CN114943116A - Bench test load spectrum generation method based on hybrid transmission - Google Patents
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Abstract
The invention relates to the technical field of vehicle testing, in particular to a bench test load spectrum generation method based on a hybrid transmission, which comprises the following steps: the method comprises the following steps of road condition definition, road route definition, road spectrum data acquisition, whole vehicle simulation, reference cycle condition acquisition, damage calculation and bench test load spectrum generation. The method includes the steps that a reference vehicle is adopted to collect actual road data, the actual road data are transmitted to a target vehicle through vehicle dynamics simulation of the target vehicle, damage under a service life target is calculated for a related failure mode of a transmission, and a rack load spectrum is generated through a damage target value covering the related failure mode. The load spectrum generated by the method can truly reflect the influence of a target vehicle type on the durability of the transmission in actual use, and the problem that the reasonable and accurate durability test load spectrum is difficult to define due to the lack of the load spectrum generation standard of the durability test of the hybrid transmission stand at present is solved.
Description
Technical Field
The invention relates to the technical field of vehicle testing, in particular to a bench test load spectrum generation method based on a hybrid transmission.
Background
The vehicle has to be subjected to various safety tests before leaving a factory, such as a transmission endurance test, at present, the national recommended standard or the enterprise standard exists for the bench endurance test of the manual transmission in China to carry out the endurance verification of the transmission, but the relevant standard is lacked for defining the bench test load spectrum of the hybrid transmission, and the existing relevant standard based on the manual transmission is difficult to meet the requirement of the hybrid transmission. The existing bench test load spectrum of the manual transmission generally meets certain cycle times aiming at different gear requirements, and durability examination is carried out according to the maximum torque of each gear. However, the hybrid transmission needs to consider the balance between the rotational speed and the torque of the engine and the motor, and needs to improve the efficiency of the engine and the motor as much as possible according to a control strategy, so that it is difficult to specify a certain number of cycles as in the case of a manual transmission, and in addition, since a bench test needs to be performed in consideration of the temperature rise of the motor, it is impossible to perform the bench test completely in accordance with the maximum torque.
Therefore, when a hybrid transmission is developed, a load spectrum of a bench endurance test is often difficult to accurately define, and effective test verification of the transmission cannot be guaranteed, so that the problems of design defects or over-design of parts exist, and the autonomous development capability of the hybrid transmission is restricted.
The ability to develop how to build a bench test load spectrum for a hybrid transmission is therefore particularly critical.
Disclosure of Invention
The invention aims to overcome the problems in the prior art and provides a method for generating a bench test load spectrum based on a hybrid transmission, which is characterized in that actual road load information is obtained by road collection through a reference vehicle type, road load data is transmitted to a target vehicle type through vehicle simulation based on the target vehicle type, further load information of an engine and a driving motor of the hybrid transmission is obtained, and damage of each failure mode under the bench test load spectrum can meet a damage target value through damage calculation, so that the generated load spectrum truly reflects the influence of the target vehicle type on the durability of the transmission in the whole life cycle in the actual use process, and the problem of insufficient design or over design of the transmission is avoided.
The above purpose is realized by the following technical scheme:
a method for generating a bench test load spectrum based on a hybrid transmission comprises the following steps.
Step 1, defining road working conditions, researching market information of a target vehicle type which can be loaded with a hybrid transmission, and defining road distribution;
step 2, road route definition, namely defining a driving city and a driving route as road routes according to traffic characteristics in the road distribution in the step 1;
step 3, road spectrum data acquisition, namely selecting a reference vehicle type matched with the target vehicle type, installing and debugging test acquisition equipment on the reference vehicle type, and acquiring actual road load data according to the road route in the step 2;
step 4, whole vehicle simulation, namely establishing a dynamic simulation model of the target vehicle type, wherein the dynamic simulation model is used for loading the road load data in the step 3;
step 5, acquiring reference cycle working conditions, dividing the road load data in the step 3 into a plurality of typical reference working conditions, and respectively simulating through the dynamic simulation model in the step 4 to obtain working data of an engine and a driving motor in the hybrid transmission under each typical reference working condition, wherein the working data are used as original road spectrum data of the hybrid transmission;
step 6, calculating damage, namely calculating the damage of failure modes of all concerned parts in the hybrid transmission according to the original road spectrum data corresponding to each typical reference working condition in the step 5 to obtain a damage target value;
and 7, generating a bench test load spectrum, defining an initial load spectrum working condition according to the boundary conditions of the hybrid transmission and the bench, and performing cyclic iterative optimization on the initial load spectrum working condition parameters until the relative damage of each failure mode under the bench load spectrum meets the damage target value in the step 6, thereby realizing the generation of the bench test load spectrum.
Further, the market information of the target vehicle type in step 1 includes market positioning, a sales area, an application scene and a transportation distance.
Further, the whole vehicle simulation model of the target vehicle type in the step 4 comprises an engine model, a transmission model, a motor model, a battery model, a whole vehicle model and a controller model, and the whole vehicle simulation is carried out according to the control strategy of the hybrid transmission.
Further, in step 6, the damage calculation needs to calculate the relative damage of the relevant failure mode under each reference cycle condition, and extend each reference cycle condition to the design target of the hybrid transmission, and define the damage target value of each failure mode containing 95% of the reference cycle condition as the damage target value generated by the bench test load spectrum.
Further, the hybrid transmission is designed to target 10 years or 60 kilometers.
Further, the relevant failure modes need to cover at least 95% of the damage at the reference cycle condition while not exceeding 100% of the damage at the reference cycle condition under the bench test load spectrum.
Further, the initial load spectrum working condition definition in step 7 needs to consider the allowable ranges of the rotating speed and the torque of the engine and the motor, the control capability of the rack on the rotating speed and the torque, and the temperature rise influence of the motor.
Furthermore, the generation mode of the rack load spectrum is obtained by covering all damage target values of concerned failure modes in the hybrid transmission, and the generated rack load spectrum can be reasonably represented by a road spectrum.
Advantageous effects
The invention provides a bench test load spectrum generation method based on a hybrid transmission. The load spectrum generated by the method can truly reflect the influence of a target vehicle type on the durability of the transmission in actual use, and the problem that the reasonable and accurate durability test load spectrum is difficult to define due to the lack of the hybrid transmission bench durability test load spectrum generation standard at present is solved.
Drawings
FIG. 1 is a flow chart of a method for generating a bench test load spectrum based on a hybrid transmission according to the present invention;
FIG. 2 is a gear bending fatigue failure schematic diagram of a rack test load spectrum generation method based on a hybrid transmission according to the present invention;
fig. 3 is a flowchart of the generation of the bench test load spectrum in the method for generating the bench test load spectrum based on the hybrid transmission according to the present invention.
Detailed Description
The present invention will be described in further detail with reference to the drawings and examples.
As shown in fig. 1, a method for generating a bench test load spectrum based on a hybrid transmission includes the following steps:
step 1, road working condition definition, which is to investigate market information of a target vehicle type capable of carrying a hybrid transmission and define road distribution; the method is characterized in that factors such as market positioning, sales areas, application scenes, transportation distances and the like of target vehicle models carrying development products (namely hybrid transmissions) are comprehensively considered, and reasonable road distribution such as the occupation ratio of roads in urban areas, high-speed areas, suburban areas and the like in the whole life cycle is defined.
Step 2, road route definition, namely defining a driving city and a driving route as road routes according to traffic characteristics in the road distribution in the step 1; selecting a proper city as a data acquisition place according to factors such as the approximate speed and traffic characteristics of a target vehicle model in road conditions such as urban areas, high speed, suburban areas and the like, and further selecting a specific driving route as a road route for actual road spectrum data acquisition;
step 3, road spectrum data acquisition, namely selecting a reference vehicle type matched with the target vehicle type, installing and debugging test acquisition equipment on the reference vehicle type, and acquiring actual road load data according to the road route in the step 2; specifically, during forward development, no real product exists, so that a reference vehicle type matched with a target vehicle type on the market is selected as a test vehicle type to prepare the vehicle, the installation and debugging of the test acquisition equipment are completed, the influence of different load states such as no-load, half-load and full-load of the vehicle is considered, a test acquisition plan is arranged according to a defined road route, and the actual road data is acquired;
step 4, whole vehicle simulation, namely establishing a dynamic simulation model of the target vehicle type, wherein the dynamic simulation model is used for loading the road load data in the step 3; specifically, a complete vehicle dynamics simulation model of a target vehicle type is established, the complete vehicle dynamics simulation model comprises an engine model, a transmission model, a motor model, a battery model, a complete vehicle model and a controller model, collected road load data is used as input of the complete vehicle model, complete vehicle simulation is carried out based on a control strategy of a hybrid transmission, and the collected road data is transmitted to the target vehicle type;
step 5, acquiring reference cycle working conditions, dividing the road load data in the step 3 into a plurality of typical reference working conditions, and respectively simulating through the dynamic simulation model in the step 4 to obtain working data of an engine and a driving motor in the hybrid transmission under each typical reference working condition, wherein the working data are used as original road spectrum data of the hybrid transmission; specifically, the collected road data is divided into a plurality of typical reference working conditions (usually, the road data is divided according to the parking state of the test vehicle, such as parking every 0.5-1 hour under the urban working condition, parking every 1.5-2 hours under the suburban working condition, parking every 2-3 hours under the high-speed working condition, the number of the reference working conditions depends on the test plan and the data collection amount, the actual demand of the target vehicle cannot be covered due to too small number, the development period and the workload are increased due to too large number, and the reference working conditions need to be considered as appropriate), and each reference working condition can be regarded as a client driving behavior. Through the whole vehicle simulation of a target vehicle type, the information of the rotating speed, the torque, the gear position and the like of an engine and a driving motor of the hybrid transmission under the reference working conditions can be obtained and used as the original road spectrum data of the hybrid transmission;
step 6, calculating damage, namely calculating damage of failure modes of all concerned parts in the hybrid transmission according to the original road spectrum data corresponding to each typical reference working condition in the step 5 to obtain a damage target value (namely the damage target value of each failure mode); in particular, the DFEMA (DFMEA is a reliability design analysis technology which is based on prevention, the application of the technology is beneficial to enterprises to improve the product quality, reduce the cost and shorten the research and development period) to carry out system analysis and define the relevant failure mode of the transmission, establishing a damage model of a failure mode through analyzing a damage mechanism, performing damage calculation based on typical reference working conditions to obtain relative damage of each failure mode under each reference cycle working condition, extending each reference cycle working condition to a design target (such as 10 years or 60 kilometers) of the hybrid transmission, and defining a damage target value of each failure mode containing 95% of reference cycle working conditions (namely containing 95% of customer driving behaviors, which is generally considered in the industry to meet the requirements of the whole vehicle) as a damage target value generated by a rack test load spectrum, wherein the partial flow is shown in the left side of fig. 3;
and 7, generating a bench test load spectrum, defining an initial load spectrum working condition according to the boundary conditions of the hybrid transmission and the bench, and performing cyclic iterative optimization on the initial load spectrum working condition parameters until the relative damage of each failure mode under the bench load spectrum meets the damage target value in the step 6, thereby realizing the generation of the bench test load spectrum. Specifically, as shown in fig. 3, the method for generating the rack load spectrum includes defining an initial working condition of the rack load spectrum based on the result of the damage calculation in step 6, considering the allowable ranges of the rotation speed and the torque of the engine and the motor, the control capability of the rack on the rotation speed and the torque, the temperature rise influence of the motor, and other factors according to the boundary conditions of the transmission and the test rack, calculating the relative damage of each failure mode under the initial working condition, comparing the relative damage with the corresponding damage target value, and performing iterative optimization on the torque, the rotation speed, and the time variation of the initial working condition until the relative damage of each failure mode under the rack load spectrum can meet the corresponding damage target value, thereby obtaining a final rack test load spectrum.
The process of damage calculation is described below by taking a gear bending fatigue failure mode as an example, and the damage calculation principles of other failure modes are similar.
As shown in FIG. 2, the gear bending fatigue failure is caused by that when the gear works, the tooth root is subjected to bending stress, and damage is formed and accumulated under the repeated action of the bending stress, and finally the tooth root fracture fatigue failure is caused.
The principle of gear bending fatigue failure can be described by the following formula:
wherein the content of the first and second substances,
is the magnitude of the stress, C f Is fatigue coefficient, N is number of load cycles, N E Number of cycles of load failure, b f The fatigue index is obtained according to a material SN curve (the SN curve is a curve which takes the fatigue strength of a material standard test piece as a vertical coordinate, takes a logarithmic value IgN of the fatigue life as a horizontal coordinate and expresses the relation between the fatigue strength and the fatigue life of the standard test piece under certain cycle characteristics, and is also called a stress-life curve), D is total damage, and i is an increment step.
The gear bending fatigue damage calculation formula can be obtained according to the formula as follows:
because the damage of each failure mode also needs to be calculated for the generated working condition of the rack load spectrum, and the evaluation index RAD is obtained by the ratio of the damage of each failure mode under the working condition of the rack load spectrum to the damage target value, the constant is used as a common divisor and is divided without determining a specific value, the damage result without considering the constant is defined as relative damage, and therefore, the gear bending fatigue damage calculation formula can be processed as follows:
wherein D is i，rel In relative injury increments, D rel For relative damage, n i The rotating speed at a certain moment, delta t is a time interval,
as the rate of damage, t tol Is the time corresponding to the reference cycle condition.
And according to a damage calculation formula corresponding to the failure mode, carrying out damage calculation aiming at the reference cycle working condition obtained by road collection. For the reference cycle working condition, after the whole vehicle simulation, the torque-time curve and the rotating speed-time curve, namely T, of the hybrid transmission engine and the driving motor corresponding to each reference cycle working condition can be obtained engine (t)、n engine (t)、T EM (t)、n EM (t)。T engine (t)、T EM Each time point on the curve (t) is regarded as a working point (a proper time interval is selected for calculation, such as 0.1 second), the corresponding bending stress of the gear can be obtained according to the torque value of the working point, and further the bending stress-time curve corresponding to the gear under the reference cycle working condition is obtained (the gear stress result can be accurately obtained according to simulation software of a transmission system, and a stress cloud chart can be generated through three-dimensional interpolation for data processing), namely sigma (t), and the working point is also considered as a working point according to n engine (t) and n EM (t), obtaining a corresponding rotating speed-time curve n (t) of the gear.
And substituting the bending stress and the rotating speed data corresponding to the time points into the gear bending fatigue damage calculation formula by the sigma (t) curve and the n (t) curve at the same time interval, so as to obtain the relative damage of the gear under the reference cycle working condition. The relative damage rate can be obtained by dividing the relative damage by the time of the reference cycle working condition, which means the damage corresponding to the failure mode in each hour under the reference cycle working condition, and the relative damage rate is calculated, mainly for the convenience of calculating the total relative damage of the reference cycle working condition extended to the life cycle in the next step.
Assuming that the life cycle of the transmission is 60 kilometres, according to the average vehicle speed (obtained by test data) of the reference cycle working condition, the time required by the reference cycle working condition to extend to 60 kilometres is obtained, and the time is multiplied by the relative damage rate, so that the total relative damage of the failure mode extending to the whole life cycle based on the reference cycle working condition can be obtained.
Assuming n groups of reference cycle working conditions, obtaining n groups of relative damage values, defining the damage value capable of containing 95% of the reference cycle working conditions as the damage target value of the failure mode, and generating the damage target value of each failure mode in the bench test load spectrum.
FIG. 3 is a diagram of a rack load spectrum generation method, which is based on the damage calculation result, according to the boundary conditions of the transmission and the test rack, considering the allowable ranges of the engine and the motor rotation speed and torque, the control capability of the rack on the rotation speed and torque, the temperature rise influence of the motor, and other factors, defining the initial working condition of the rack load spectrum, calculating the relative damage of each failure mode under the initial working condition, comparing with the corresponding damage target value, and performing iterative optimization on the torque, the rotation speed and the time variation of the initial working condition until the relative damage of each failure mode under the rack load spectrum can meet the corresponding damage target value, thereby obtaining the final rack test load spectrum;
wherein D test For relative damage corresponding to bench test conditions, D ref For injury target value, by RADAnd evaluating whether the generated rack load spectrum meets the requirements, if not, performing cycle optimization on the initial working condition parameters until the conditions are met, thereby realizing the generation of the rack test load spectrum.
RAD refers to relative accumulated damage, which is the ratio of the relative damage of each failure mode under the rack load spectrum to a damage target value, and is used for evaluating the relative size of the damage of the rack load spectrum generated by conversion to the failure mode and the damage of the road spectrum;
1≤RAD≤max
the expression is the requirement of RAD, and when the expression is equal to 1, the damage caused by the gantry load spectrum generated by conversion is equal to the target damage value. max is the ratio of the relative damage containing 100% customer driving behavior to the relative damage containing 95% customer driving behavior. Therefore, the RAD value of each failure mode is calculated, so that the RAD value is between the lower limit and the upper limit, the failure mode of the concerned part can meet the fatigue damage caused by at least 95% of customer driving behaviors under the examination of the rack load spectrum, and meanwhile, the excessive examination cannot be caused. It should be noted that if there are a few failure modes that cannot meet the requirements or the bench test time is too long for meeting the requirements, the evaluation through the single test can be considered.
While the invention has been described with reference to specific preferred embodiments, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.
Claims (8)
1. A method for generating a bench test load spectrum based on a hybrid transmission is characterized by comprising the following steps:
step 1, road working condition definition, which is to investigate market information of a target vehicle type capable of carrying a hybrid transmission and define road distribution;
step 2, road route definition, namely defining a driving city and a driving route as road routes according to traffic characteristics in the road distribution in the step 1;
step 3, road spectrum data acquisition, namely selecting a reference vehicle type matched with the target vehicle type, installing and debugging test acquisition equipment on the reference vehicle type, and acquiring actual road load data according to the road route in the step 2;
step 4, whole vehicle simulation, namely establishing a dynamic simulation model of the target vehicle type, wherein the dynamic simulation model is used for loading the road load data in the step 3;
step 5, acquiring reference cycle working conditions, dividing the road load data in the step 3 into a plurality of typical reference working conditions, and simulating through the dynamic simulation model in the step 4 respectively to obtain working data of an engine and a driving motor in the hybrid transmission under each typical reference working condition as original road spectrum data of the hybrid transmission;
step 6, calculating damage, namely calculating the damage of failure modes of all concerned parts in the hybrid transmission according to the original road spectrum data corresponding to each typical reference working condition in the step 5 to obtain a damage target value;
and 7, generating a bench test load spectrum, defining an initial load spectrum working condition according to the boundary conditions of the hybrid transmission and the bench, and performing cyclic iterative optimization on the initial load spectrum working condition parameters until the relative damage of each failure mode under the bench load spectrum meets the damage target value in the step 6, thereby realizing the generation of the bench test load spectrum.
2. The method as claimed in claim 1, wherein the market information of the target vehicle model in step 1 includes market location, sales area, application scenario and transportation distance.
3. The method for generating the bench test load spectrum based on the hybrid transmission as claimed in claim 1, wherein the whole vehicle simulation model of the target vehicle type in the step 4 comprises an engine model, a transmission model, a motor model, a battery model, a whole vehicle model and a controller model, and the whole vehicle simulation is performed according to the control strategy of the hybrid transmission.
4. The method according to claim 1, wherein the damage calculation in step 6 is performed by calculating the relative damage of the failure mode under each reference cycle, and extending each reference cycle to the design target of the hybrid transmission, and defining the damage target value of each failure mode including 95% of the reference cycle as the damage target value of the generation of the bench test load spectrum.
5. The method of generating a bench test load spectrum for a hybrid transmission according to claim 4, wherein the hybrid transmission is designed to target 10 years or 60 kilometers.
6. The method of generating a bench test load spectrum for a hybrid transmission of claim 4, wherein the associated failure mode is required to cover at least 95% of damage from the reference cycle operating conditions and not more than 100% of damage from the reference cycle operating conditions in the bench test load spectrum.
7. The method of claim 1, wherein the initial load spectrum condition definition in step 7 considers allowable ranges of engine and motor speeds and torques, the ability of the gantry to control speed and torque, and the effect of temperature rise on the motor.
8. The method according to claim 1, wherein the bench test load spectrum is generated in step 7 by covering all damage target values of failure modes of interest in the hybrid transmission, so as to ensure a reasonable road spectrum representation of the generated bench load spectrum.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN116183220A (en) * | 2023-04-17 | 2023-05-30 | 北京航空航天大学 | Hybrid electric vehicle transmission system load spectrum compiling method based on energy management |
| CN116337484A (en) * | 2023-05-30 | 2023-06-27 | 麦格纳动力总成(江西)有限公司 | Drive axle endurance test method, system, computer and readable storage medium |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116183220A (en) * | 2023-04-17 | 2023-05-30 | 北京航空航天大学 | Hybrid electric vehicle transmission system load spectrum compiling method based on energy management |
| CN116183220B (en) * | 2023-04-17 | 2023-06-30 | 北京航空航天大学 | Hybrid electric vehicle transmission system load spectrum compiling method based on energy management |
| CN116337484A (en) * | 2023-05-30 | 2023-06-27 | 麦格纳动力总成(江西)有限公司 | Drive axle endurance test method, system, computer and readable storage medium |
| CN116337484B (en) * | 2023-05-30 | 2023-09-26 | 麦格纳动力总成(江西)有限公司 | Drive axle endurance test method, system, computer and readable storage medium |
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