CN111967131B - Method for compiling actual measurement load power assembly suspension load spectrum based on test field endurance road - Google Patents
Method for compiling actual measurement load power assembly suspension load spectrum based on test field endurance road Download PDFInfo
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- CN111967131B CN111967131B CN202010650945.3A CN202010650945A CN111967131B CN 111967131 B CN111967131 B CN 111967131B CN 202010650945 A CN202010650945 A CN 202010650945A CN 111967131 B CN111967131 B CN 111967131B
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Abstract
The invention discloses a test field endurance road based suspension load spectrum compilation method for an actually measured load power assembly, which comprises the following steps of: modifying a suspension bracket structure, and embedding a three-component force load sensor between a suspension bracket and a suspension; according to the requirement of endurance standards, carrying out actual measurement on a typical pavement of a endurance road of a test field to obtain a power assembly suspension three-component load signal acquired by a three-component load sensor; the actual measurement signals are inspected and preprocessed, and the load value under the suspension coordinate system is converted into the load value under the whole vehicle coordinate system; carrying out load frequency statistics on the test signal by using a rain flow counting method, and then extrapolating the load frequency by using a rain flow matrix method; synthesizing the multi-channel section load frequency results according to the durable standard cycle times; and compiling a load spectrum according to the synthesized load frequency data by applying a fatigue accumulated damage theory and a pseudo damage equivalent principle.
Description
Technical Field
The invention relates to a method for editing a single-shaft load spectrum from a test field endurance road load to a laboratory in a power assembly suspension, and belongs to the field of automobile component fatigue endurance.
Background
The power assembly is suspended and connected with the power assembly and the frame, force transmission between the power assembly and the frame is attenuated by the elastic damping element, fatigue failure is easy to occur when the elastic damping element is excited by a road surface and an engine, fatigue durability is one of the most important performance requirements of a suspension system, and analysis and verification of the fatigue durability of the elastic damping element need to accurately acquire load information in the actual working process of the elastic damping element.
The fatigue durability examination mainly comprises a finished automobile durability test and a laboratory bench test, the finished automobile durability test is the last examination in the development process, the cost is high, the period is long, once problems occur, the design change and the re-verification are very tense in time, and the development and the marketing progress of the finished automobile are seriously influenced.
The verification precision of the bench test depends on the used load spectrum, the load spectrum is derived from simulation calculation or the existing experience spectrum, and the load is possibly too large, so that the over-design and cost increase of parts are caused, and the aim of light weight cannot be achieved; if the load is too small, the purpose of early test verification cannot be achieved.
Disclosure of Invention
The invention aims to provide a test field endurance road based actual measurement load power assembly suspension load spectrum compilation method to obtain a power assembly suspension load spectrum, wherein the compiled load spectrum can be used for early laboratory bench endurance test verification and can also be used for load input conditions of suspension system endurance simulation calculation. The method is characterized in that a three-component force load sensor is embedded in a suspension system in the early stage of a durability test of the whole vehicle, a durable road load spectrum of the real vehicle in a test field is obtained, and single-axis load spectrum compilation in a laboratory is realized by processing load signals, carrying frequency statistics extrapolation and combining with rain flow counting.
The purpose of the invention is realized by the following technical scheme:
a method for compiling a suspension load spectrum of a power assembly based on actual measurement load of a durable road in a test field comprises the following steps:
step 2, carrying out actual measurement on a typical pavement of a durable road of a test field according to the durable standard requirement to obtain a power assembly suspension three-component force load signal acquired by a three-component force load sensor;
step 3, the actual measurement signals obtained in the step 2 are inspected and preprocessed, and the load value under the suspension coordinate system is converted into the load value under the whole vehicle coordinate system;
step 4, carrying out load frequency statistics on the test signal by using a rain flow counting method, and then extrapolating the load frequency by using a rain flow matrix method;
step 5, synthesizing the multi-channel section load frequency results according to the durable standard cycle times;
and 6, compiling a load spectrum according to the synthesized load frequency data by applying a fatigue accumulated damage theory and a pseudo damage equivalent principle.
Further, in the step 1, the three-component force load sensor is installed between the suspension support and the suspension, the three-component force load sensor is connected with the suspension through the fixing device, and the installation hole position of the suspension is guaranteed to be consistent with that of the original suspension support.
Further, in the step 3, the actually measured signal is checked and preprocessed, the data check includes the repeatability and consistency check of the signal, and the preprocessing includes the elimination of signal drift and the elimination of abnormal values.
Further, in step 3, the load value in the suspension coordinate system is converted into the load value in the vehicle coordinate system, and the load value is converted through the following formula:
in the formula, F xi 、F yi ,F zi Converting the suspension load under the coordinate system of the whole vehicle;
F ui 、F vi 、F wi actually measuring the suspension load under a suspension coordinate system;
Further, in the step 4, the rain flow counting method adopts a matrix counting form From-To:
in the formula: i-a load interval at the beginning point of the rain flow circulation;
j-the load interval of the closing point of the rain flow circulation;
r ij -the rain flow cycle starts at i and ends at j;
u, v-number of columns and rows of the rain flow matrix.
Further, in step 4, an Epanechkov kernel function is selected for load distribution estimation:
the extrapolation multiple of a certain typical road surface test data = number of cycles required for the typical durable road surface divided by the number of actual tests for the typical road surface in the specification.
Further, in step 5, the synthesis of the load spectrum is to synthesize a rain flow matrix of each typical road segment:
firstly, the load frequency extrapolation work of each typical road section in the step 4 is completed, and the load frequency extrapolation multiple H of each typical road section is obtained n Then extrapolating the load frequency of the actual test rain flow matrix of each typical road section in the specification, and superposing the extrapolated rain flow matrices to obtain full-load rain flow matrix data meeting the specification requirement:
H(n)=C(n)/T(n)
in the formula, H (n) -a frequency extrapolation multiple of a load rain flow matrix of a typical road surface test data;
c (n) -the number of cycles required for a typical road surface in a durable road specification;
t (n) -the actual test times of a certain typical road surface;
n is the number of durable pavement types tested in the specification;
R (n) -testing a rain flow matrix for a typical road segment;
R a -a full load rain flow matrix meeting the specification requirements.
Compared with the prior art, the invention has the following beneficial effects:
according to the invention, a suspension bracket structure is reformed, a three-component load sensor is embedded in a power assembly suspension stress path, actual load acquisition is carried out on a test field durable pavement (a vibration road, a road strip road, a Belgium road and the like) according to a reinforced durable standard, an acquired load signal is inspected, the result is counted and counted by using a rain flow counting method, then a rain flow matrix method is used for extrapolating the load frequency, and uniaxial load spectrum compilation is carried out by combining a fatigue accumulated damage theory and a pseudo damage equivalent principle.
Compared with the existing simulation calculation or the existing reference load spectrum, the load spectrum compiled by the method comes from the real working condition of the endurance road of the test field, and has high accuracy and strong pertinence. Meanwhile, the change of an experimental failure mode caused by overlarge load can not occur, so that the over-design and cost increase of parts can be caused, and the aim of early experimental verification can not be achieved due to the overlarge test load can not occur.
Drawings
FIG. 1 is a flow chart of a method for compiling a suspension load spectrum of a power assembly based on actual measurement load of a durable road in a test field according to the invention;
FIG. 2 is a From-To rain flow matrix distribution plot;
FIG. 3 is a load frequency extrapolation profile of the From-To rain flow matrix.
Detailed Description
The technical scheme of the invention is described in detail in the following with reference to the attached drawings and embodiments:
as shown in fig. 1, a test field endurance road based suspension load spectrum compilation method for a measured load power assembly includes the following steps:
installing a three-component force load sensor between a suspension bracket and a suspension, wherein the three-component force load sensor is connected with the suspension through a fixing device; the three-component force load sensor is arranged on a force transmission axis of a suspension system, and main design parameters of static rigidity, dynamic rigidity and the like of the suspension are ensured to be unchanged;
and 2, actually measuring the typical road surface of the durable road of the test field according to the durable standard requirement to obtain a power assembly suspension three-component force load signal acquired by the three-component force load sensor. And 3 times of tests are carried out on different pavements, so that the repeatability and consistency of test data are ensured. (Table 1 is only an exemplary table)
Table 1 test field typical test pavement list
And 3, checking and preprocessing the actually measured signals, wherein the data checking mainly comprises the repeatability and consistency of the signals, and the preprocessing mainly comprises the elimination of signal drift and the elimination of abnormal values.
The measured signal is a load value under a suspension coordinate system, and needs to be converted into a load value under a finished automobile coordinate system, the directions of the suspension coordinate system and the finished automobile coordinate system are inconsistent, the relation is shown in table 2, and the conversion method is shown in formula (1).
TABLE 2 relationship between suspension coordinate system and vehicle coordinate system
Coordinate values | x | y | z |
u i | α ui | β ui | γ ui |
v i | α vi | β vi | γ vi |
w i | α wi | β wi | γ wi |
In the formula, F xi 、F yi ,F zi Converting the suspension load under the coordinate system of the whole vehicle;
F ui 、F vi 、F wi actually measuring the suspension load under a suspension coordinate system;
Step 4, carrying out load frequency statistics on the test signals by using a rain flow counting method, and then extrapolating the load frequency by using a rain flow matrix method:
the load spectrum obtained by using the rain flow counting no longer contains the time, the load occurrence sequence and the frequency information of the load. The rain flow counting method is a double-parameter counting method, and the counting result is the cycle frequency corresponding to different amplitudes and different mean loads. The invention applies rain flow counting as shown in formula (2); in the form of matrix counting From-To, as shown in FIG. 2. The size and number of load intervals are determined according to actual test data. When the rain flow counting analysis is carried out, the maximum value of the analysis is set to be 4000N, the minimum value is set to be-4000N, the number of the intervals is 80, and the size of the intervals is 100N.
In the formula: i-a load interval at the beginning of the rain flow circulation;
j-the load interval of the rain flow circulation closing point;
r ij -the rain flow cycle starts at the number of cycles i ends at j;
u, v-the number of columns and rows of the rain flow matrix;
because the cycle number of each typical durable road surface in the durable specification cannot be completely measured in the real vehicle data acquisition process, the load frequency extrapolation is carried out by adopting a rain flow matrix extrapolation method, the cost can be saved, the test period can be shortened, the test load data required by the durable specification can be deduced from shorter test load data, and the load estimation accuracy can be ensured.
The invention selects the Epanechkov kernel function to carry out load distribution estimation, and the probability distribution function model of the invention has better adaptability with the rain flow matrix and is also suitable for the rain flow matrix in the form of load mean value and amplitude distribution. Extrapolation multiple of test data for a typical road surface = number of cycles required for the typical durable road surface in specification (e.g. vibration path C) 1 ) Actual number of tests on the representative surface. Fig. 3 shows an example of extrapolation of the load frequency of a certain durable road.
Step 5, synthesizing the multi-channel section load frequency results according to the endurance standard cycle times;
the load spectrum synthesis is mainly to synthesize the rain flow matrix of each typical road section. Firstly, the load frequency extrapolation of each typical road section in the step 4 is completedWorking, obtaining the load frequency extrapolation multiple H of each typical road section n As shown in formula 3. And extrapolating the load frequency of the actual test rainfall flow matrix of each typical road section in the specification, and superposing the extrapolated rainfall flow matrices to obtain full-load rainfall flow matrix data meeting the specification requirement, wherein the data is shown in a formula 4.
H(n)=C(n)/T(n) (3)
In the formula, H (n) -a frequency extrapolation multiple of a load rain flow matrix of a typical road surface test data;
c (n) -the number of cycles required for a typical road surface in a durable road specification;
t (n) -the actual test times of a certain typical road surface;
n is the number of durable pavement types tested in the specification;
R (n) -testing a rainfall matrix for a typical road section;
R a -a full load rain flow matrix meeting the specification requirements.
And 6, compiling a load spectrum according to the synthesized load frequency data by applying a fatigue accumulated damage theory and a pseudo damage equivalent principle.
Combining the rain flow matrix R in the step 5 a And processing the load spectrum into a program load spectrum for loading the rack, wherein the load spectrum describes the relation between the amplitude and the cycle number, is used for verifying the fatigue endurance performance of the suspension by the rack and can also be used as a load input for simulation analysis of the endurance performance of the suspension. Load spectrums in the X direction and the Z direction of the whole vehicle coordinate are compiled, and single-stage load spectrums are compiled in the X direction. The Z-direction compiles a 3-level load spectrum and is divided into 10 subcycles. The specific forms are shown in tables 3 and 4.
TABLE 3 Single-stage load spectrum in X direction under whole vehicle coordinate system
TABLE 4Z-direction 3-level load spectrum under whole vehicle coordinate system
Claims (4)
1. A method for compiling a suspension load spectrum of a power assembly based on actual measurement load of a durable road in a test field is characterized by comprising the following steps:
step 1, modifying a suspension bracket structure, embedding a three-component force load sensor between a suspension bracket and a suspension, and ensuring that the stress center of the three-component force load sensor is on the force transmission axis of a suspension system, wherein the main design parameters of the suspension are unchanged;
step 2, actually measuring a typical pavement of a durable road in a test field according to the durable standard requirement to obtain a power assembly suspension three-component force load signal acquired by a three-component force load sensor;
step 3, the actual measurement signals obtained in the step 2 are inspected and preprocessed, and the load value under the suspension coordinate system is converted into the load value under the whole vehicle coordinate system through the following formula:
in the formula, F xi 、F yi ,F zi Converting the suspension load under the coordinate system of the whole vehicle;
F ui 、F vi 、F wi actually measuring the suspension load under a suspension coordinate system;
step 4, carrying out load frequency statistics on the test signals by using a rain flow counting method, and then extrapolating the load frequency by using a rain flow matrix method; the rain flow counting method adopts a matrix counting form From-To:
in the formula: i-a load interval at the beginning point of the rain flow circulation;
j-the load interval of the closing point of the rain flow circulation;
r ij -the rain flow cycle starts at i and ends at j;
u and v are the number of columns and the number of rows of the rain flow matrix;
step 5, synthesizing the multi-channel section load frequency results according to the durable standard cycle times; the synthesis of the load spectrum is to synthesize a rain flow matrix of each typical road section:
firstly, the load frequency extrapolation work of each typical road section in the step 4 is completed, and the load frequency extrapolation multiple H of each typical road section is obtained n Then extrapolating the load frequency of the actual test rain flow matrix of each typical road section in the specification, and superposing the extrapolated rain flow matrices to obtain full-load rain flow matrix data meeting the specification requirement:
H(n)=C(n)/T(n)
in the formula, H (n) -a frequency extrapolation multiple of a load rain flow matrix of a typical road surface test data;
c (n) -the number of cycles required for a typical road surface in a durable road specification;
t (n) -the actual test times of a certain typical road surface;
n is the number of durable pavement types tested in the specification;
R (n) -testing a rain flow matrix for a typical road segment;
R a -a full load rain flow matrix meeting the specification requirements;
and 6, compiling a load spectrum according to the synthesized load frequency data by applying a fatigue accumulated damage theory and a pseudo damage equivalent principle.
2. The test field endurance road based suspension load spectrum compilation method for the power assembly with the measured load according to claim 1, wherein in the step 1, a three-component force load sensor is installed between a suspension support and a suspension, the three-component force load sensor is connected with the suspension through a fixing device, and the installation hole position of the suspension is guaranteed to be consistent with that of an original suspension support.
3. The test field endurance road based measured load power assembly suspension load spectrum compilation method as claimed in claim 1, wherein in step 3, the measured signal is inspected and preprocessed, the data inspection comprises signal repeatability and consistency inspection, and the preprocessing comprises signal drift elimination and abnormal value elimination.
4. The test field endurance road based measured load power assembly suspension load spectrum compilation method as claimed in claim 1, wherein in step 4, an Epanechkov kernel function is selected for load distribution estimation:
the extrapolation multiple of a certain typical road surface test data = number of cycles required for the typical durable road surface divided by the number of actual tests for the typical road surface in the specification.
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