Altair > Case Studies > Achieving Superior Crash Performance for the Soueast DX7 with IoT

Achieving Superior Crash Performance for the Soueast DX7 with IoT

Technology Category

Analytics & Modeling - Digital Twin / Simulation
Cybersecurity & Privacy - Intrusion Detection

Applicable Industries

Automotive
Packaging

Applicable Functions

Product Research & Development

Use Cases

Intrusion Detection Systems
Virtual Prototyping & Product Testing

Services

System Integration
Testing & Certification

About The Customer

Soueast is a China-based automobile manufacturer with a mission of “providing an exciting mobile lifestyle and cultivating a cultured automotive community.” After more than twenty years in business, Soueast has successfully integrated advanced technologies from internationally renowned companies - Chrysler and Mitsubishi, and established two of its brands, Soueast and Mitsubishi in China. Looking to the future, while continuing to partner with international companies, Soueast is dedicated to strengthening its own R&D capabilities and its product brand. The DX7 is Soueast’s drive into the competitive SUV market based on its 3.0 new product strategy. The DX7 features an exterior and interior designed by top Italian design company, Pininfarina, who have over 100 years of leading European concept automobile design, along with world quality and safety standards systems using Mitsubishi technology.

The Challenge

Soueast, a China-based automobile manufacturer, was faced with the challenge of optimizing the crash performance of its DX7 vehicle while reducing reliance on physical tests. Crash safety is a crucial part of the development process, and designing a car body that has good collision energy absorption performance is one of the main goals of automotive design. However, due to the high cost of prototype crash tests, it is not practical to validate a design’s feasibility through trial and error alone. The key to the success of virtual simulation is dependent on whether the simulation results are an accurate representation of the physical test results. The target for the DX7 project was to achieve the best possible crashworthiness while under tight time and budget constraints. The two main challenges were ensuring the CAE simulation results accurately reflect the physical crash test and analyzing and optimizing the restraint system.

The Solution

To overcome these challenges, Soueast partnered with Altair’s engineering services division, Altair ProductDesign. The team utilized the HyperWorks suite and its RADIOSS solver to simulate and optimize the crash performance of the DX7 vehicle. This process involved analyzing the current structure and restraint system and suggesting potential enhancements to the design that could improve performance. A critical loadcase in the development of the body structure of the DX7 was the C-NCAP high speed 40% offset deformable barrier. Extensive optimization using HyperStudy was then performed for bumper beam, longitudinal rail, shotgun, kick-down, and sill design. Finally, the targets of acceleration and intrusion results could be achieved, and furthermore, the weight of the front body was reduced. Regarding development of the restraint systems, optimization was performed on the steering column crush, footrest design, seat design, seat belt force limiters, airbag size and the venting opening.

Operational Impact

The use of RADIOSS for collision simulation proved to be highly successful for the DX7 project. The vehicle’s body achieved very good crashworthiness performance and the restraint system was optimized to enhance performance while minimizing weight. This further proved the tremendous role simulation has in guiding design, and not just analyzing performance. Following the project with Altair, the DX7 successfully achieved the 5-star C-NCAP test rating which Soueast had been striving for. This success not only validated the effectiveness of the simulation and optimization process but also demonstrated the potential of such technologies in improving the safety performance of vehicles while reducing the reliance on physical tests.

Quantitative Benefit