a software functional module mode. The integrated module, if implemented in the form of a software functional module and sold or used as a stand-alone product, may also be stored in a computer readable storage medium.
The storage medium mentioned above may be a read-only memory, a magnetic or optical disk, etc.
In the description herein, references to the description of the term "one embodiment," "some embodiments," "an example," "a specific example," or "some examples," etc., mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention, and that variations, modifications, substitutions and alterations can be made to the above embodiments by those of ordinary skill in the art within the scope of the present invention.