目的 在跌落冲击工况下，对风管机包装泡沫进行优化设计，得到缓冲性能可靠的泡沫优化方案，以降低包装成本。方法 通过OptiStruct与LS-DYNA联合仿真，建立带有包装的风管机整机有限元模型，并通过跌落实验验证有限元模型的准确性。获取所有工况泡沫载荷响应;其次通过OptiStruct开展拓扑优化，同时施加多工况载荷，并以惯性释放法作为边界条件，最后得到满足所有跌落工况要求的轻量化优化方案。结果 新泡沫方案较原方案质量减少了30%，各跌落实验工况加速度峰值均有所下降，产品跌落实验合格;仿真与实验加速度峰值相似度达到90%以上，泡沫失效位置一致。结论 结构拓扑优化方法可以在保证包装结构可靠性的前提下，降低包装成本。

This article aims to improve the structural design of the packaging foam of a commercial duct type air conditioner so that an optimized solution for both the energy-absorbing performance under drop test and economical advantages through weight reduction can be realized. Such optimized foam structure is obtained by analyzing a series of simulation results utilizing both LS-DYNA® and OptiStruct® and further verified under drop test. The major approach is as follows:firstly, the dynamic responses of the foam are extracted from all the testing conditions under simulation; secondly, the dynamic responses are converted to the equivalent stress state using inertial release method and utilized by the topology optimization method offered by OptiStruct®; lastly, the new foam is designed, fully assembled, tested and verified under drop test. Through our systematic approach, in comparison to the original design, a 30% weight reduction of the foam can be attained. The complete package with assembled foam and product not only passed the drop test but also achieved an overall reduced peak acceleration. In addition, simulation results are consistent with experimental results with over 90% accuracy for the acceleration curve and very similar region for the failed foam. In conclusion, through structural topology optimization method, the packaging cost can be reduced while ensuring the survivability of the product under drop test.