Drop test analysis and optimization

1 . A computer-implemented method for performing a drop test using a response surface comprising:

(a) acquire inputs comprising a target safety factor, a drop height, and a computer model, wherein the computer model comprises a design that comprises model points that define a body;

(b) evaluating the computer model based on a set of points in a design space, wherein:

(1) the evaluating comprises performing a physics-based drop test simulation from the drop height for each point;

(2) the design space is reduced to three (3) parameters by aligning a floor normal and a gravity field;

(3) the evaluating results in a list of generated minimum safety factors and associated orientations for each point in the set of points;

(c) generating a response surface, for the entire computer model based on the generated minimum safety factors in the list of generated minimum safety factors, wherein:

(i) the response surface comprises a smooth surface in parametric space that is representative of the generated minimum safety factors; and

(ii) the response surface comprises a computation of one or more additional points corresponding to an orientation having an estimated minimum safety factor;

(d) performing the drop test simulation on the additional one or more points to generate an actual safety factor;

(e) based on the actual safety factor and the target safety factor, determining via results from the physics-based drop test simulation that the entire computer model fails the drop test;

(f) reporting the failure; and

(g) based on the failure, adjusting the design by adjusting the model points;

wherein the computer model is stored in memory and the evaluating, generating, and adjusting are performed by a processor executing instructions to improve computational efficiency of drop test simulations.

2 . The computer-implemented method of claim 1 , further comprising:

based on the actual safety factor and the target safety factor, determining that the entire computer model has not failed the drop test;

determining that the estimated minimum safety factor comprises a global minimum safety factor; and

reporting that the entire computer model has passed the drop test.

3 . The computer-implemented method of claim 2 , further comprising:

determining that the estimated minimum safety factor does not comprise the global minimum safety factor;

updating the set of points by adding the additional one or more points to the set of points; and

returning to the generating the response surface step based on the updated set of points.

4 . The computer-implemented method of claim 1 , wherein the inputs further comprise one or more material properties of the computer model.

5 . The computer-implemented method of claim 1 , wherein the parametric space is defined by a spherical parametrization.

6 . The computer-implemented method of claim 1 , wherein the response surface is based on a radial basis function:

ƒ( x )=Σ w i Φ (| x - x i |)

where the function ƒ(x) is dependent on radial distance, x i reflects points with known values, and x consists of any point.

7 . The computer-implemented method of claim 6 , wherein a kernel for ƒ(x) is based on a Gaussian kernel.

8 . The computer-implemented method of claim 6 , wherein a kernel for ƒ(x) is based on a multiquadric kernel.

9 . The computer-implemented method of claim 6 , wherein a kernel for ƒ(x) is based on an inverse multiquadric kernel.

10 . The computer-implemented method of claim 1 , wherein the performing the drop test comprises:

constructing an overlay grid for the response surface;

computing values at each grid point; and

determining a minimum value across all grid points.

11 . A system for performing a drop test using a response surface comprising:

(a) a computer having a processor;

(b) a drop test analysis application executing on the computer by the processor;

(c) inputs, acquired by the drop test analysis application, wherein the inputs comprise a target safety factor, a drop height, and a computer model, wherein the computer model comprises a design that comprises model points that define a body;

(d) a set of points in a design space that is evaluated by the drop test analysis application, wherein:

(1) the design space is reduced to three (3) parameters by aligning a floor normal and a gravity field;

(2) the drop test analysis application evaluates by:

(i) performing a physics-based drop test simulation from the drop height for each point;

(ii) generating a list of generated minimum safety factors and associated orientations for each point in the set of points;

(e) a response surface, generated by the drop test analysis application, for the entire computer model based on the generated minimum safety factors in the list of generated minimum safety factors, wherein:

(1) the response surface comprises a smooth surface in parametric space that is representative of the generated minimum safety factors; and

(2) the response surface comprises a computation of one or more additional points corresponding to an orientation having an estimated minimum safety factor;

(f) an actual safety factor, generated by the drop test analysis application, wherein the actual safety factor is generated by performing the physics-based drop test simulation on the additional one or more points to generate an actual safety factor;

wherein the drop test analysis application further:

(g) determines, based on the actual safety factor and the target safety factor, via results from the physics-based drop test simulation, that the entire computer model fails the drop test; and

(h) reports the failure; and

wherein:

the computer adjusts the design by adjusting the model points based on the failure; and

the computer model is stored in memory on the computer and the evaluating, generating, and adjusting are performed by the processor executing instructions to improve computational efficiency of drop test simulations.

12 . The system of claim 11 , wherein the drop test analysis application further:

determines, based on the actual safety factor and the target safety factor, that the entire computer model has not failed the drop test;

determines that the estimated minimum safety factor comprises a global minimum safety factor; and

reports that the entire computer model has passed the drop test.

13 . The system of claim 12 , wherein the drop test analysis application further:

determines that the estimated minimum safety factor does not comprise the global minimum safety factor;

updates the set of points by adding the additional one or more points to the set of points; and

returns to the generating the response surface step based on the updated set of points.

14 . The system of claim 11 , wherein the inputs further comprise one or more material properties of the computer model.

15 . The system of claim 11 , wherein the parametric space is defined by a spherical parametrization.

16 . The system of claim 11 , wherein the response surface is based on a radial basis function:

ƒ( x )=Σ w i Φ (| x - x i |)

where the function ƒ(x) is dependent on radial distance, x i reflects points with known values, and x consists of any point.

17 . The system of claim 16 , wherein a kernel for ƒ(x) is based on a Gaussian kernel.

18 . The system of claim 16 , wherein a kernel for ƒ(x) is based on a multiquadric kernel.

19 . The system of claim 16 , wherein a kernel for ƒ(x) is based on an inverse multiquadric kernel.

20 . The system of claim 11 , wherein the drop test analysis application further:

constructs an overlay grid for the response surface;

computes values at each grid point; and

determines a minimum value across all grid points.