CN104296974A - Automobile headlamp structure fatigue life analysis method - Google Patents
Automobile headlamp structure fatigue life analysis method Download PDFInfo
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Abstract
The invention discloses an automobile headlamp structure fatigue life analysis method. The method comprises the steps that 1a, road spectrum data are collected and corrected; 1b, corrected road spectrums are simplified and calibrated; 2, environment temperatures in winter and summer are simulated respectively, and internal temperatures on the turn-on condition and the turn-off condition of a headlamp are simulated to obtain headlamp temperature field data on four conditions; the time scale between turn-on condition and turn-off condition of the headlamp is determined according to a market survey result, and temperature field combination data are established; 3, a headlamp assembly finite element model is established, thermo-physical properties and mechanical properties of all parts are input into the headlamp assembly finite element model, contact relations and assembly relations between all structures are defined, the temperature field combination data are imported, road spectrum simulation is applied, the thermo-mechanical coupling stress strain response of an automobile headlamp assembly structure within one cycle is calculated, and the thermo-mechanical fatigue life of the headlamp is calculated through fatigue analysis software. By means of the method, the fatigue life of the headlamp can be predicted at the design stage.
Description
Technical field
The invention belongs to Automobile Measuring Techniques, be specifically related to a kind of Vehicle headlamp structure analysis of Fatigue-life method.
Background technology
Along with the excitation day by day of automobile market competition, the Fatigue Life Problems of each auto vendor to vehicle is more and more paid attention to.Automobile front is as the main light fixture of vehicle, and its structural reliability, directly affects maneuverability and the security of vehicle.At present, Vehicle lamp structure mainly considers the realization of assembly relation with car load and optical property at the design initial stage, only its life-span is assessed by test in the Product Validation stage, lack enough means and predict its fatigue lifetime in the design phase, the headlight fault because of fatigure failure generation on market is more.
Headlight is subject to the random load that vehicle body transmission comes in vehicle travel process, and mainly contain two kinds of typical conditions of turning on light and do not turn on light, under these two kinds of operating modes, the Temperature Distribution of lamp body inside is widely different.Meanwhile, headlight also will accept the heat radiation from engine, and seasonal variations causes environment temperature also to have very large difference.Headlight housing and internal stent major part all adopt plastic material, and its material property is very responsive to temperature, when calculating the fatigue lifetime of headlight, must consider the impact of temperature on material property.
Large-scale finite element model cannot process long time-domain signal, needs to simplify time-domain signal, and the accuracy how ensureing to simplify after load is a difficult problem always.At present, time-domain signal is converted into frequency-region signal by fatigue mechanisms for random load usually, and utilize based on power spectrum density (Power spectral Density, PSD) transfer function method of loading spectrum solves, this method cannot consider the impact of temperature variation on structure, have significant limitation, accuracy fatigue lifetime being used for calculating headlight is lower.Carry out model analysis to headlight, find that the natural frequency of structure is much larger than excitation load frequency, there is not dynamic structure response in headlight, based on this feature, the invention provides a kind of new Vehicle headlamp structure analysis of Fatigue-life method.
Summary of the invention
The object of this invention is to provide a kind of Vehicle headlamp structure analysis of Fatigue-life method, fatigue lifetime of automobile front can be predicted in the design phase.
Vehicle headlamp structure analysis of Fatigue-life method of the present invention, comprises the following steps:
Step 1, the process of headlight mechanical load
1a, road modal data gather and correct
At headlight and vehicle body junction, three-way vibration acceleration transducer is installed, by the section requirement of testing field car load road fail-test, gather the combination road spectrum on different stage road surface, and the modal data that satisfies the need corrects, the trend term eliminated singular point in data and cause because of systemic disturbing factor;
1b, the road spectrum after correcting is simplified, calibrated
Retain the feature of the peak load in data, equivalent process is carried out to the load lower than fatigue limit, Fourier transform is utilized to be converted into the power spectral density signal of frequency domain and to carry out contrasting and calibrating the road spectrum signal before and after simplifying, until the root-mean-square value error that the power spectral density signal before simplifying rear and simplification is composed on road meets the demands, then the road after this simplification is composed as equivalent road is composed;
The process of step 2, headlight thermal force: the environment temperature simulating winter and summer respectively, turns on light to headlight and to emulate with the internal temperature field under two kinds of operating modes of not turning on light, obtain the headlight temperature field data in four kinds of situations; The time scale determined to turn on light in combination with market study result again and do not turn on light, sets up temperature field data splitting;
Step 3, heat engine coupling analysis of Fatigue-life: set up headlight assembly finite element model, input the hot physical property of each parts and mechanical characteristic, to to contact with each other between each structure and assembly relation defines, the temperature field data splitting that steps for importing 2 calculates, the equivalent road spectrum applying step 1b gained encourages, calculate the thsrmal-mech coupling strain-responsive of vehicle lamp assembly structure in a circulation, the structure thsrmal-mech coupling strain data calculated is imported in analysis of fatigue software, the fatigue properties of material is set, thsrmal-mech coupling field in the time period that appointment is analyzed above is a Life Cycle load, by calculating headlight heat engine fatigue lifetime.
Ambient temperature data in described step 2 respectively by winter vehicle road test and summer vehicle road test collect;
Thermo parameters method under using thermal analysis software to obtain consideration environment temperature simulation analysis headlight closed condition respectively, and consider the Temperature Distribution under environment temperature and bulb heat radiation simulation analysis headlight opening.
In described step 1a, high-pass filtering method, balance deflection method and least square method is used to correct the road modal data gathered.
In described step 1b, the root-mean-square value error of the power spectral density signal after road spectrum simplifies and before simplifying is within 10%.
The present invention has the following advantages: can predict fatigue lifetime of automotive headlamp in the design phase, with in the Product Validation stage by compared with verification experimental verification, can cost-saving, shorten the R&D cycle, find in advance and cause the danger position that headlight structure fatigue life is low, for the structure optimization of design phase and improvement provide foundation.
Accompanying drawing explanation
Fig. 1 is structured flowchart of the present invention.
Embodiment
Below in conjunction with accompanying drawing, the invention will be further described:
Vehicle headlamp structure analysis of Fatigue-life method as shown in Figure 1, comprises the following steps:
Step 1, the process of headlight mechanical load
1a, road modal data gather and correct: install three-way vibration acceleration transducer at headlight and vehicle body junction, by the section requirement (the road spectrum that this section is combined in proportion by the road surface of the different stages such as hollow road, pebble path, washboard road and Billy's time channel) of testing field car load road fail-test, gather the combination road spectrum on different stage road surface, high-pass filtering method, balance deflection method and least square method is used to correct the road modal data gathered, the trend term eliminated singular point in data and cause because of systemic disturbing factor.The concrete grammar corrected writes algorithm in MATLAB, inputs original road spectrum, namely draw and correct way of escape spectrum loading after program computation.
1b, the road spectrum after correcting is simplified, calibrate: the road spectrum signal data volume of testing due to reality is very large, the applying of excitation load during for the ease of analyzing, test data need be simplified, retain the feature of the peak load in data, equivalent process is carried out to the load lower than fatigue limit, such as: the less saw-toothed type curve section of fluctuation is fitted to smooth curve, the curve of load lower than fatigue limit is reduced to straight line, makes data volume in the magnitude of hundreds of.Fourier transform is utilized to be converted into the power spectral density signal of frequency domain and to carry out contrasting and calibrating the road spectrum signal before and after simplifying.If the power spectral density signal before simplifying differs larger with the root-mean-square value of the power spectral density signal after simplification, the road spectrum after to simplification is then needed to revise, until the root-mean-square value error of the power spectral density signal before simplifying rear and simplification is composed within 10% in road, then think that the road after this simplification is composed as equivalent road is composed.
The process of step 2, headlight thermal force
Simulate the environment temperature of winter and summer respectively, turning on light to headlight emulates with the internal temperature field under two kinds of operating modes of not turning on light, and obtains the headlight temperature field data in four kinds of situations.Wherein, ambient temperature data respectively by winter vehicle road test and summer vehicle road test collect.Thermo parameters method under using thermal analysis software (such as: Flotherm) to obtain consideration environment temperature simulation analysis headlight closed condition respectively, and consider the Temperature Distribution under environment temperature and bulb heat radiation simulation analysis headlight opening.The time scale determined to turn on light in combination with market study result again and do not turn on light, sets up temperature field data splitting.
Step 3, heat engine coupling analysis of Fatigue-life
In HyperMesh software, grid carries out to each parts of headlight discrete, discrete grid model is imported ABAQUS, set up headlight assembly finite element model, input the hot physical property of each parts and mechanical characteristic, to to contact with each other between each structure and assembly relation defines, such as: the dimming mechanism regulating high beam light angle and direction, the larger magnitude of interference is there is in its universal ball end in initial assembling, be subject to the pretightning force effect of pretension bolt simultaneously, under original state, just bear larger mechanical load effect.The temperature field data splitting that steps for importing 2 calculates, the equivalent road spectrum applying step 1b gained encourages, calculate the thsrmal-mech coupling strain-responsive of vehicle lamp assembly structure in a circulation, the structure thsrmal-mech coupling strain data calculated is imported in analysis of fatigue software (such as: MSC.Fatigue), the fatigue properties of material is set, thsrmal-mech coupling field in the time period that appointment is analyzed above is a Life Cycle load, by calculating headlight heat engine fatigue lifetime.
Claims (4)
1. a Vehicle headlamp structure analysis of Fatigue-life method, is characterized in that, comprises the following steps:
Step 1, the process of headlight mechanical load
1a, road modal data gather and correct
At headlight and vehicle body junction, three-way vibration acceleration transducer is installed, by the section requirement of testing field car load road fail-test, gather the combination road spectrum on different stage road surface, and the modal data that satisfies the need corrects, the trend term eliminated singular point in data and cause because of systemic disturbing factor;
1b, the road spectrum after correcting is simplified, calibrated
Retain the feature of the peak load in data, equivalent process is carried out to the small magnitude load lower than fatigue limit, Fourier transform is utilized to be converted into the power spectral density signal of frequency domain and to carry out contrasting and calibrating the road spectrum signal before and after simplifying, until the root-mean-square value error that the power spectral density signal before simplifying rear and simplification is composed on road meets the demands, then the road after this simplification is composed as equivalent road is composed;
The process of step 2, headlight thermal force: the environment temperature simulating winter and summer respectively, turns on light to headlight and to emulate with the internal temperature field under two kinds of operating modes of not turning on light, obtain the headlight temperature field data in four kinds of situations; The time scale determined to turn on light in combination with market study result again and do not turn on light, sets up temperature field data splitting;
Step 3, heat engine coupling analysis of Fatigue-life: set up headlight assembly finite element model, input the hot physical property of each parts and mechanical characteristic, to to contact with each other between each structure and assembly relation defines, the temperature field data splitting that steps for importing 2 calculates, the equivalent road spectrum applying step 1b gained encourages, calculate the thsrmal-mech coupling strain-responsive of vehicle lamp assembly structure in a circulation, the structure thsrmal-mech coupling strain data calculated is imported in analysis of fatigue software, the fatigue properties of material is set, thsrmal-mech coupling field in the time period that appointment is analyzed above is a Life Cycle load, by calculating headlight heat engine fatigue lifetime.
2. Vehicle headlamp structure analysis of Fatigue-life method according to claim 1, is characterized in that: the ambient temperature data in described step 2 respectively by winter vehicle road test and summer vehicle road test collect;
Thermo parameters method under using thermal analysis software to obtain consideration environment temperature simulation analysis headlight closed condition respectively, and consider the Temperature Distribution under environment temperature and bulb heat radiation simulation analysis headlight opening.
3. Vehicle headlamp structure analysis of Fatigue-life method according to claim 1 and 2, is characterized in that: in described step 1a, uses high-pass filtering method, balance deflection method and least square method to correct the road modal data gathered.
4. Vehicle headlamp structure analysis of Fatigue-life method according to claim 1 and 2, is characterized in that: in described step 1b, and the root-mean-square value error of the power spectral density signal after road spectrum simplifies and before simplifying is within 10%.
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Cited By (10)
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| CN106610355A (en) * | 2015-10-22 | 2017-05-03 | 中国科学院力学研究所 | Heat engine fatigue test method and device |
| CN106768760A (en) * | 2016-12-21 | 2017-05-31 | 航天东方红卫星有限公司 | A kind of spacecraft swept-sine vibration Fatigue Invalidation Analysis method |
| CN107389478A (en) * | 2017-06-22 | 2017-11-24 | 上海工程技术大学 | A kind of Forecasting Methodology of the material fatigue life based on wavelet packet analysis |
| CN108052717A (en) * | 2017-12-01 | 2018-05-18 | 中国航空工业集团公司沈阳飞机设计研究所 | A kind of fatigue life calibration method based on Local Stress Strain Method |
| CN108573081A (en) * | 2017-07-05 | 2018-09-25 | 常州星宇车灯股份有限公司 | A kind of thermal deformation analysis method of Thermal-mechanical Coupling simulated automotive lamp reflector |
| CN110414087A (en) * | 2019-07-10 | 2019-11-05 | 北京华安中泰检测技术有限公司 | A kind of electronic product lifetime estimation method under more stress couplings effect |
| CN110598234A (en) * | 2019-05-07 | 2019-12-20 | 重庆长安汽车股份有限公司 | Vehicle dynamics model parameter calibration method |
| CN112989665A (en) * | 2021-03-23 | 2021-06-18 | 重庆理工大学 | Fatigue life analysis method for differential shell of electric drive assembly |
| CN114184405A (en) * | 2021-11-29 | 2022-03-15 | 重庆长安汽车股份有限公司 | Method and system for evaluating thermal strain fatigue life of automobile radiator assembly |
| CN114297884A (en) * | 2021-11-08 | 2022-04-08 | 常诚车业江苏有限公司 | Car lamp fatigue life simulation evaluation and optimization method for composite vibration at high temperature |
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| CN107389478B (en) * | 2017-06-22 | 2019-11-12 | 上海工程技术大学 | A kind of prediction technique of the material fatigue life based on wavelet packet analysis |
| CN108573081A (en) * | 2017-07-05 | 2018-09-25 | 常州星宇车灯股份有限公司 | A kind of thermal deformation analysis method of Thermal-mechanical Coupling simulated automotive lamp reflector |
| CN108052717B (en) * | 2017-12-01 | 2021-09-03 | 中国航空工业集团公司沈阳飞机设计研究所 | Fatigue life calibration method based on local stress-strain method |
| CN108052717A (en) * | 2017-12-01 | 2018-05-18 | 中国航空工业集团公司沈阳飞机设计研究所 | A kind of fatigue life calibration method based on Local Stress Strain Method |
| CN110598234A (en) * | 2019-05-07 | 2019-12-20 | 重庆长安汽车股份有限公司 | Vehicle dynamics model parameter calibration method |
| CN110414087A (en) * | 2019-07-10 | 2019-11-05 | 北京华安中泰检测技术有限公司 | A kind of electronic product lifetime estimation method under more stress couplings effect |
| CN112989665A (en) * | 2021-03-23 | 2021-06-18 | 重庆理工大学 | Fatigue life analysis method for differential shell of electric drive assembly |
| CN112989665B (en) * | 2021-03-23 | 2023-02-07 | 重庆理工大学 | Fatigue life analysis method for electric drive assembly differential mechanism shell |
| CN114297884A (en) * | 2021-11-08 | 2022-04-08 | 常诚车业江苏有限公司 | Car lamp fatigue life simulation evaluation and optimization method for composite vibration at high temperature |
| CN114184405A (en) * | 2021-11-29 | 2022-03-15 | 重庆长安汽车股份有限公司 | Method and system for evaluating thermal strain fatigue life of automobile radiator assembly |
| CN114184405B (en) * | 2021-11-29 | 2023-06-16 | 重庆长安汽车股份有限公司 | Assessment method and system for thermal strain fatigue life of automobile radiator assembly |
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