CN108984866B - Compilation method of test load spectrum - Google Patents

Compilation method of test load spectrum Download PDF

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CN108984866B
CN108984866B CN201810684838.5A CN201810684838A CN108984866B CN 108984866 B CN108984866 B CN 108984866B CN 201810684838 A CN201810684838 A CN 201810684838A CN 108984866 B CN108984866 B CN 108984866B
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stress
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period
reference point
load
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CN108984866A (en
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赵方伟
张关震
吴斯
吴毅
张澎湃
丛韬
尹鸿祥
张弘
张斌
付秀琴
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China Academy of Railway Sciences Corp Ltd CARS
Railway Engineering Research Institute of CARS
Beijing Teletron Telecom Engineering Co Ltd
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Railway Engineering Research Institute of CARS
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    • G01MTESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M17/00Testing of vehicles
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Abstract

The invention relates to a compilation method of a test load spectrum, which comprises the steps of selecting a stress reference point, processing an actually measured data signal, setting an invalid stress cycle threshold value, judging an invalid stress cycle, determining an invalid load time period and connecting breakpoints. The method can shorten the test period, truly reflect the loading condition of the key parts, and meet the principle of damage consistency before and after concentration.

Description

Compilation method of test load spectrum
Technical Field
The invention belongs to the field of test systems, and particularly relates to a compilation method of a test load spectrum.
Technical Field
The key parts of the railway vehicle are one of important influencing factors influencing the safe operation of the train, and the test is an important means for designing and evaluating the key parts. In the aspect of testing, the circuit testing method can reflect the real working conditions of key components, but the testing period is long, the cost is high, and the circuit actual measurement test cannot be carried out on each vehicle type of each circuit. The indoor simulation line bench test method can be used for testing with a shorter period and higher efficiency. Therefore, analog line bench testing is essential for the design and evaluation of critical components.
When a circuit simulation loading test is carried out on an indoor test bed, a test load spectrum for loading needs to be compiled as a driving excitation signal. The source of the test load spectrum is the time history of the load measured by the processed line test. Because the large load which can cause the fatigue damage of the structure is relatively less when the vehicle actually runs on a road, and the small load which does not greatly contribute to the fatigue damage or is not damaged occupies most time, the load time course needs to be concentrated and simplified to shorten the test period and effectively reduce the test cost.
When a vehicle runs on a road, key components are subjected to the combined action of various loads at any time, the various loads are coupled together, and the combined action of the various loads causes the fatigue damage of the key components, so that it is difficult to analyze how much a certain load can cause the fatigue damage to the key components, and it cannot be directly determined how much a certain load should be kept and how much should be deleted. Even if the load with larger load type is reserved through correlation calculation, the corresponding time law of each load is destroyed, and the corresponding time law cannot be used for simulating the line bench test.
Regardless of how the load is applied to the critical component, fatigue failure of the critical component by the load is characterized by internal stresses. The stress is the only basis of fatigue failure, when the stress range of the structure in a certain time period is higher than the fatigue cut-off limit, the structure in the time period generates fatigue damage, and the load corresponding to the time period is regarded as the effective load which can cause damage to the key components. And eliminating the time period with the stress range lower than the fatigue cut-off limit in the stress time history, and synchronously eliminating the corresponding load time period, so that the effective load time history can be kept. The concentration of the load time history is simplified, the load is not strengthened, the load cycle sequence is not changed, all the loads are synchronously maintained, the rule of the combined action of all the loads is not changed, the coupling relation is not changed, and the conditions of the loading condition, the vibration form, the fatigue damage and the like of the key parts are truly reproduced.
In the prior art, two methods are mainly used for compiling a test load spectrum of a key component of a railway vehicle, one method is to adopt a rain flow counting method to obtain a load spectrum block based on an actually measured load time course and compile the test load spectrum block according to a damage consistency principle, and the method converts a time domain signal into a frequency domain signal, does not consider the change process of a load and cannot reproduce the real loading condition of the key component; the other method is to directly use the actually measured load time history as a test load spectrum to carry out a loading test, and the test period of the method is too long, so that the research and development cost is greatly increased.
Disclosure of Invention
In order to overcome the defects of the prior art, the inventor of the application provides a load spectrum compiling method for a simulation circuit loading test of key components of a railway vehicle based on stress-based points, the method can shorten the test period, truly reflect the loading condition of the key components, and meet the damage consistency principle before and after concentration.
The above object of the present invention is achieved by the following technical means.
The invention provides a compilation method of a test load spectrum, which comprises the following steps:
step one, selecting a stress reference point
By utilizing a simulation calculation method, a fatigue dangerous part is selected by combining the actual application condition of a key part, and then a point with relatively large stress in the simulation calculation and a point with frequent problems in the actual application are selected as stress reference points. The invention takes the fatigue dangerous part as a stress reference point, and can reduce the workload and the cost of the actual measurement test of the line and the compilation of the test load spectrum.
Step two, actually measured data signal processing
Before a test load spectrum is compiled, burr removing signals, zero drift removing processing and interference removing filtering processing are carried out on a stress time history and a load time history obtained by synchronous testing.
Step three, setting of invalid stress cycle threshold value
Setting a stress amplitude threshold σ for an ineffective stress cycle aH And stress mean threshold σ mH
Step four, judging the invalid stress cycle
Obtaining stress cycle of stress time history by rain flow counting method, firstly, stress amplitude of stress cycle and stress amplitude threshold value sigma aH Comparing, if the stress amplitude value is higher than the threshold value of the stress amplitude value, judging the stress amplitude value is an effective stress cycle; if the stress amplitude value is lower than the stress amplitude value threshold value, temporarily judging the stress amplitude value as small stress circulation; the stress average value of small stress cycle and the stress average threshold value sigma mH Comparing, if the average value of the stress is higher than the threshold value of the stress average value, judging the stress is an effective stress cycle; if the stress average value is lower than the stress average value threshold value, judging as an invalid stress cycle, and recording a corresponding invalid stress time period.
Step five, determining the invalid load time period
And determining invalid stress time periods of all the stress reference points, and solving an intersection on a time axis to further obtain an invalid load time period.
Step six, breakpoint connection
And deleting the time history of the invalid load by using the invalid load time period, and smoothly connecting two adjacent breakpoints by using a half-sine curve so as to obtain an effective test load spectrum.
In step five, the invalid stress time period of the stress reference point is as follows:
ineffective stress period for stress reference point 1:
Figure BDA0001711446630000031
invalid stress period for stress reference point 2:
Figure BDA0001711446630000032
invalid stress period for stress reference point 3:
Figure BDA0001711446630000033
·
·
·
invalid stress period for the ith stress reference point:
Figure BDA0001711446630000034
·
·
·
invalid stress period for nth stress reference point:
Figure BDA0001711446630000041
the invalid load time period is:
Figure BDA0001711446630000042
in the formula,. DELTA.T 1 An invalid stress time period for the ith stress reference point;
Figure BDA0001711446630000043
a of the ith stress reference point i A period of ineffective stress; n is the number of stress reference points; the operation symbol # represents an intersection operation on the time axis.
Compared with the prior art, this application has following excellent technological effect:
1. the stress is the real response of the load, and a test load spectrum is compiled by a stress reference point by using the synchronous corresponding relation of the load and the stress, so that the accuracy is high;
2. due to the fact that invalid time periods in the load time process are omitted, the test period is shortened, and the test cost is reduced.
3. The method has the advantages that the selection of the stress reference point is required, the specific optimized selection method of the stress reference point is provided, the fatigue dangerous part is used as the stress reference point, and the workload and the cost of the actual measurement test of the line and the compilation of the test load spectrum can be reduced.
4. According to the method, a stress average value threshold value is introduced, the influence of the average value is considered, and after the judgment is carried out by utilizing the stress amplitude value threshold value, the invalid stress cycle is judged by utilizing the stress average value threshold value. In the prior art, only setting the stress amplitude threshold value can mistakenly delete the stress cycle with small stress amplitude but large stress average value, and the stress cycle contributes to the damage of key parts. The method of the patent is more accurate.
5. In the prior art, a great number of singular points are easily introduced into breakpoint linear connection, a test load spectrum compiled by the method is inconsistent with the actual situation, and the test bed is easily failed to load or damaged during a loading test. The method specially utilizes the half-sine curve to smoothly connect the breakpoints, thereby avoiding the above conditions.
6. In the prior art, redundant 'effective circulation' is easily introduced to stress cycle waveform expansion, and the accuracy of a test load spectrum is reduced. This patent utilizes half sinusoidal curve smooth connection breakpoint, has avoided above condition.
Drawings
FIG. 1 is a flow chart of load spectrum compilation for a simulation line test;
FIG. 2 is a processing result of an actually measured stress time history and a load time history of a wagon body of a certain railway wagon;
FIG. 3 is a flowchart of the invalid stress cycle determination;
FIG. 4 shows the load spectrum compilation results of a railway wagon body test;
FIG. 5 is a stress time history of a certain rail wagon body stress reference point 1;
FIG. 6 load time history adjacent breakpoints;
fig. 7 shows the connection mode of adjacent break points of the load time history, wherein (a) is a straight line connection, and (b) is a half-sine curve connection.
Detailed Description
The invention is further explained in detail with the determination of the test load spectrum of the body of a railway wagon in the figures and the embodiments.
Example 1
As shown in fig. 1, a compilation method of a load spectrum of a simulated line loading test of key components of a railway vehicle comprises the following steps:
step one, selecting a stress reference point
By utilizing a simulation calculation method, a fatigue dangerous part is selected by combining the actual application condition of a key component, and then a point with relatively large stress in the simulation calculation and a point with frequent problems in the actual application are selected as stress reference points. The results of selecting the stress reference points of a railway wagon body are shown in table 1.
TABLE 1 selection result of stress reference point of certain railway wagon body
Numbering Position of
1 Connecting area of lower cover plate and center sill of sleeper beam
2 Connecting area of lower cover plate and middle beam of inner sleeper beam
3 Middle large cross beam lower cover plate and middle beam joint
Step two, actually measured data signal processing
Before a test load spectrum is compiled, burr removing signals, zero drift removing processing and interference removing filtering processing are carried out on a stress time history and a load time history obtained by synchronous testing. The processing results of the measured stress time history and the load time history of a railway wagon body are shown in fig. 2.
Step three, setting of invalid stress cycle threshold value
Setting stress amplitude threshold σ for ineffective stress cycling aH And stress mean threshold σ mH . The determination results of the invalid stress cycle threshold values of the stress reference points of the body of a railway wagon are shown in table 2.
TABLE 2 determination of invalid stress cycle threshold for stress reference point of certain rail wagon body
Figure BDA0001711446630000061
Step four, judging the invalid stress cycle
Obtaining stress cycle of stress time course by rain flow counting method, firstly, the stress amplitude value and threshold value sigma of the stress cycle aH Comparing, and if the value is higher than the threshold value, judging the stress cycle is effective; if the stress is lower than the threshold value, temporarily judging the stress is a small stress cycle; taking the absolute value and the threshold value sigma of the stress average value of the small stress cycle mH Comparing, and if the value is higher than the threshold value, judging the stress cycle is effective; if the value is lower than the threshold value, the stress cycle is judged to be invalid, and the corresponding invalid stress time period is recorded (the flow is shown in figure 3). The determination results of the invalid stress time period of a certain railway freight car body are shown in table 3.
TABLE 3 determination of invalid stress time period of a railway wagon body
Figure BDA0001711446630000062
Step five, determining the invalid load time period
Determining invalid stress time periods of all stress reference points, and solving an intersection on a time axis to further obtain an invalid load time period, wherein the invalid load time period is as follows:
invalid stress period for the 1 st stress reference point:
Figure BDA0001711446630000071
invalid stress period for stress reference point 2:
Figure BDA0001711446630000072
invalid stress period for stress reference point 3:
Figure BDA0001711446630000073
·
·
·
invalid stress period for the ith stress reference point:
Figure BDA0001711446630000074
·
·
·
invalid stress period for nth stress reference point:
Figure BDA0001711446630000075
the invalid load period is:
Figure BDA0001711446630000076
in the formula,. DELTA.T 1 An invalid stress time period for the ith stress reference point;
Figure BDA0001711446630000077
a of the ith stress reference point i A period of ineffective stress; n is the number of stress reference points; the operation symbol # represents an intersection operation on the time axis. The determination results of the invalid load period of a certain railway wagon body are shown in table 4.
TABLE 4 determination of invalid load time period of certain railway wagon body
Figure BDA0001711446630000078
Step six, breakpoint connection
And deleting the time history of the invalid load by using the invalid load time period, and smoothly connecting two adjacent breakpoints by using a half-sine curve so as to obtain an effective test load spectrum. The compilation result of the test load spectrum of the body of a certain railway wagon is shown in figure 4.
Example 2
This example compares the stress average threshold value not introduced and only sets the difference between the stress amplitude threshold value and the method of the present invention, except for the special description, the same method as that of example 1 is adopted.
The stress time history of a certain railway wagon body stress reference point 1 is subjected to a rain flow counting method to obtain two stress cycles 1 and 2, and the stress cycles are shown in fig. 5. The statistical results of stress cycle 1 and stress cycle 2 are shown in table 5. The stress amplitude of the stress cycle 1 and the stress cycle 2 is lower than the stress amplitude threshold value sigma aH Stress mean value higher than stress mean value threshold value sigma mH Two stress cycles belong to the ineffective stress cycle, judged according to the prior art, but the part of the stress cycle is contributed to the damage of the key part and belongs to the effective stress cycle.
TABLE 5 statistical results for stress cycle 1 and stress cycle 2
Number of Stress amplitude (MPa) Mean value of stress (MPa)
Stress cycle 1 6.62 21.24
Stress cycle 2 9.51 26.86
Example 3
Except for special description, the same method as that in embodiment 1 is adopted, and the effect difference between the straight line connection and the semi-positive flare curve connection after the invalid load time period is deleted is compared in this embodiment.
After the invalid load time period is deleted, a breakpoint occurs in the load time history, as shown in fig. 6. The connection mode between two adjacent breakpoints is shown in fig. 7, fig. 7(a) is a conventional connection mode, after the invalid time period is deleted, the breakpoint 2 is translated to the same time point as the breakpoint 1, and the two breakpoints are connected in a straight line. A test load spectrum compiled by the connection mode introduces a large number of singular points, which is inconsistent with the actual situation, and during the loading test, the operation of the test bed can not realize smooth transition, which easily causes the loading failure or damage of the test bed. Fig. 7(b) shows the connection mode selected in this patent, two break points are smoothly connected by a half-sine curve, and the test load spectrum compiled according to the connection mode avoids the generation of singularities and is more effectively used for bench tests.

Claims (2)

1. A method for compiling a test load spectrum comprises the following steps:
step one, selecting a stress reference point
Selecting fatigue dangerous parts by using a simulation calculation method and combining with the actual application condition of a key component, and then selecting points with relatively large stress in the simulation calculation and points with frequent problems in the actual application as stress reference points;
step two, actually measured data signal processing
Before a test load spectrum is compiled, burr removing signals, zero drift removing processing and interference removing filtering processing are carried out on a stress time history and a load time history obtained by synchronous testing;
step three, setting of invalid stress cycle threshold value
Setting stress amplitude threshold σ for ineffective stress cycling aH And stress mean threshold σ mH
Step four, judging the invalid stress cycle
Obtaining stress cycle of stress time history by rain flow counting method, firstly, stress amplitude of stress cycle and stress amplitude threshold value sigma aH Comparing, and judging as effective stress circulation if the stress amplitude value is higher than the threshold value of the stress amplitude value; if the stress amplitude value is lower than the stress amplitude value threshold value, temporarily judging the stress amplitude value as small stress circulation; taking the absolute value of the stress average value of the small stress cycle and the threshold value sigma of the stress average value mH Comparing, if the average value of the stress is higher than the threshold value of the stress average value, judging the stress is an effective stress cycle; if the stress is lower than the stress average value threshold value, judging the stress cycle as invalid stress cycle, and recording a corresponding invalid stress time period;
step five, determining the invalid load time period
Determining invalid stress time periods of all the stress reference points, and solving an intersection on a time axis to further obtain an invalid load time period;
step six, breakpoint connection
And deleting the time history of the invalid load by using the invalid load time period, and smoothly connecting two adjacent breakpoints by using a half-sine curve so as to obtain an effective test load spectrum.
2. The method of claim 1, wherein in step five, the stress reference point has an invalid stress time period as follows:
ineffective stress period for stress reference point 1:
Figure FDA0001711446620000011
invalid stress period for stress reference point 2:
Figure FDA0001711446620000021
invalid stress period for stress reference point 3:
Figure FDA0001711446620000022
Figure FDA0001711446620000023
invalid stress period for the ith stress reference point:
Figure FDA0001711446620000024
Figure FDA0001711446620000025
invalid stress period for nth stress reference point:
Figure FDA0001711446620000026
the invalid load period is:
Figure FDA0001711446620000027
in the formula,. DELTA.T i An invalid stress time period for the ith stress reference point;
Figure FDA0001711446620000028
a as the ith stress reference point i A period of ineffective stress; n is the number of stress reference points; the operation symbol # represents an intersection operation on the time axis.
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CN116187041B (en) * 2023-02-10 2023-10-20 南京航空航天大学 Load spectrum filtering method based on continuous fiber reinforced composite material microscopic damage threshold

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