Crash-Optimized BIW Design for Electric Buses Using Topology Simulation
DOI:
https://doi.org/10.22399/ijcesen.4685Keywords:
Electric bus, body-in-white (BIW), crashworthiness, rollover safety, topology optimization, topology simulationAbstract
The emergence of electric buses poses fresh body-in-white (BIW) crashworthiness problems due to the changes in the mass distribution, structural packaging limits, and allowable areas of deformation caused by the high-voltage energy storage systems.Meanwhile, driving-range targets also increase the lightweighting needs and the BIW layout choices become more decisive than the tuning of thickness only. The review brings together BIW design strategies based on crash-optimal topology simulation and the associated computational optimization strategies with focus on rollover-applicable structural integrity, multi-scenario performance, and manufacturable embodiment. The major methodological families are structured in terms of their treatment of the nonlinear crash dynamics such as direct crash-driven update strategies of topology and dynamic-to-static transformation and in terms of how they permit the BIW-scale iteration by surrogate, reduced-order, and data-efficient optimization. The existing constraints are reduced into gaps in research in the model uncertainty, numerical noise, multi-fidelity governance, minimum feature-size control, translation between topology and buildable bus structures. Future directions are regulation-consistent multi-scenario optimization, uncertainty-conscious digital workflows, new machine-learning-enabled nonlinear finite element analysis that can better clarify the feasibility of crash-optimized topologies of electrified buses.
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