CN112948975B - Load spectrum analysis method for fusing simulation and test loads - Google Patents
Load spectrum analysis method for fusing simulation and test loads Download PDFInfo
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- CN112948975B CN112948975B CN202110266677.XA CN202110266677A CN112948975B CN 112948975 B CN112948975 B CN 112948975B CN 202110266677 A CN202110266677 A CN 202110266677A CN 112948975 B CN112948975 B CN 112948975B
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Abstract
The invention discloses a load spectrum analysis method for fusing simulation and test loads, which comprises the following steps: s1, acquiring a test load and a simulation load of the part to be tested; s2, preprocessing the data of the test load and the simulation load; s3, obtaining a rain flow matrix by adopting a rain flow counting method based on the preprocessed test load and the preprocessed simulation load, and representing the rain flow matrix through a three-dimensional histogram; s4, recompiling the preprocessed test load and simulation load based on the rain flow matrix to obtain a test load spectrum and a simulation load spectrum; s5, performing time domain fusion on the test load spectrum and the simulation load spectrum according to the road condition proportion to obtain a fused load spectrum; s6, acquiring a fusion stress spectrum of the tooth surface contact stress based on the fusion load spectrum; and S7, acquiring the fatigue life of the part to be tested based on the S-N curve and the fusion stress spectrum of the part material to be tested. The method can effectively improve the accuracy of the load spectrum analysis of the automobile parts.
Description
Technical Field
The invention relates to the technical field of vehicle engineering machinery, in particular to a load spectrum analysis method integrating simulation and test loads.
Background
The automobile is formed by combining a plurality of parts, and is subjected to real-time variable dynamic load in the working process, and load analysis is needed for researching the service life of the automobile parts. At present, two methods of test analysis and simulation analysis are mainly used for analysis of automobile loading, but generally, the two methods are used separately, for example, simulation load spectrum analysis is carried out alone or test load spectrum analysis is carried out alone, and few methods of analysis are carried out by combining simulation and test loading. For the test load, the test load is a real vehicle test load or a processed real vehicle test load, so that the test load has certain non-repeatability, such as the test load is limited by the factors of a driver, the locality and the like; the simulation load is repeatable and more stable than the test load, but it is lack of reality. Therefore, it is necessary to provide a load spectrum analysis method combining simulation and test load fusion, which can achieve both repeatability and authenticity.
Disclosure of Invention
The invention aims to provide a load spectrum analysis method integrating simulation and test loads, which aims to solve the technical problems in the prior art, effectively improve the accuracy of load spectrum analysis of automobile parts and further provide a data basis for the evaluation of the fatigue life of the automobile parts.
In order to achieve the purpose, the invention provides the following scheme: the invention provides a load spectrum analysis method integrating simulation and test loads, which comprises the following steps:
s1, acquiring a test load and a simulation load of the part to be tested;
s2, preprocessing the acquired test load and simulation load;
s3, obtaining a rain flow matrix by adopting a rain flow counting method based on the preprocessed test load and the preprocessed simulation load, and representing the rain flow matrix through a three-dimensional histogram;
s4, recompiling the preprocessed test load and simulation load based on the rain flow matrix to obtain a test load spectrum and a simulation load spectrum;
s5, performing time domain fusion on the test load spectrum and the simulation load spectrum according to the road condition proportion to obtain a fused load spectrum;
s6, acquiring a fusion stress spectrum of the tooth surface contact stress based on the fusion load spectrum;
and S7, acquiring the fatigue life of the part to be tested based on the S-N curve and the fusion stress spectrum of the part material to be tested.
Preferably, in step S1, the test load is obtained through an actual vehicle test, the simulated load is obtained through simulation, and the parameter setting in the simulated load obtaining process is the same as the actual vehicle test.
Preferably, the parameters set in the process of acquiring the simulated load include: motor parameters, vehicle parameters and transmission ratio of a speed reducer; the motor parameters comprise maximum rotating speed and maximum power.
Preferably, in step S2, the data preprocessing includes spike signal processing, drift processing, stationarity checking, and invalid amplitude deleting.
Preferably, in the circulation process, when the amplitude of the torque is smaller than a preset threshold value, the torque is an invalid amplitude, and the invalid amplitude is deleted; the invalid amplitude is selected as follows:
the preset threshold is (Mmax-Mmin) multiplied by 5%
Where Mmax and Mmin are the maximum and minimum values, respectively, in the torque data.
Preferably, in step S4, the method for compiling the test load and the simulation load again includes: and compiling the test load and the simulation load into a one-dimensional load spectrum of the mean value according to the mean values of the test load data and the simulation load data respectively.
Preferably, in step S5, the fused load spectrum f (t) after time-domain fusion is as shown in formula 1:
f(t)＝fa(t)+λfb(t) 1
in the formula (f)a(t) is the experimental load spectrum, fbAnd (t) is a simulated load spectrum, lambda is the ratio of the simulated load spectrum to the test load spectrum according to time domain fusion, and the value range of lambda is 0.2-5.0.
Preferably, in the step S6, the merged stress spectrum σ of the tooth surface contact stressHCalculated from equation 2:
wherein K represents a load factor, FtDenotes the circumferential force, Ft(2f (t))/d, B represents the tooth width of the driving wheel, d represents the pitch diameter of the driving wheel, and epsilonαIndicating the overlap ratio of the helical gear section, igRepresenting gear ratio, ZHRepresenting the area coefficient, ZERepresenting the elastic influence coefficient.
The invention discloses the following technical effects:
the invention provides a load spectrum analysis method integrating simulation and test load, which is characterized in that a rain flow matrix is obtained by a rain flow counting method based on the test load and the simulation load of a part to be tested, the preprocessed test load and the preprocessed simulation load are recompiled by the rain flow matrix to obtain a test load spectrum and a simulation load spectrum, the effective integration of the test load and the simulation load is realized by road condition proportion, and the accuracy of the load spectrum analysis of the part to be tested is effectively improved based on the defect complementation of the test load and the simulation load; meanwhile, a fusion stress spectrum of the tooth surface contact stress is obtained through the fused load spectrum calculation, and the fatigue life of the part to be tested is accurately predicted according to the S-N curve and the fusion stress spectrum of the material of the part to be tested.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without creative efforts.
FIG. 1 is a flow chart of a load spectrum analysis method of the present invention with integration of simulation and test loads;
FIG. 2 is a schematic illustration of the test load in an embodiment of the present invention;
FIG. 3 is a schematic diagram of a simulated load in an embodiment of the invention;
FIG. 4 is a schematic illustration of a test load rain flow matrix in an embodiment of the invention;
FIG. 5 is a schematic diagram of a simulated load rain flow matrix in an embodiment of the invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
Referring to fig. 1, the present embodiment provides a load spectrum analysis method for fusing simulation and test loads, including the following steps:
s1, acquiring a test load and a simulation load of the part to be tested;
the test load is obtained through a real vehicle test, specifically, the test load is obtained by measuring the torque of the transmission half shaft in the real vehicle test.
The simulation load is obtained by building a simulation model for simulation; the parameter setting in the process of acquiring the simulation load is the same as the real vehicle test, and the specific parameters comprise: the system comprises motor parameters, finished automobile parameters and a transmission ratio of a speed reducer, wherein the motor parameters comprise maximum rotating speed and maximum power. In this embodiment, schematic diagrams of the test load and the simulated load are shown in fig. 2 and fig. 3, respectively.
Acquiring the simulation load under a typical working condition; in this embodiment, the WLTC cycle condition is used as the typical condition.
S2, preprocessing the acquired test load and simulation load;
the data preprocessing comprises burr signal processing, drift processing, stationarity checking and invalid amplitude deletion; under the condition that the collected data of the test load and the simulation load are good, only burr signal processing is needed; the method for processing the glitch signal comprises the following steps: for a torque abnormal point (namely a point with abnormally high torque), the torque value of the abnormal point is replaced by taking the average value of the torques of data points at two sides of the abnormal point.
The definition method of the invalid amplitude comprises the following steps: in the circulation process, when the amplitude of the torque is smaller than a preset threshold value, the torque is an invalid amplitude, and the invalid amplitude is deleted; the invalid amplitude is selected as follows:
the preset threshold is (Mmax-Mmin) multiplied by 5%
Where Mmax and Mmin are the maximum and minimum values, respectively, in the torque data.
S3, obtaining a rain flow matrix by adopting a rain flow counting method based on the preprocessed test load and the preprocessed simulation load, and representing the rain flow matrix through a three-dimensional histogram;
rain flow counting, also known as "tower top", has been proposed by two engineers in Matsuiski and Endo, uk for over 50 years to date. The rain flow counting method is mainly used in the engineering field, and is particularly widely applied to fatigue life calculation. The strain-time history data recording is rotated by 90 degrees, the time coordinate axis is vertical downwards, the data recording is like a series of roofs, and rainwater flows downwards along the roofs, so the method is called a rainwater flow counting method. The process of counting the time history of the load by the rain flow counting method reflects the memory characteristics of the material and has a clear mechanical concept, so that the method is generally accepted. In this embodiment, the rain flow counting method is implemented by an MATLAB program, and the preprocessed test load and simulation load data are input into the MATLAB program, so as to obtain the rain flow matrix.
The three-dimensional histogram is a visual representation of the rain flow matrix.
In this embodiment, the rain flow matrices obtained based on the test load and the simulation load are shown in fig. 4 and 5, respectively.
S4, recompiling the preprocessed test load and simulation load based on the rain flow matrix to obtain a test load spectrum and a simulation load spectrum;
most of the amplitude statistics of the test load and the simulation load are 0, so that the test load and the simulation load are recompiled into a one-dimensional load spectrum of the mean value according to the mean value of the test load data and the simulation load data. In this embodiment, the test load and the simulation load mean are respectively classified into 8 stages at equal intervals, and the recompilation of the test load spectrum and the simulation load spectrum are respectively shown in table 1 and table 2.
TABLE 1
| Number of stages | Loading (N.m) | Number of cycles |
| 1 | 150.46 | 0.19 |
| 2 | 129.29 | 0.86 |
| 3 | 108.14 | 2.71 |
| 4 | 86.99 | 8.41 |
| 5 | 65.84 | 14.35 |
| 6 | 44.69 | 50.93 |
| 7 | 23.54 | 86.56 |
| 8 | 2.39 | 20.99 |
TABLE 2
S5, testing the load spectrum f according to the road condition proportiona(t) and simulated load spectra fb(t) performing time domain fusion to obtain a fusion load spectrum;
the road conditions of the simulated load spectrum are all good road conditions of a city, the road conditions of the test load spectrum are mixed of good and bad road conditions, the good and bad road conditions are mainly distinguished by whether the road surface is flat (flat, uneven/bumpy), and no road surface change exists in the simulated load.
The fused load spectrum f (t) after time domain fusion is shown as the formula (1):
f(t)＝fa(t)+λfb(t) (1)
in the formula (f)a(t) is the experimental load spectrum, fbAnd (t) is a simulated load spectrum, lambda is the ratio of the simulated load spectrum to the test load spectrum according to time domain fusion, and the value range of lambda is 0.2-5.0 according to the road condition structure of the test load spectrum.
S6, acquiring a fusion stress spectrum of the tooth surface contact stress based on the fusion load spectrum;
the final fatigue life is the fatigue life of the gear, and therefore, a fusion stress spectrum of the tooth surface contact stress of the gear is obtained based on the fusion load spectrum. Wherein the fusion stress spectrum sigma of the tooth flank contact stressHCalculated from equation (2):
wherein K represents a load factor, FtDenotes the circumferential force, Ft(2f (t))/d, B represents the tooth width of the driving wheel, d represents the pitch diameter of the driving wheel, and epsilonαThe overlap ratio of the cross section of the helical gear is generally 1.47, igRepresenting gear ratio, ZHRepresenting the area coefficient, ZEThe elastic influence coefficient is expressed, and the value of the elastic influence coefficient is related to the material.
And S7, acquiring the fatigue life of the part to be tested based on the S-N curve and the fusion stress spectrum of the part material to be tested.
And inputting the S-N curve and the fusion stress spectrum of the gear material into an MATLAB program, and calculating to obtain the fatigue life of the gear.
In order to further verify the effectiveness of the load spectrum analysis method based on the combination of simulation and test load, the fatigue life of the component to be tested is obtained by the present embodiment based on the three methods of test load, simulation load and combination of simulation and test load, and the result pair is shown in table 3:
TABLE 3
| Load spectrum | Test load spectrum | Simulated load spectrum | Fused load spectra |
| Prediction of fatigue Life (Km) | 308456.21 | 349328.30 | 323697.94 |
As can be seen from table 1, the fatigue life prediction result using the test load spectrum obtained by the real vehicle test is lower than the simulation load spectrum due to the poor road condition of the real vehicle test; in addition, some working conditions of the real vehicle test cannot be considered, and the simulated load spectrum makes up for the defect. Therefore, the method for performing load spectrum analysis and fatigue life prediction by using the fused load spectrum after the test load and the simulation load are fused is feasible, and the accuracy of the load spectrum analysis and the fatigue life prediction of the automobile parts is effectively improved.
The above-described embodiments are merely illustrative of the preferred embodiments of the present invention, and do not limit the scope of the present invention, and various modifications and improvements of the technical solutions of the present invention can be made by those skilled in the art without departing from the spirit of the present invention, and the technical solutions of the present invention are within the scope of the present invention defined by the claims.
Claims (5)
1. A load spectrum analysis method for fusing simulation and test loads is characterized by comprising the following steps:
s1, acquiring a test load and a simulation load of the part to be tested;
s2, preprocessing the acquired test load and simulation load;
s3, obtaining a rain flow matrix by adopting a rain flow counting method based on the preprocessed test load and the preprocessed simulation load, and representing the rain flow matrix through a three-dimensional histogram;
s4, recompiling the preprocessed test load and simulation load based on the rain flow matrix to obtain a test load spectrum and a simulation load spectrum;
s5, performing time domain fusion on the test load spectrum and the simulation load spectrum according to the road condition proportion to obtain a fused load spectrum;
s6, acquiring a fusion stress spectrum of the tooth surface contact stress based on the fusion load spectrum;
s7, acquiring the fatigue life of the part to be tested based on the S-N curve and the fusion stress spectrum of the part material to be tested;
in step S2, the data preprocessing includes spur signal processing, drift processing, stationarity checking, and invalid amplitude deletion;
in the circulation process, when the amplitude of the torque is smaller than a preset threshold value, the torque is an invalid amplitude, and the invalid amplitude is deleted; the invalid amplitude is selected as follows:
the preset threshold is (Mmax-Mmin) multiplied by 5%
Where Mmax and Mmin are the maximum and minimum values, respectively, in the torque data;
in step S6, the blend stress spectrum σ of the tooth surface contact stressHCalculated from equation 2:
wherein K represents a load factor, FtDenotes the circumferential force, Ft(2f (t))/d, B represents the tooth width of the driving wheel, d represents the pitch diameter of the driving wheel, and epsilonαIndicating the overlap ratio of the helical gear section, igRepresenting gear ratio, ZHRepresenting the area coefficient, ZERepresenting the elastic influence coefficient.
2. The method for analyzing load spectrum fused with simulation and test load according to claim 1, wherein in step S1, the test load is obtained through a real vehicle test, the simulation load is obtained through simulation, and the parameter setting in the process of obtaining the simulation load is the same as that of the real vehicle test.
3. The method for load spectrum analysis with integration of simulation and test loads according to claim 2, wherein the parameters set in the process of acquiring the simulation load comprise: motor parameters, vehicle parameters and transmission ratio of a speed reducer; the motor parameters comprise maximum rotating speed and maximum power.
4. The method for analyzing load spectrum fused with simulation and test loads according to claim 1, wherein in step S4, the method for compiling the test loads and the simulation loads is: and compiling the test load and the simulation load into a one-dimensional load spectrum of the mean value according to the mean values of the test load data and the simulation load data respectively.
5. The method for analyzing a load spectrum fused with a simulation and a test load according to claim 1, wherein in step S5, the fused load spectrum f (t) after time domain fusion is represented by formula 1:
f(t)＝fa(t)+λfb(t) 1
in the formula (f)a(t) is the experimental load spectrum, fbAnd (t) is a simulated load spectrum, lambda is the ratio of the simulated load spectrum to the test load spectrum according to time domain fusion, and the value range of lambda is 0.2-5.0.
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