LAUSR

A hybrid conceptual design approach was introduced in this study to develop a conceptual design of oil palm polymer composite automotive crash box (ACB). A combination of theory of inventive problem solving (TRIZ), morphological charts and biomimetics was applied where the foremost requirements in terms of the material characteristics, function specifications, force identification, root cause analysis, geometry profile and design selection criteria were considered. The strategy was to use creations of nature to inspire five innovative conceptual designs of the ACB structure and the AHP method was applied to perform the pairwise analysis of selecting the best ACB conceptual design. A new conceptual design for a composite ACB was conceived bearing in mind the properties of natural fibre, unlike those of conventional materials such as steel alloys and aluminium alloys. The design with the highest ranking (26.6 %) was chosen as the final conceptual design, which was the one with a honeycomb structure for the outermost profile, reinforced with a spider web structure inside the part, supported by fibre foam structure extracted from the woodpecker sponge tissue at the centre to maximize the energy absorption capability. The new design could solve the problem of bending collapse which is a major cause of failure to absorb maximum impact energy for ACB during collision. However, the final conceptual design will still need several modifications for production and assembly purposes, which will be completed in a further study. 采用混合概念设计方法, 对油棕复合材料汽车防撞箱进行了概念设计. 结合创新问题解决(TRIZ)理论、形态图和仿生学, 考虑材料特性、功能规格、力识别、根本原因分析、几何形状和设计选择标准等方面的首要要求. 该策略是利用自然物来激发五种创新的 ACB 结构的概念设计, 并运用层次分析法进行两两分析来选择最佳的 ACB 概念设计. 复合 ACB 的新概念设计考虑到了天然纤维的特性, 而不像传统材料如钢合金和铝合金. 排名最高(26.6%)的设计被选为最终的概念设计, 该设计的最外层具有蜂窝结构, 内部结构由蜘蛛网结构强化, 中心部位是由啄木鸟海绵组织中提取的纤维泡沫结构支撑, 以达到能量吸收能力最大化. 新的设计可以解决 ACB 在碰撞过程中无法吸收最大冲击能量的主要原因—弯曲塌陷的问题. 但是, 为了生产和装配需要, 最后的概念设计仍需修改, 这些修改将在今后研究中完成.