轻质多材料重载AGV总成优化设计

自动导引车（Automated Guided Vehicle，AGV）在智能制造领域的高速发展过程中逐渐呈现大型化、重载化的趋势，关键承载部件的优化设计能够显著降低重载AGV的重量及运行时的能耗，直接降低制造及使用成本。使用碳纤维增强树脂基复合材料（Carbon Fiber Reinforced Polymer，CFRP）作为轻质材料，针对80t级标准平台AGV关键承载部件从材料到结构进行总成优化设计。使用双向渐进结构法（Bi-directional Evolutionary Structural Optimization，BESO）拓扑优化车架及舵轮安装板，单元灵敏度过滤技术消除细小的分叉结构，得到了适合实际制造的优化结构。然后，制备了不同层数及编织方向的CFRP试样，进行拉伸及面内剪切实验，获得了CFRP的力学性能参数。随后优化了复合材料层合板的铺层角度，仿真结果表明，复合材料优化后的铺层角度为-12/33/55/-68]，使得多层材料面内最大Mises应力和位移分别降低了25.79%和9.95%。最后，针对车身进行有限元分析。研究结果表明：优化设计使重载AGV重量明显降低，新结构在未大幅提升最大应力与位移的前提下，总质量降低21.79%，其中舵轮安装板采用角度优化后的CFRP铺层组，质量仅为优化前的8.83%。模态分析表明，新结构的前六阶特征频率在核定工况范围内随着载荷增加呈减速下降的趋势，满载情况下在61.95~109.75Hz之间变化平稳。为实现重载AGV的低能耗、轻量化以及低成本制造提供一定的参考。

Optimized Design of Lightweight Multi-material Heavy-duty AGV Assembly

In the field of intelligent manufacturing, the rapid development of Automated Guided Vehicle (AGV) is accompanied by the trend of large-scale and heavy-duty, the optimal design of key load-bearing components can significantly reduce the weight of heavy-duty AGVs, the energy consumption during operation, and the manufacturing and usage costs. Carbon Fiber Reinforced Polymer (CFRP) was used as a lightweight replacement material, and the assembly was designed from material to structure to optimize the key load-bearing components of an 80t class AGV. The Bi-directional Evolutionary Structural Optimization (BESO) method was used to optimize the frame and rudder wheel mounting plate separately, while the cell sensitivity filtering technique was used to eliminate the fine bifurcation structure, resulting in an optimized structure suitable for actual manufacturing. Secondly, CFRP specimens with different layers and weave directions were prepared, and tensile and in-plane shear experiments were conducted to obtain the mechanical property of CFRP. Subsequently, the lay-up angles of the composite laminates were optimized, and the simulation results show that the optimized lay-up angles of the composite material are -12/33/55/-68], which results in a 25.79% and 9.95% reduction in the maximum Mises stress and displacement, respectively. Finally, finite element analysis was performed, and the results show that the optimized design leads to a significant weight reduction of the heavy-duty AGV, the total mass of the optimized structure is reduced by 21.79% without significantly increasing the maximum stress and displacement, in which the rudder wheel mounting plate adopts the angle-optimized CFRP paving set, and the mass is only 8.83% of that before optimization. The modal analysis shows that the first sixth-order eigenfrequency of the new structure decreases slowly with increasing load in the approved working condition range, and varies smoothly between 61.95 and 109.75 Hz under full load. This work provides some support for achieving low energy consumption, and low-cost manufacturing of heavy-duty AGVs.