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Table of Content

    25 December 2025, Volume 47 Issue 12 Previous Issue   
    A Review of Core Support Technologies for Flying Car System Operation
    Chenyuan He,Yilong Guo,Guanyu Zhu,Zhouyu Zhang,Yingfeng Cai,Hai Wang,Long Chen
    2025, 47 (12):  2277-2288.  doi: 10.19562/j.chinasae.qcgc.2025.12.001
    Abstract ( 249 )   HTML ( 25 )   PDF (1833KB) ( 167 )   Save

    Flying cars can effectively expand the dimensionality of transportation systems, offering innovative solutions to alleviate ground traffic congestion and broaden spatial mobility options. In recent years, China has actively promoted the development of flying cars, with increasing policy support and accelerated technological progress from enterprises. Against this backdrop, related research has grown steadily; however, most studies remain focused on specific modules such as flight control systems, energy systems, or individual path planning algorithms. A comprehensive perspective on the overall operational process and the coordination among subsystems is still lacking. To address this gap, In this paper, from the perspective of core enabling technologies for system-level operation, focusing on the challenges of safety, energy efficiency, and decision-making complexity in real-world flying car operations, a three-layer collaborative framework is proposed, consisting of bottom-layer fault tolerance and safety assurance; middle-layer energy management and power allocation; and top-layer path planning and autonomous decision-making. The key technologies and interdependencies within each layer are systematically reviewed, along with representative research progress and engineering practice. This work aims to provide theoretical insights and systematic references to support the safe and scalable deployment of flying car systems.

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    Solid-State Battery Technology Roadmap and Management Systems for eVTOL
    Zhen Yin,Jiangong Zhu,Longchen Lü,Haifeng Dai,Xuezhe Wei
    2025, 47 (12):  2289-2302.  doi: 10.19562/j.chinasae.qcgc.2025.12.002
    Abstract ( 143 )   HTML ( 13 )   PDF (4577KB) ( 98 )   Save

    With the rapid development of the low-altitude economy, electric vertical take-off and landing (eVTOL) aircraft have placed higher performance demand on batteries. Solid-state batteries, due to their higher energy density and improved safety compared to liquid electrolyte lithium-ion batteries, have become a key technology for addressing the challenges of eVTOL. In this paper, the characteristics of different flight stages of eVTOL and the requirements for batteries are analyzed, with the technological advancements of three types of solid-state electrolytes of polymer, oxide, and sulfide summarized. Considering the practical application of eVTOL, the optimization paths for solid-state battery management systems are explored from the perspectives of electrical, thermal, and pressure aspects. This paper aims to provide a theoretical basis and technical references for the development of high-performance solid-state batteries and management systems that meet the extreme operating requirements of eVTOL aircraft.

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    An Integrated Path Planner for Flying Cars with Sampling Nodes State Augmentation
    Longlong Liu,Wei Fan,Han Xiao,Yibo Zhang,Bin Xu
    2025, 47 (12):  2303-2313.  doi: 10.19562/j.chinasae.qcgc.2025.12.003
    Abstract ( 78 )   HTML ( 5 )   PDF (4105KB) ( 41 )   Save

    As a new type of transportation, flying cars offer the advantages of rapid aerial flight and stable ground driving. However, most existing path planning algorithms rely on separate planning strategies for aerial and ground states, and followed by their combined superposition, which results in slow state transition and leads to frequent takeoffs and landings at switching points. To address these issues, in this paper a land-air integrated path planning method based on the state augmentation of sampling points is proposed. Considering the differences in land-air states and spatial environment, a classification strategy for path sampling points is established. Furthermore, land-air state information is incorporated to augment the traditional sampling points. This enables rapid and efficient transition between aerial and ground states during vehicle movement, while also reducing path planning computation time. The experimental results show that, compared to conventional combined path planning algorithms, the proposed method reduces travel distance by 22.3% and path planning time by 34.2%. Compared to stateless augmentation-based integrated planning algorithms, the proposed method achieves an 8.4% reduction in path length and an 11.1% decrease in motion cost.

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    Modeling, Simulation and Experimental Study on Swelling Behavior of Semi-Solid-State Lithium-Ion Batteries
    Jielun Meng,Jun Peng,Ruixiang Zhao,Xuan Zhao,Jian Ma,Dean Meng,Xiakai Wang,Juncheng Yao
    2025, 47 (12):  2314-2325.  doi: 10.19562/j.chinasae.qcgc.2025.12.004
    Abstract ( 78 )   HTML ( 3 )   PDF (5022KB) ( 40 )   Save

    Semi-solid-state lithium batteries, combining the high ionic conductivity of liquid electrolytes with the safety advantages of solid-state electrolytes, have become a critical next-generation power source for aviation systems. The swelling behavior during charge-discharge cycles significantly impacts both electrochemical performance and safety. However, the mechanism and evolution patterns of expansion deformation and swelling force in semi-solid-state batteries remain insufficiently understood. In this study, taking a commercial semi-solid-state battery as the research object, the expansion characteristics under two distinct scenarios of constant-gap constraint and free-expansion conditions are experimentally analyzed. Further an electro-thermal-mechanical coupled model is developed for semi-solid-state lithium batteries to simulate expansion behavior under varying temperatures and C-rates. The simulation results show good agreement with experimental data. The experimental results show that under constant gap conditions, the fixed constraint converts the expansion of negative electrode material into stress accumulation; under free expansion conditions, the expansion of negative electrode material is directly presented in the form of displacement. The expansion force or expansion displacement increases rapidly in the constant-current charging stage, decreases slightly in the constant-voltage charging stage, and then decreases gradually in the constant-current discharging stage. The MAPE of the model simulation and experimental values is 4.69% and 5.37% (at 25 ℃, 1C) under both conditions, respectively. The results provide a theoretical basis for predicting and controlling the mechanical failure risk of semi-solid lithium batteries and optimizing the mechanical constraint design.

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    Thermal Performance Analysis of Liquid-Cooling Battery Pack for Flying Cars Based on Cellular Structure with Negative Poisson's Ratio
    Ying Zhao,Jibo Hao,Xiaoyu Sun,Jie Yang,Xiaosong Hu,Yueqiang Wang,Yangwei Wang
    2025, 47 (12):  2326-2335.  doi: 10.19562/j.chinasae.qcgc.2025.12.005
    Abstract ( 73 )   HTML ( 3 )   PDF (4031KB) ( 37 )   Save

    A novel battery pack for flying cars embedded with triangle umbrella-shaped cellular structure (TUCS) is proposed is proposed in this paper. Firstly, heat generation model of lithium battery is derived and corresponding finite element model of lithium battery cell is established. Then, discharge tests are conducted on lithium battery cells and the accuracy of heat generation model and finite element model is verified. Moreover, theoretical thermodynamic model of TUCS is derived and the optimization design is conducted. The optimal TUCS is achieved and then embedded into liquid-cooling battery pack of flying car. Meanwhile, the effects of coolant flow velocity, coolant flow direction, internal density gradient within TUCS, and interlayer density gradient on heat dissipation performances of novel battery pack is investigated to obtain the novel flying car battery pack with optimal heat dissipation performance. The maximum temperature and maximum temperature difference of the novel flying car battery pack is 32.0 and 4.01 ℃ respectively under typical operating conditions of flying cars, which are within the normal operating range, a decrease by 24.24% and 71.72% in comparation with those of conventional battery pack, respectively, thus verifying the excellent heat dissipation performance of the new flying car battery pack. Finally, the novel flying car battery pack sample is fabricated and discharge tests on TUCS battery pack sample are conducted. The accuracy of theoretical models and numerical simulation presented are verified.

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    Research on Updating Method of Energy Management Strategy for Fuel Cell Bus with Integrated PER and TL
    Ruchen Huang,Hongwen He
    2025, 47 (12):  2336-2345.  doi: 10.19562/j.chinasae.qcgc.2025.12.006
    Abstract ( 54 )   HTML ( 1 )   PDF (4332KB) ( 24 )   Save

    For the problems of low training efficiency and delayed updating in deep reinforcement learning-based energy management strategies (EMSs), taking the fuel cell bas as the research object, an intelligent EMS updating method integrating prioritized experience replay (PER) and transfer learning (TL) for fuel cell buses is proposed in this paper. A sampling mechanism-enhanced soft actor-critic (ESAC) algorithm is designed to improve EMS training efficiency by incorporating PER into the SAC framework. Furthermore, a TL-based EMS updating method is proposed to enhance the updating efficiency and long-term optimization performance by leveraging the knowledge-sharing mechanism for cross-cycle knowledge transfer and policy reuse of the ESAC-based EMS. Finally, the updated EMS is deployed to the energy management controller for online power distribution optimization. The experimental simulation results show that, compared with SAC, the proposed ESAC algorithm improves training efficiency by 58.33%. Additionally, the proposed updating method enhances EMS updating efficiency by 63.01% and fuel economy by 5.24% over baseline methods, while demonstrating real-time application potential.

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    Quantitative Study on the Corrosion Acceleration Factor of Bipolar Plates Under Various Operating Conditions
    Feiyu Li,Daokuan Jiao,Dong Hao,Yongping Hou
    2025, 47 (12):  2346-2357.  doi: 10.19562/j.chinasae.qcgc.2025.12.007
    Abstract ( 68 )   HTML ( 2 )   PDF (6811KB) ( 24 )   Save

    Corrosion of bipolar plates in proton exchange membrane fuel cells at high temperature and high potential becomes a key challenge restricting their durability. In this paper, the influence of different temperature and potential on the corrosion acceleration factor of bipolar plates is studied quantitatively by electrochemical test. The synergistic mechanism of temperature and potential on corrosion rate is revealed by establishing the corrosion acceleration factor model of three kinds of bipolar plates. The results show that the effect of electric potential on the electrochemical corrosion of bipolar plate is very obvious. The research results provide theoretical support for bipolar plate material selection, operation parameter optimization and PEMFC durability improvement.

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    Online Estimation Model and Experimental Study of Water Temperature for Vehicular Fuel Cell Systems
    Changchun Li,Tao Zeng,Jin Huang,Hongxu Ran,Long Xiao,Caizhi Zhang
    2025, 47 (12):  2358-2365.  doi: 10.19562/j.chinasae.qcgc.2025.12.008
    Abstract ( 53 )   HTML ( 0 )   PDF (3885KB) ( 21 )   Save

    The reliability of temperature control in automotive fuel cells is critical for their efficient and long-term operation. To enable rational diagnosis of temperature sensors or accurately obtain the coolant temperature at fuel cell inlet/outlet after sensor failure, and to avoid power interruption or rapid overheating damage to the fuel cell caused by control failure, in this paper an online estimation model for the inlet and outlet coolant temperature of the fuel cells is established based on heat generation and dissipation principles, incorporating environmental temperature corrections. The validation results from real vehicle experiments show that the transient estimation error for inlet and outlet temperature is ≤2 ℃ and the steady-state estimation error is ≤1 ℃, meeting the required estimation accuracy. This estimation model plays a significant role in enhancing the reliability of the fuel cell thermal management system.

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    Designing and Developing High Durability Low-Pt Oxygen Reduction Reaction Catalyst
    Lutian Zhao,Jia Wang,Yi Wang,Haifeng Fang
    2025, 47 (12):  2366-2377.  doi: 10.19562/j.chinasae.qcgc.2025.12.009
    Abstract ( 56 )   HTML ( 1 )   PDF (1738KB) ( 12 )   Save

    Hydrogen fuel cell vehicles (FCVs) are considered as the ultimate solution fore zero carbon transportation. In recent years, the key components' technologies of FCVs have been continuously promoted to meet the basic needs of short-distance transportation. However, the diverse commercial application scenarios in the future have put forward higher requirements for manufacturing cost and durability of the core components of the fuel cell stack. The cathode Pt-based catalyst fundamentally enhances the power density of the fuel cell stack, but its high price has become the main reason for the increase of stack cost. Decreasing the Pt content while improving catalyst performance has become an important research direction for catalysts. However, the durability of the catalyst will face new challenges with the decrease of the Pt content. Therefore, the design and development of high-durability, low-Pt catalysts are crucial for enhancing the lifespan of the fuel stack and hydrogen fuel cell vehicles. Starting from the analysis of the catalytic reaction mechanism of Pt-based catalysts and the attenuation mechanism of low Pt catalysts under actual operating conditions of FCVs, this paper focuses on the optimization of Pt active sites to explore the principles of improving their durability. Additionally, a review of existing research results is conducted and finally the design and development direction of high-performance low-Pt oxygen reduction catalysts in the future are discussed.

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    Simulation Test Method of Intelligent Vehicle Camera Function in Strong Light Environment
    Yinzi Huang,Bing Zhu,Jian Zhao,Peixing Zhang,Zhitong Gao,Jiayi Han,Xinwei Fan
    2025, 47 (12):  2378-2386.  doi: 10.19562/j.chinasae.qcgc.2025.12.010
    Abstract ( 63 )   HTML ( 3 )   PDF (5106KB) ( 26 )   Save

    The strong light environment generated by vehicle high beams, sunlight, and other light sources can significantly affect the camera functions of intelligent vehicle. Establishing accurate and controllable testing methods for such strong light environment is crucial for improving the environmental adaptability of intelligent vehicles. However, real-world testing on roads or closed fields under strong light conditions faces challenges such as high testing cost, long cycles, and the difficulty of precisely replicating controlled scenarios. In this paper a simulation test method for intelligent vehicle camera function under strong light environment is proposed. It uses a geometric-physical fusion simulation model to simulate image responses in strong light environment, and employs strong light simulation images to test camera functions. Firstly, a geometric model of strong light environment imaging is constructed to determine the area affected by strong light. Secondly, the camera imaging physical model and the physical characteristics of strong light sources are used to determine the pixel intensity corresponding to the strong light effect. Based on the strong light impact region and pixel values, images collected from real vehicles under normal light conditions are combined to generate strong light simulation images. Finally, real-world test results under strong light environment are taken as ground truth, and the testing results for the same camera functions in strong light environment are compared with traditional simulation software, large model methods, and the method proposed in this paper. The experimental results show that the proposed method can improve the performance of strong light environment simulation testing. Compared to traditional simulation software and large model methods, it achieves more effective and accurate camera function testing under strong light conditions. Additionally, it offers the advantages of lower testing cost, higher efficiency, and precise controllability of simulation parameters, as compared to physical scene testing.

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    Yaw Stability Control of Vehicles Under Extreme Working Conditions
    Yong Han,Sihang Xie,Shuiwen Shen,Zhenyu Qin,Di Pan,Zhiqun Yuan
    2025, 47 (12):  2387-2396.  doi: 10.19562/j.chinasae.qcgc.2025.12.011
    Abstract ( 124 )   HTML ( 13 )   PDF (5728KB) ( 67 )   Save

    A high-speed vehicle running unilaterally over a low traction coefficient road surface (e.g., water or sand) is very likely to cause a large yaw loss of control, and the traditional control system relies on the driver's operation and is not robust enough, resulting in an increased risk of misoperation under emergency conditions. To address this problem, in this paper a front wheel active steering strategy is proposed based on radial basis function neural network sliding mode control (RBF-SMC). Firstly, a two-degree-of-freedom model of the vehicle is established, and the RBF neural network is fused with the sliding mode control, which effectively suppresses the vibration problem of the traditional sliding mode control by approximating the system uncertainty through the adaptive law. Secondly, a nonlinear tire model is established based on the magic tire formula to solve the differential equations of the vehicle dynamics to obtain the dynamic stability domain of the vehicle phase plane, so as to realize that the controller intervenes only when the vehicle is on the verge of going out of control, reducing the interference to the normal operation of the driver. Finally, the control performance of different controllers is compared by double-shifted line conditions, and a folio road condition is designed to simulate the above emergency conditions to verify the effectiveness of the controller proposed in this paper. The simulation results show that this method has better yaw stability control effect than the traditional Sliding Mode Control (SMC) and Linear Quadratic Regulator (LQR).

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    Road Sense Simulation Method for Steer-by-Wire Bumpy Pavement Based on Wavelet Decomposition and Reconstruction
    Haobin Jiang,Xianpeng Lin,Chenxu Li,Tonghui Shen,Bin Tang
    2025, 47 (12):  2397-2408.  doi: 10.19562/j.chinasae.qcgc.2025.12.012
    Abstract ( 71 )   HTML ( 2 )   PDF (5484KB) ( 37 )   Save

    Due to the cancellation of the mechanical connection between the steering wheel and the steering gear, the interaction torque between the road surface and the tires, the unevenness of the road surface and other information cannot be directly transmitted to the steering wheel, and the driver cannot obtain the real "road feeling" when controlling the steering wheel, so the road sense simulation is one of the key technologies of the steer-by-wire system. At present, the road sense simulation method of steer-by-wire system in flat road conditions has been relatively mature, but it is still difficult and challenging to simulate road sense in bumpy road conditions. In this paper, an extended state observer is designed based on the steer-by-wire actuator model to estimate the steering rack force, and the main torque of the SBW system is determined with reference to the power assist characteristics of the electric power steering system (EPS), and the system friction torque, damping torque, active return torque and limit torque that need to be estimated in the SBW road sensing simulation under conventional road conditions are analyzed. Considering the particularity of the bumpy road sense simulation, it is necessary to determine the corresponding compensation torque according to the influence of the steering wheel vibration frequency on the driver, grasp the driver's acceptance of different frequencies of the bumpy road surface based on the wavelet decomposition of the vibration signal, and reconstruct the bumpy road vibration through screening, attenuation or amplification of the rack force signal, so as to reasonably calculate and compensate the road sense simulation torque of the bumpy road. The simulation and bench experiment results show that the bumpy road sense simulation method based on wavelet decomposition and reconstruction not only does not affect the steering comfort of the driver, but also makes the driver clearly feel the unevenness of the road surface and obtain a good road feeling.

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    Urban Logistics Mixed Fleet Scheduling Strategy Under Demand Uncertainty
    Weilu Hou,Qin Shi,Xinnan Fu
    2025, 47 (12):  2409-2419.  doi: 10.19562/j.chinasae.qcgc.2025.12.013
    Abstract ( 50 )   HTML ( 1 )   PDF (2651KB) ( 20 )   Save

    For the practical demand of urban logistics mixed fleet scheduling, considering the typical characteristics of electric vehicle fleet scheduling, a mixed fleet scheduling model is systematically constructed encompassing both electric logistics and traditional fuel vehicles. To solve demand uncertainty, a joint cumulative distribution function is introduced, and a mixed-integer programming model is developed. To efficiently solve the model, an improved starfish optimization algorithm is proposed, in which a simulated annealing mechanism is embedded within the neighborhood solution generation process to evaluate newly generated solutions. The integration enhances the global search capability and prevents convergence to local optima. To validate the effectiveness of the proposed algorithm, comparative experiments based on the JD Logistics are carried out with the starfish optimization algorithm, simulated annealing algorithm and genetic algorithm. The results demonstrate that the proposed algorithm outperforms the benchmarks in terms of both total cost and convergence efficiency. In terms of operational efficiency, a comparative analysis with purely electric logistics fleet reveals that the mixed fleet achieves superior performance under various operating conditions, reducing the total cost by up to 7.73%. Moreover, sensitivity analysis indicates that increasing battery capacity and improving charging speed can reduce total cost, though with diminishing marginal returns. Notably, charging speed exerts a more pronounced influence on cost reduction than battery capacity.

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    Vehicle Matching Test and Its Evaluation Method of Vehicle Grade MCU Chips
    Yongchang Zhang,Zhaolin Li
    2025, 47 (12):  2420-2430.  doi: 10.19562/j.chinasae.qcgc.2025.12.014
    Abstract ( 61 )   HTML ( 2 )   PDF (3843KB) ( 32 )   Save

    Recently, China's automotive chip industry has made significant progress, however promoting the application of domestically produced automotive chips in vehicles faces enormous challenges. Taking the core component of the vehicle controller - vehicle grade MCU (microcontroller unit) chip as an example, although traditional ATE testing can simulate the environmental conditions of real vehicle driving to verify the functionality, performance, and reliability of MCU chips, there is a large technical gap in whether the independently developed vehicle specification level MCU chips meet the strict technical requirements of actual vehicles in complex driving conditions and harsh working environment in terms of functionality, performance, and reliability and functional safety, mainly manifested in the lack of vehicle specification level MCU chips matching test methods in China, the lack of relevant testing systems and experimental data statistical analysis methods, and the inability to carry out vehicle specification level MCU chips matching evaluation under real vehicle driving conditions. For the above problems, in this paper a vehicle compatibility testing concept and actual vehicle testing method for automotive grade MCU chips is proposed. The experiments prove that this testing method can achieve 100% coverage testing of the basic functions of typical automotive grade MCU chips. The data sampling synchronization period of the vehicle matching testing equipment system is less than 1 ms, which can cover the data acquisition cycle requirements under typical vehicle operating conditions. In addition, in this paper the stability and consistency of vehicle grade MCU chips vehicle environment testing performance data is also defined. A stability and consistency evaluation index system based on vehicle grade MCU chips vehicle environment testing performance data is established, and a data statistical analysis method is proposed that integrates vehicle testing data preparation, analysis, and evaluation. The coefficient of variation is studied and recommended values are provided, filling the technical gap in vehicle grade MCU chip matching evaluation under real vehicle driving conditions.

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    Research on the Multi-dimensional Dynamic Characteristics of Tripod Joints Considering Contact Geometry
    Yinyuan Qiu,Guojing Lin,Yunfei Zha,Xiaoyong Wu,Liang Hong,Qinda Zeng
    2025, 47 (12):  2431-2440.  doi: 10.19562/j.chinasae.qcgc.2025.12.015
    Abstract ( 41 )   HTML ( 0 )   PDF (2311KB) ( 23 )   Save

    In order to investigate the influence of geometries of contact pairs on the multi-dimensional dynamic characteristics of tripod joints, in this paper a dynamic performance analysis method considering contact geometry is proposed. Firstly, based on the principles of conjugate surface, the contact geometry model of a roller-track pair is established, and the constraint relationship between them is solved. Subsequently, a multi-body dynamics model integrating contact geometry characteristics is developed using ADAMS software. And by combining the automatic contact point detection algorithm with geometric projection constraint equations, the computational accuracy of the positions of contact points between rollers and tracks is improved, enabling more precise simulation of their contact mechanics properties. The accuracy of the model is validated through bench tests. The results show that when the contact pressure angle between rollers and tracks increases to 20°, the generated axial force can be reduced by approximately 29% without increasing the joint size, significantly mitigating the excitation of vehicle lateral vibration. This study provides a new approach to resolving the conflict between high NVH performance and lightweight design in tripod constant velocity joints.

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    Manufacturing and Recycling of Thermoset Composite Support Plate for Car B-pillar
    Le An,Yuezhan Feng,Heshan Bai,Shujuan Wang,Bo Lu,Chuntai Liu,Ming Huang,Tiejun Wang
    2025, 47 (12):  2441-2449.  doi: 10.19562/j.chinasae.qcgc.2025.12.016
    Abstract ( 56 )   HTML ( 2 )   PDF (5067KB) ( 34 )   Save

    Composite is the most promising material for achieving structural lightweight. Thermosetting composites have excellent mechanical properties and chemical stability, but their remanufacturing and recycling are extremely challenging. In this work the manufacturing and recycling methods for the thermoset composite support plate of car B-pillar are studied. The basic idea is to introduce dynamic covalent bonds into thermosetting composites, and achieve manufacturing and recycling of thermosetting resin based composite reinforcement plates through layer by layer laying and hot pressing of carbon fiber prepreg. Compared with steel reinforced plates, the prepared thermoset composite reinforced plates reduce weight by more than 50%, and the peak impact force of composite B-columns is reduced by more than 30%. The non-destructive full recovery of carbon fibers in thermosetting composite reinforcement plates has been achieved, and the uniaxial tensile strength retention rate of the recovered resin exceeds 95%. This study provides a new approach for manufacturing lightweight and recyclable thermosetting resin based composite automotive components, which can be extended to other related fields.

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    Experimental and Numerical Analysis of Impact Resistance of Polyurea-Coated Aluminum Longitudinal Beams
    Hui Wang,Yang Zhao,Jinbo Zhou,Haifeng Jin,Jiajian Cao,Chao Liu
    2025, 47 (12):  2450-2458.  doi: 10.19562/j.chinasae.qcgc.2025.12.017
    Abstract ( 53 )   HTML ( 4 )   PDF (4125KB) ( 46 )   Save

    To meet the dual demand of lightweight design and crash safety performance improvement in passenger vehicles, in this study the synergistic reinforcement mechanism of polyurea coating thickness (0-7 mm) and interface strength (6 - 14 MPa) on the impact resistance of a one-piece die-cast aluminum rail that directly carries longitudinal loads is investigated. Through material-level static and dynamic tensile tests on polyurea, interfacial double cantilever beam (DCB) tests, and component-level quasi-static and dynamic crush tests on the rails, combined with a three-dimensional finite element model built on the LS-DYNA platform, multi-dimensional validation and parametric analysis of the coating are conducted. The results show that polyurea exhibits significant strain rate hardening behavior. When the coating thickness is 6 mm, the impact peak load of the rail can be increased by 16.53%. However, parameter analysis reveals that a thickness of approximately 3 mm achieves optimal energy absorption efficiency. The interface strength of around 12 MPa provides the best energy transfer efficiency, while insufficient strength may lead to interfacial delamination. The comparison between simulation and experimental results shows that the error in peak impact force is controlled within 10%, with highly consistent failure modes observed. In conclusion, by appropriately matching the polyurea coating thickness and interface strength, the load-bearing capacity, energy absorption efficiency, and structural integrity (e.g., reduced fragment scattering) of the rail can be effectively enhanced, while improving deformation behavior during impact and suppressing local brittle fracture and buckling instability, thereby providing both theoretical support and engineering guidance for the coordinated design of automotive lightweight and safety.

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    Multi-Level Topology Optimization Design of Aluminum Alloy Vehicle Frames Driven by Internet of Vehicles Big Data
    Zihao Meng,Dengfeng Wang,Xiaopeng Zhang,Yenan Ni,Yongfei Wang,Weiguang Wang
    2025, 47 (12):  2459-2466.  doi: 10.19562/j.chinasae.qcgc.2025.12.018
    Abstract ( 94 )   HTML ( 7 )   PDF (2585KB) ( 46 )   Save

    In order to improve the lightweight level of electric commercial vehicles, in this paper a multi-level and multi-condition topology optimization design method is proposed for the aluminum alloy frame driven by Internet of Vehicles (IoV) big data. Firstly, the big data of the IoV is analyzed to obtain the proportion of working conditions to determine the objective weight, and the subjective weight is obtained through the Analytic Hierarchy Process (AHP). Subsequently, a game theory approach integrates these weights through compromise programming to normalize conditions, establishing a multi-condition topology optimization objective function. Then, taking an aluminum alloy frame of a tractor as the research object, the Solid Isotropic Material with Penalization (SIMP) method is used to carry out the overall multi-condition topology optimization design of the first level of the frame, and the number and relative position information of the beams are obtained. Finally, the multi-body dynamic model is used to extract the multi-condition loads between the longitudinal and cross beams, and the second level cross beam section topology optimization is carried out on the frame, leading to the extraction of the cross-section shape of the cross beam. The results show that after topology optimization, the weight of the frame is reduced by 31.4% on the premise of performance improvement.

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    Active Learning Kriging Based Structural Reliability Analysis Method and Application
    Hui Lü,Weijie Yan,Xiaoting Huang
    2025, 47 (12):  2467-2482.  doi: 10.19562/j.chinasae.qcgc.2025.12.019
    Abstract ( 79 )   HTML ( 7 )   PDF (13196KB) ( 48 )   Save

    For the problems of low computational accuracy and efficiency in the reliability analysis of complex automotive structures, an active learning Kriging reliability analysis method is proposed based on the limit state approximation and normalized response. Firstly, based on the probability density function under the assumption of Gaussian distribution and the Expected improvement criterion, the expectation of improved distance is derived when the degree of limit state surface (LSS) approximation improves, and the expected improvement index is proposed in combination with the current maximum distance. Then, considering the uncertainty of prediction, a learning function named expectation of redefined improvement (ERI) is developed based on the Kriging standard variance, which is used to adaptively increase the training samples. Next, a normalized response method is introduced to optimize the convergence threshold, which effectively alleviates the instability of dimensional convergence criteria. Finally, the effectiveness of the proposed method is verified through four application examples. The results show that the proposed method can achieve strong fitting of LSS with fewer function calls, with good applicability in multiple reliability analysis scenarios.

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