CN115824545A - Method and system for determining fatigue damage accelerated endurance test conditions of airborne equipment - Google Patents
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Abstract
The invention relates to equipment fatigue testing in intelligent manufacturing, and discloses a method and a system for determining fatigue damage accelerated endurance test conditions of airborne equipment, so as to quickly and reliably determine the accelerated endurance test conditions. The method comprises the following steps: judging whether the load data of any task segment is greater than or equal to a grading threshold value according to the load amplitude change of the preprocessed actual measurement signal, if so, sequencing, recombining and grading the corresponding task segments according to the load amplitude change trend, intercepting the waveform of a representative time segment from the load data of each grade of task segment, calculating a corresponding fatigue damage value, and obtaining the fatigue damage value of the airborne equipment in the full-task state according to the interception proportion of each grade of task segment; and finally, according to the acceleration time of the preset endurance test condition, by taking the equivalence of the fatigue damage spectrum as a principle, through iterative calculation, reversely deducing the input load condition capable of generating the same fatigue damage spectrum.
Description
Technical Field
The invention relates to equipment fatigue testing in intelligent manufacturing, in particular to a method and a system for determining fatigue damage accelerated endurance test conditions of airborne equipment.
Background
The vibration endurance test is used for simulating the longest vibration time which can be experienced by the equipment in the whole life cycle so as to check the fatigue resistance of the equipment in the life cycle.
Most of conditions and methods of vibration endurance test projects in airborne equipment environment tests in China in the past are formulated by referring to GJB 150.16A-2009 or related industry standards, and the vibration endurance test method is characterized in that 1.6 times of acceleration factors are directly given and the magnitude and duration of the vibration endurance test are calculated through a fatigue endurance equivalent formula. Although the standard recommendation method is simple and convenient to calculate, the vibration endurance test condition recommended by the standard is different from the actual measurement environment, the examination of the long-life multi-task equipment is too conservative, and the condition that the actual vibration load cannot be covered by the standard recommendation condition exists in an extremely individual equipment.
Along with the improvement of the equipment development unit on the importance of the general quality characteristics of the equipment, the actual measurement of the vibration environment conditions becomes the work content generally developed in the equipment development process, and along with the accumulation of the vibration actual measurement data of various types of equipment, the difficult problem that the coverage of the actual measurement data is poor or the actual measurement data is not available is gradually solved. If the real load borne by the airborne equipment can be completely repeated on the vibration table, the method can accurately check the fatigue resistance of the equipment in the service life cycle, but the endurance test cycle directly based on the unaccelerated time domain measured data is too long, and the method for establishing accurate and efficient vibration endurance test conditions aiming at the vibration measured data is not mature, so that the method for determining the fatigue damage accelerated endurance test conditions of the airborne equipment based on the measured signals is to be established.
Disclosure of Invention
The invention mainly aims to disclose a method and a system for determining the fatigue damage accelerated endurance test condition of airborne equipment so as to quickly and reliably determine the accelerated endurance test condition.
To achieve the above object, the method of the present invention comprises:
the method comprises the following steps: and preprocessing the acquired full task segment actual measurement signals.
Step two: judging whether the load data of any task segment is greater than or equal to a grading threshold value according to the load amplitude change of the preprocessed actual measurement signals, if so, sequencing, recombining and grading the corresponding task segments according to the load amplitude change trend, and then carrying out load data T of each grade of task segments i Intercepting a representative time period T i section The waveform of (a), wherein,
，
the task segment is the grading number of the full task segment, and the task segment smaller than the grading threshold value is regarded as the same grade.
Step three: fatigue damage value D generated by waveform intercepted by corresponding stages of computer-mounted equipment Ti section 。
Step four: according to the fatigue damage value D generated by the waveform intercepted by each stage Ti section And obtaining a fatigue damage value D of the airborne equipment in the full-task state:
step five: the method comprises the steps of presetting acceleration time of endurance test conditions, using the load stress less than or equal to the material yield strength of equipment, not changing the failure mechanism of the equipment as constraints, using the equivalence of a fatigue damage spectrum as a principle, through iterative calculation, reversely pushing input load conditions capable of generating the same fatigue damage spectrum, and obtaining the endurance vibration test conditions under the condition that the damage mechanism of a system structure is not changed.
Preferably, the pretreatment in the first step comprises: removing abnormal data, filling up lost data, and carrying out induction processing on multiple times of measured data through tolerance upper limit coefficient estimation and tolerance upper limit estimation.
Optionally, the classification threshold is such that the absolute value ratio of the maximum amplitude and the minimum amplitude is equal to 2.
Optionally, in the recombination process of the second step, the same load amplitudes at the original discrete time points are continuously arranged, and are adjoined in a descending order or a descending order according to the sequence of the load amplitude variation trend.
Preferably, in the third step, the method specifically comprises: respectively calculating a stress-time function for each intercepted waveform, and counting stress cycle times under each amplitude by adopting a rain flow counting method; and then according to Miner criterion, calculating fatigue damage values generated by the corresponding intercepted waveforms at all levels by combining the characteristic parameters of the standard S-N curve of the airborne equipment. Further, calculating the stress-time function may specifically include:
applying the waveform intercepted by each stage of task segment to a series of linear single-degree-of-freedom mass-spring systems, and calculating the time function of the relative displacement between each single-degree-of-freedom system and an excitation platform applying a load
。
Proportionality constant through stress-relative displacement
Calculating the stress on the equipment system
Time function of
。
Preferably, in the iterative calculation process of the fifth step, the method specifically includes:
calculating the fatigue damage value of the original load acting on the airborne equipment in the acceleration time after the preprocessing and before the recombination by the same method for calculating the fatigue damage value of the airborne equipment in the full-task state, and if the fatigue damage value after the acceleration is smaller than the fatigue damage value before the acceleration, enlarging 2 the amplitude of the corresponding load intercepted in the acceleration time u Multiplying until the fatigue damage value after acceleration is larger than the fatigue damage value before acceleration; and then continuously reducing the load amplitude through the load attenuation coefficient, when the fatigue damage value after acceleration is smaller than the fatigue damage value before acceleration, continuously increasing the load amplitude through the load amplification coefficient, and performing iterative calculation to finally enable the fatigue damage value before acceleration to be equal to the fatigue damage value after acceleration, and reversely deducing the time domain load after acceleration, wherein u is a positive integer.
Optionally, the durations of the representative time periods intercepted by the respective ranks are equal.
In order to achieve the above object, the present invention further discloses a system for determining a fatigue damage accelerated endurance test condition of an onboard equipment, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor implements the above method when executing the computer program.
The invention has the following beneficial effects:
1. the accelerated endurance test condition is determined based on the measured signal, the actual use environment of the equipment can be better simulated, the phenomena of 'over test' and 'under test' cannot be generated, and the accuracy of the load of the airborne equipment is ensured.
2. Under the condition of not changing the fatigue damage mechanism of the equipment, the endurance test is reasonably accelerated based on the fatigue damage equivalent principle, and a more scientific test assessment method is provided for the service life evaluation of the equipment in the endurance vibration environment; the device is not only suitable for equipment in a single task state, but also suitable for equipment which experiences different vibration loads in a long-life multi-task state.
3. In the calculation process of fatigue damage, the fatigue damage value of the airborne equipment in the full-task section can be determined and obtained quickly and reliably through grading, segmentation and proportional amplification.
The present invention will be described in further detail below with reference to the accompanying drawings.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:
fig. 1 is a schematic diagram of measured data of a certain model of project disclosed in the embodiment of the present invention.
FIG. 2 is a schematic diagram of the piecewise reassembly of the data of FIG. 1.
Fig. 3 is a distribution diagram of the single-degree-of-freedom systems of the excitation platform of the embodiment.
Fig. 4 is a schematic diagram of intercepting time-domain payload data before acceleration according to an embodiment of the present invention.
FIG. 5 is a comparative graphical representation of the fatigue damage spectra before and after acceleration for embodiments of the present invention.
Fig. 6 is a schematic diagram of time-domain payload data after acceleration according to an embodiment of the present invention.
FIG. 7 is a time consuming illustration of calculating fatigue loss without segmentation according to an embodiment of the present invention.
FIG. 8 is a time consuming illustration of the calculation of fatigue loss after a segment of the data of FIG. 7 according to an embodiment of the present invention.
Detailed Description
The embodiments of the invention will be described in detail below with reference to the drawings, but the invention can be implemented in many different ways as defined and covered by the claims.
Example 1
The embodiment discloses a method for determining fatigue damage accelerated endurance test conditions of airborne equipment based on measured signals. Firstly, carrying out data preprocessing on an actually measured signal, including data inspection and data induction, and confirming the validity of data; according to the load amplitude variation, carrying out hierarchical processing on the load data of different task segments; and calculating fatigue damage values of different sections of load signals according to Miner criterion (fatigue damage linear accumulation hypothesis) and by combining with the characteristic parameters of the standard S-N curve of the equipment to obtain a fatigue damage spectrum. And finally, setting the accelerated endurance vibration test time by taking the load stress not higher than the material yield strength of the equipment, not changing the failure mechanism of the equipment as constraint and the equivalence of the fatigue damage spectrum as a principle, reversely pushing the input load condition capable of generating the same fatigue damage spectrum through iterative calculation, and obtaining the endurance vibration test condition under the condition of not changing the damage mechanism of the system structure.
The technical scheme of the invention mainly comprises the following steps:
the method comprises the following steps: and confirming the validity of the acquired full-task segment measured signal, and checking whether the data has abnormity, including but not limited to signal clipping, false trend, electromagnetic interference, intermittent noise, singular points, data loss and the like. And editing the time domain data according to the screening, correcting or eliminating rules of the data, and carrying out induction processing on the measured data of the same measuring point for multiple times through tolerance upper limit coefficient estimation and tolerance upper limit estimation.
In the step, the acquired full task segment actual measurement signals are preprocessed. For the source of the measured data, a vibration data acquisition system suitable for a multi-equipment multi-task state can be adopted to carry out actual measurement on the environmental vibration data of the equipment. Covering the full-mission flight process of the service process of the airborne equipment in the actual measurement process, and acquiring an actual measurement vibration signal, wherein the vibration signal is generally a time-vibration acceleration two-dimensional array, such as actual measurement data of a certain type of project shown in figure 1; and the measured vibration data of the same type of airborne equipment can be collected.
Step two: judging whether the load data of any task segment is greater than or equal to a grading threshold value according to the load amplitude change of the preprocessed actual measurement signals, if so, sequencing, recombining and grading the corresponding task segments according to the load amplitude change trend, and then carrying out load data T of each grade of task segments i Intercepting a representative timeSegment T i section The waveform of (a); wherein,
，
the task segment is the grading number of the full task segment, and the task segment smaller than the grading threshold value is regarded as the same grade.
In this step, when the time domain signal is used to calculate the fatigue damage spectrum, because the endurance test random load usually has a long duration, if the time domain data simplification processing is not performed, directly calculating the full time domain data would result in a large amount of calculation, which affects the solution efficiency. In order to accelerate the calculation time of the fatigue damage spectrum, the full time domain section is subjected to hierarchical simplification processing according to different task states and load amplitude changes. Preferably, the classification threshold is such that the absolute value ratio of the maximum amplitude to the minimum amplitude is equal to 2. If two levels of the low-amplitude time domain segment and the high-amplitude time domain segment are adopted for grading, a grading schematic diagram of each task segment based on the data shown in the figure 1 is shown in figure 2; the specific process comprises the following steps:
firstly, segmenting full-time-domain data according to different task states, wherein the different task states are determined according to flight profiles (climbing, cruising, gliding and the like) of a carrier; and then, judging the time domain amplitude change condition of each task state, when the absolute value ratio of the maximum amplitude and the minimum amplitude of the time domain is less than 2, considering that the time domain data of the task state is stable random data, not segmenting the task state data, when the absolute value ratio of the maximum amplitude and the minimum amplitude of the time domain is more than 2, indicating that the time domain data of the task state has the condition of large amplitude change and cannot be considered as stable random data, performing secondary segmentation and data recombination on the task state data, and dividing and recombining the task segment into a high-amplitude time domain segment and a low-amplitude time domain segment according to all time histories containing the maximum load peak value of the task segment with the load absolute value of more than 50 percent. And finally, grading the full-time-domain measured data into stable random data containing different task states. Therefore, through processing, dividing the full-time-domain data into stable random data with each history; further, in order to improve the overall meterEfficiency, load data T for each segment i Intercepting a representative time period T i section The fatigue damage spectrum is calculated according to the waveform. For example, the intercepted representative time period may take 5s; generally, selecting a time period with the peak absolute value being on the middle upper side and different amplitude numbers after recombination as an intercepting section; therefore, the fatigue damage of each stage of task section can be estimated with enough safety margin according to the interception proportion. Referring to fig. 2, the nature of the recombination process is: and continuously arranging the same load amplitude values of the original discrete time points, and carrying out adjacency in a sequence from large to small or from small to large according to the sequence of the change trend of the load amplitude values.
Step three: for intercepted T i section Calculating a stress-time function by using a waveform, and counting stress cycle times under each amplitude by using a rain flow counting method; according to Miner criterion, the fatigue damage value D under each task segment of the equipment is calculated by combining the characteristic parameters of the standard S-N curve of the equipment Ti section 。
In this step, it can be further subdivided into:
step S31, T of intercepting each segment i section The waveforms are applied to a series of linear single degree of freedom mass-spring systems, shown in figure 3, with the natural frequency of each single degree of freedom
Different, the damping ratio is the same and is
Calculating the time function of the relative displacement between the excitation platforms corresponding to the single-degree-of-freedom systems relative to the applied load
. In the calculation process, the following conditions are satisfied:
in the formula ：
is the absolute displacement of the excitation platform.
Step S32, proportional constant by stress-relative displacement
Calculating the stress on the equipment system
Time function of
。
Step S33, counting peak-valley values of the stress-time function by using a rain flow counting method to obtain each stress amplitude value
Corresponding number of cycles
。
Step S34, calculating fatigue damage values of each section of airborne equipment by combining characteristic parameters of standard S-N curves of the equipment according to Miner criterion
：
in the formula ：
is the intercept of the standard S-N curve,
is the inverse slope of the standard S-N curve;
the number of stress amplitude values.
Step four: fatigue damage value D calculated from each segment Ti section And obtaining a fatigue damage value D of the airborne equipment in the full-task state:
step five: presetting the acceleration time of a endurance test condition, using the load stress not higher than the material yield strength of the equipment and not changing the failure mechanism of the equipment as constraint, using the equivalence of a fatigue damage spectrum as a principle, reversely pushing the input load condition capable of generating the same fatigue damage spectrum through iterative calculation, and obtaining the endurance vibration test condition under the condition of not changing the damage mechanism of a system structure.
Preferably, in this step, the fatigue damage value of the original load acting on the onboard equipment in the acceleration time after the preprocessing and before the reorganization is calculated by the same method for calculating the fatigue damage value of the onboard equipment in the full-mission state, and if the fatigue damage value after the acceleration is smaller than the fatigue damage value before the acceleration, the amplitude of the corresponding load intercepted in the acceleration time is enlarged by 2 u Multiplying until the fatigue damage value after acceleration is larger than the fatigue damage value before acceleration; and then continuously reducing the load amplitude through the load attenuation coefficient, when the fatigue damage value after acceleration is smaller than the fatigue damage value before acceleration, continuously increasing the load amplitude through the load amplification coefficient, sequentially carrying out iterative calculation, finally enabling the fatigue damage value before acceleration to be equal to the fatigue damage value after acceleration, and reversely deducing the time domain load after acceleration, wherein u is a positive integer.
Wherein the material yield strength or sigmas or material S-N curve life 10 is for a location exceeding structural risk during iterative calculations 3 ~10 4 And (3) retaining the load of the corresponding stress section, and equivalently accelerating the damage of the section with low stress caused by the structure. And finally, obtaining an accelerated time domain signal under the condition of not changing a damage mechanism of the structure. And performing Fast Fourier Transform (FFT) on the accelerated time domain signal to convert the accelerated time domain signal into Power Spectral Density (PSD), performing segmented envelope processing on the PSD, and finally obtaining the accelerated endurance test condition of the fatigue damage of the airborne equipment based on the actually measured signal.
The above accelerated iteration process is described below by taking a random time-domain loading signal as an example. The original task segment load duration is 180s, and 5s of time domain representative data is intercepted as shown in FIG. 4. Presetting equipment characteristic parameters: the quality factor was set to 10, the inverse slope of the standard S-N curve was set to 8, the intercept of the standard S-N curve was 1, the proportionality constant of stress/displacement was 1, the upper limit frequency of the fatigue damage spectrum was set to 2000Hz, the inter-spectral spacing was 1Hz, and the fatigue damage spectrum was calculated as the pre-acceleration fatigue damage spectrum curve shown in fig. 5. When 36s is used as an input parameter of the endurance test duration, the fatigue damage spectrum equivalence is used as a principle, as shown in fig. 5, the fatigue spectrums before and after acceleration are close to each other, the load input condition when the fatigue damage spectrum approaches is reversely deduced through 20 times of iterative calculation, the iterative calculation value of the load acceleration coefficient factor is 1.7, and the accelerated time-domain load is obtained as shown in fig. 6. Namely, the time domain load signal after the acceleration with the duration of 36s is used for carrying out the endurance vibration test, so that the time domain load signal before the acceleration with the duration of 180s can be replaced, and the aim of improving the test efficiency is fulfilled.
It is worth mentioning that: in this embodiment, the length of the above-mentioned truncated time period does not affect the solving accuracy within a certain range. For example: and respectively intercepting time domain data of 5s and 9s from a certain task segment, wherein the fatigue damage spectrum integral value calculated by the time domain data of 5s is 9.9e-26, the fatigue damage spectrum integral value calculated by the time domain data of 9s is 1.58e-25, the fatigue damage spectrum ratio is 1.6, and the time length ratio is 1.8, which indicates that the solution precision of the section time to the fatigue damage spectrum is low, so that the section time can be determined according to the actual situation. In contrast; if the measured signal is not subjected to the segmentation simplification processing, the fatigue damage spectrum calculation is directly carried out, as shown in fig. 7, the calculation time of 60s of time domain data is 473s, after the time domain segment is segmented, 5s of time domain data is taken to calculate the fatigue damage spectrum, as shown in fig. 8, the calculation time is 97s, so that the time is shortened by 387%, and the solving efficiency is greatly improved.
In conclusion, the embodiment directly adopts the airborne equipment to measure the vibration data, accords with the actual environment, and ensures the accuracy of the load of the airborne equipment; fatigue acceleration is carried out on the vibration fatigue of the airborne equipment by utilizing a fatigue damage spectrum equivalent theory, so that the fatigue acceleration device is not only suitable for equipment in a single-task state, but also suitable for equipment which experiences different vibration loads in a long-life multi-task state; by adopting the method based on the actual measurement spectrum and the fatigue damage equivalence, the phenomena of 'over test' and 'under test' are not generated, and a more scientific test assessment method is provided for the service life evaluation of the durable vibration environment of the airborne equipment.
Example 2
The embodiment discloses a system for determining a fatigue damage accelerated endurance test condition of an airborne device, which comprises a memory, a processor and a computer program stored on the memory and capable of running on the processor, wherein the processor executes the computer program to realize the method corresponding to the embodiment.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (9)
1. A method for determining fatigue damage accelerated endurance test conditions of airborne equipment is characterized by comprising the following steps:
the method comprises the following steps: preprocessing the acquired full task segment actual measurement signals;
step two: judging whether the load data of any task segment is greater than or equal to a grading threshold value according to the load amplitude change of the preprocessed actual measurement signals, if so, sequencing, recombining and grading the corresponding task segments according to the load amplitude change trend, and then carrying out load data T on each grade of task segments i Intercepting a representative time period T i section The waveform of (a); wherein,
，
the task segments are the grading number of the full task segments, and the task segments smaller than the grading threshold value are regarded as the same grade;
step three: fatigue damage value D generated by waveform intercepted by corresponding stages of computer-mounted equipment Ti section ；
Step four: according to the fatigue damage value D generated by the waveform intercepted by each stage Ti section And obtaining a fatigue damage value D of the airborne equipment in the full-task state:
step five: presetting the acceleration time of a endurance test condition, using the material yield strength of the equipment with the load stress less than or equal to the yield strength of the equipment and without changing the failure mechanism of the equipment as constraints, using the equivalence of a fatigue damage spectrum as a principle, reversely pushing the input load condition capable of generating the same fatigue damage spectrum through iterative calculation, and obtaining the endurance vibration test condition under the condition of not changing the damage mechanism of a system structure.
2. The method of claim 1, wherein the preprocessing of step one comprises: removing abnormal data, filling up lost data, and carrying out induction processing on multiple times of measured data through tolerance upper limit coefficient estimation and tolerance upper limit estimation.
3. The method of claim 1, wherein the classification threshold is an absolute ratio of the maximum amplitude to the minimum amplitude equal to 2.
4. The method according to claim 3, wherein in the recombination process of the second step, the same load amplitudes at the originally discrete time points are continuously arranged and are adjoined in a descending or descending order according to the sequence of the load amplitude variation trend.
5. The method according to claim 1, characterized in that in step three, it specifically comprises: respectively calculating a stress-time function for each intercepted waveform, and counting stress cycle times under each amplitude by adopting a rain flow counting method; and then according to Miner criterion, calculating fatigue damage values generated by the corresponding intercepted waveforms at all levels by combining the characteristic parameters of the standard S-N curve of the airborne equipment.
6. The method according to claim 5, wherein calculating the stress-time function comprises in particular:
applying the waveform intercepted by each stage of task segment to a series of linear single-degree-of-freedom mass-spring systems, and calculating the time function of the relative displacement between each single-degree-of-freedom system and an excitation platform applying load
；
Proportionality constant through stress-relative displacement
Calculating the stress on the equipment system
Time function of
。
7. The method according to any one of claims 1 to 6, wherein in the iterative calculation process of step five, specifically comprising:
calculating the fatigue damage value of the original load acting on the airborne equipment in the full-task state after pretreatment and before recombination in the same method for calculating the fatigue damage value of the airborne equipment in the full-task state, and if the fatigue damage value after acceleration is smaller than the fatigue damage value before acceleration, enlarging 2 the amplitude of the corresponding load intercepted in the acceleration time u Multiplying until the fatigue damage value after acceleration is larger than the fatigue damage value before acceleration; and then continuously reducing the load amplitude through the load attenuation coefficient, when the fatigue damage value after acceleration is smaller than the fatigue damage value before acceleration, continuously increasing the load amplitude through the load amplification coefficient, sequentially carrying out iterative calculation, finally enabling the fatigue damage value before acceleration to be equal to the fatigue damage value after acceleration, and reversely deducing the time domain load after acceleration, wherein u is a positive integer.
8. The method of any one of claims 1 to 6, wherein the representative time periods intercepted by each of the ranks are equal in duration.
9. An airborne equipment fatigue damage accelerated endurance test condition determining system comprising a memory, a processor and a computer program stored on the memory and executable on the processor, wherein the processor when executing the computer program implements the method of any of the preceding claims 1 to 8.
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| CN116050229A (en) * | 2023-03-31 | 2023-05-02 | 湖南云箭科技有限公司 | Optimization method and system of finite element model in airborne store fatigue simulation |
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