CN116430160B - Device and method for testing shell stress of electric drive system - Google Patents
Device and method for testing shell stress of electric drive system Download PDFInfo
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- CN116430160B CN116430160B CN202310702429.4A CN202310702429A CN116430160B CN 116430160 B CN116430160 B CN 116430160B CN 202310702429 A CN202310702429 A CN 202310702429A CN 116430160 B CN116430160 B CN 116430160B
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- 238000012360 testing method Methods 0.000 title claims abstract description 92
- 238000000034 method Methods 0.000 title claims abstract description 44
- 238000013461 design Methods 0.000 claims abstract description 16
- 238000004458 analytical method Methods 0.000 claims description 13
- 238000009662 stress testing Methods 0.000 claims description 13
- 238000004088 simulation Methods 0.000 claims description 10
- 238000004590 computer program Methods 0.000 claims description 9
- 238000004364 calculation method Methods 0.000 claims description 6
- 238000005259 measurement Methods 0.000 claims description 6
- 230000008569 process Effects 0.000 abstract description 19
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- 238000012795 verification Methods 0.000 description 5
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Classifications
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/005—Testing of electric installations on transport means
- G01R31/006—Testing of electric installations on transport means on road vehicles, e.g. automobiles or trucks
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L1/00—Measuring force or stress, in general
- G01L1/20—Measuring force or stress, in general by measuring variations in ohmic resistance of solid materials or of electrically-conductive fluids; by making use of electrokinetic cells, i.e. liquid-containing cells wherein an electrical potential is produced or varied upon the application of stress
- G01L1/22—Measuring force or stress, in general by measuring variations in ohmic resistance of solid materials or of electrically-conductive fluids; by making use of electrokinetic cells, i.e. liquid-containing cells wherein an electrical potential is produced or varied upon the application of stress using resistance strain gauges
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L3/00—Measuring torque, work, mechanical power, or mechanical efficiency, in general
- G01L3/24—Devices for determining the value of power, e.g. by measuring and simultaneously multiplying the values of torque and revolutions per unit of time, by multiplying the values of tractive or propulsive force and velocity
- G01L3/242—Devices for determining the value of power, e.g. by measuring and simultaneously multiplying the values of torque and revolutions per unit of time, by multiplying the values of tractive or propulsive force and velocity by measuring and simultaneously multiplying torque and velocity
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- G06F30/20—Design optimisation, verification or simulation
- G06F30/23—Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
- G06F2119/14—Force analysis or force optimisation, e.g. static or dynamic forces
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/72—Electric energy management in electromobility
Abstract
The application provides a device and a method for testing the shell stress of an electric drive system, wherein the testing device comprises an input end dynamometer, a battery simulator, an integrated power unit, a differential reduction system and a wheel end dynamometer, wherein the power of the electric drive system to be tested is derived from the input end dynamometer and a motor in the system of the electric drive system, the energy of the motor is derived from the battery simulator and is subjected to power control through the integrated power unit, the power of the electric drive system to be tested is output through the differential reduction system, and the output power is balanced by the wheel end dynamometer. The two sets of power inputs can completely simulate the work of an actual electric drive system, so that the test working condition and the actual operation working condition are kept consistent. By the device, the stress of the whole shell of the electric drive system in the actual running process of the system can be tested and obtained, so that the weak point of the stress of the shell is accurately analyzed, the strength design target is rapidly achieved, and meanwhile, the support is provided for the light weight of the shell of the electric drive system.
Description
Technical Field
The application relates to the technical field of electric drive systems of electric automobiles, in particular to a device and a method for testing the stress of a shell of an electric drive system.
Background
The new energy automobile technology is an effective measure for realizing low carbon and low emission in the automobile industry, and the power energy conversion mode of the electric automobile is changed qualitatively. The electric drive system technology is one of key technologies for determining the development of new energy automobiles. The electric automobile pursues light weight and high power density, further requires a driving system to be high in efficiency, small in size, high in power density, high in output torque and high in reliability, and needs to meet various complex working conditions such as frequent starting, stopping, climbing, rapid acceleration and deceleration, reversing and the like of the automobile. The shell is used as an important part of the gearbox, has the function of supporting and containing various transmission parts, such as gears, shafts, bearings and the like, so that the normal movement relation and the movement precision can be maintained. The shell can also store lubricant to lubricate various moving parts. The shell also has the functions of safety protection and sealing, so that parts in the shell are not influenced by external environment, personal safety of operators can be protected, and the vibration isolation, heat insulation and sound insulation functions are realized. The weight reduction of the shell of the electric drive system is an important component of the weight reduction of the electric drive system, the stress of the electric drive system is complex, and the accurate acquisition of the stress distribution of the shell is the key of the weight reduction of the electric drive shell.
Currently, for the housing of an electric drive system, a standard component is generally adopted in the related art for stress testing. Because the stress test of the whole machine shell is not carried out, a designer cannot acquire the shell stress of the electric drive system under the actual load, so that the weak point of the stress of the shell cannot be accurately analyzed, and the whole system is easy to over-design.
Disclosure of Invention
The application aims to provide a device and a method for testing the stress of a shell of an electric drive system, and aims to solve the problems that the stress test mode of the shell of the electric drive system in the related art cannot acquire the shell stress of the electric drive system under the actual load, so that the weak point of the stress of the shell cannot be accurately analyzed, and the over-design of the whole system is easy to cause.
In a first aspect, the application provides a device for testing stress of a shell of an electric drive system, which comprises an input end dynamometer, a battery simulator, an integrated power unit, a subtraction system and a wheel end dynamometer, wherein: the input end dynamometer is connected with a motor input shaft of the electric drive system to be tested, and is used for providing a power source for the electric drive system to be tested and controlling the input torque and the rotating speed of the electric drive system to be tested; a strain gauge combination is arranged on the shell of the electric drive system to be tested; the battery simulator is connected with a motor of the electric drive system to be tested and is used for inputting a power supply to the motor; the integrated power unit is arranged between the electric drive system to be tested and the battery simulator and is used for controlling the battery simulator to input the power of the power supply of the motor; the difference subtracting system is respectively connected with the electric drive system to be tested and the wheel end half shaft and is used for transmitting the power of the motor output shaft of the electric drive system to be tested to the wheel end half shaft; the wheel end dynamometer is connected with the wheel end half shaft and used for balancing the power of the motor output shaft.
In the implementation process, the shell stress testing device of the electric drive system comprises an input end dynamometer, a battery simulator, an integrated power unit, a differential system and a wheel end dynamometer, wherein the power of the electric drive system to be tested is derived from the input end dynamometer and a motor in the system of the electric drive system, the energy of the motor is derived from the battery simulator and is subjected to power control through the integrated power unit, the power of the electric drive system to be tested is output through the differential system, and the output power is balanced by the wheel end dynamometer. The two sets of power inputs can completely simulate the work of an actual electric drive system, so that the test working condition and the actual operation working condition are kept consistent. By the device, the stress of the whole shell of the electric drive system in the actual running process of the system can be tested and obtained, so that the weak point of the stress of the shell is accurately analyzed, the strength design target is rapidly achieved, and meanwhile, the support is provided for the light weight of the shell of the electric drive system.
Further, in some examples, the wheel end dynamometer includes a first wheel end dynamometer coupled to a left side wheel end half shaft, and a second wheel end dynamometer coupled to a right side wheel end half shaft; the apparatus further comprises: a first torque sensor, a second torque sensor, and a third torque sensor; the first torque sensor is arranged between the electric drive system to be measured and the input end dynamometer and is used for measuring the output torque of the input end dynamometer; the second torque sensor is arranged between the left wheel end half shaft and the first wheel end dynamometer and is used for measuring the output torque of the first wheel end dynamometer; the third torque sensor is arranged between the right wheel end half shaft and the second wheel end dynamometer and is used for measuring the output torque of the second wheel end dynamometer.
In the implementation process, torque sensors are arranged between the electric drive system to be detected and the input end dynamometer and between the difference reduction system and the wheel end dynamometer, and the torque sensors are used for measuring the torque of the input end dynamometer and the torque of the wheel end dynamometer in real time, so that the input accuracy is ensured.
Further, in some examples, further comprising: a first battery voltage sensor and a second battery voltage sensor; the first battery voltage sensor is arranged between the battery simulator and the integrated power unit and is used for measuring the output current and voltage of the battery simulator; the second battery voltage sensor is arranged between the integrated power unit and the electric drive system to be tested and is used for measuring the output current and voltage of the integrated power unit.
In the implementation process, current and voltage sensors are arranged between the battery simulator and the integrated power unit and between the integrated power unit and the electric drive system to be tested, and the current and voltage of the battery simulator and the integrated power unit are measured in real time by the battery voltage sensors, so that the input accuracy is ensured.
Further, in some examples, further comprising: and the controller is used for acquiring and displaying the measurement results of the first battery voltage sensor and the second battery voltage sensor of the first torque sensor, the second torque sensor and the third torque sensor.
In the implementation process, the torque sensors and the battery voltage sensors transmit signals measured in real time to the controller, and the signals are displayed by the controller, so that a tester can judge whether the testing device needs to be adjusted according to the displayed content, and the testing accuracy is improved.
Further, in some examples, further comprising: the data acquisition device is connected with the strain gauge combination and is used for measuring the resistance of the strain gauge combination and calculating the stress of the shell test position where the strain gauge combination is located according to the measurement result.
In the implementation process, the data acquisition device is additionally arranged to acquire the resistance of the strain gauge combination, which is changed due to the stress and the strain of the shell test position in the loading process, and the stress of the shell test position is calculated.
Further, in some examples, the flat surface of the shell test site has an area greater than a circular area having a diameter of 5cm, and the stress calculated by simulation of the shell test site is greater than 20MPa, and the number of shell test sites is 5 or more.
In the implementation process, a principle of selecting a testing principle on the shell of the electric drive system is provided so as to select a proper testing position, thereby being beneficial to improving the accuracy of stress testing of the shell of the electric drive system.
In a second aspect, the present application provides a method for testing stress of a housing of an electric drive system, including: establishing a complete machine finite element model of the electric drive system according to digital-analog design data of the electric drive system prototype, and submitting the complete machine finite element model of the electric drive system to finite element analysis software for calculation to obtain an analysis result indicating the shell stress distribution of the electric drive system prototype under a target working condition; obtaining a test result obtained by carrying out stress test on the shell of the electric drive system prototype according to the target working condition by the electric drive system shell stress test device according to any one of the first aspect; and comparing the analysis result with the test result to check whether the complete finite element model of the electric drive system is accurate.
In the implementation process, verification of the finite element model is achieved through the shell stress testing device of the electric drive system, shell stress finite element analysis and simulation analysis calibration.
Further, in some examples, the method further comprises: and when the complete machine finite element model of the electric drive system is checked to be accurate, analyzing the part of the shell of the electric drive system prototype, which is provided with the stress safety margin exceeding a preset threshold, by utilizing the complete machine finite element model of the electric drive system.
In the implementation process, the part with larger stress safety margin on the shell of the electric drive system is analyzed by adopting the scaled finite element model, so that a designer can reduce the weight of the part, and the light weight level is improved.
In a third aspect, the present application provides a computer-readable storage medium having stored thereon a computer program which, when executed by a processor, implements a method according to any of the second aspects.
In a fourth aspect, the present application provides an electronic device comprising a processor, a memory and a computer program stored on the memory and executable on the processor, wherein the processor implements the method according to any one of the second aspects when executing the computer program.
Additional features and advantages of the disclosure will be set forth in the description which follows, or in part will be obvious from the description, or may be learned by practice of the disclosure.
In order to make the above objects, features and advantages of the present application more comprehensible, preferred embodiments accompanied with figures are described in detail below.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings that are needed in the embodiments of the present application will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present application and should not be considered as limiting the scope, and other related drawings can be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic diagram of a stress testing device for a housing of an electric drive system according to an embodiment of the present application;
FIG. 2 is a flowchart of a method for testing stress of a housing of an electric drive system according to an embodiment of the present application;
fig. 3 is a schematic diagram of a device for testing stress of a shell of an electric driving system of an electric automobile according to an embodiment of the present application;
FIG. 4 is a diagram of a strain force assembly according to an embodiment of the present application;
FIG. 5 is a schematic diagram of a set of stress testing and comparative optimization flows provided by an embodiment of the present application.
Detailed Description
The technical solutions in the embodiments of the present application will be described below with reference to the accompanying drawings in the embodiments of the present application.
It should be noted that: like reference numerals and letters denote like items in the following figures, and thus once an item is defined in one figure, no further definition or explanation thereof is necessary in the following figures. Meanwhile, in the description of the present application, the terms "first", "second", and the like are used only to distinguish the description, and are not to be construed as indicating or implying relative importance.
As described in the background art, in the related art, the stress test mode for the housing of the electric drive system cannot obtain the housing stress of the electric drive system under the actual load, so that the weak point of the housing stress cannot be accurately analyzed, and the problem of over-design of the whole system is easily caused. Based on this, the embodiment of the application provides a stress testing scheme for a housing of an electric drive system, which is used for solving the above problems.
The following describes embodiments of the present application:
as shown in fig. 1, fig. 1 is a schematic diagram of an electric drive system housing stress testing device provided by an embodiment of the present application, where the electric drive system housing stress testing device 11 includes an input end dynamometer 12, a battery simulator 13, an integrated power unit 14, a subtraction system 15, and a wheel end dynamometer 16, where: the input end dynamometer 12 is connected with a motor input shaft of the electric drive system 17 to be tested, and is used for providing a power source for the electric drive system 17 to be tested and controlling the input torque and the rotating speed of the electric drive system 17 to be tested; a strain gauge assembly 18 is arranged on the shell of the electric drive system 17 to be tested; the battery simulator 13 is connected with a motor of the electric drive system 17 to be tested and is used for inputting a power supply to the motor; the integrated power unit 14 is installed between the electric drive system 17 to be tested and the battery simulator 13, and is used for controlling the power input by the battery simulator 13 into the power supply of the motor; the difference and subtraction system 15 is respectively connected with the electric drive system 17 to be tested and the wheel end half shaft 19, and is used for transmitting the power of the motor output shaft of the electric drive system 17 to be tested to the wheel end half shaft 19; the wheel end dynamometer 16 is connected with the wheel end half shaft 19 and is used for balancing the power of the motor output shaft.
According to the stress testing device for the shell of the electric drive system, provided by the embodiment, the stress of the shell of the electric drive system in the actual operation process of the system can be tested and obtained, and the stress of the shell of the whole machine reflects the shell stress distribution under the actual load, so that the weak point of the stress of the shell can be accurately analyzed through the testing device, the strength design target can be rapidly achieved, and meanwhile, the support is provided for the light weight of the shell of the electric drive system.
Specifically, in the above-mentioned testing device, the to-be-tested electric driving system is an electric driving system that needs to test the stress of the housing, and during testing, the whole machine of the to-be-tested electric driving system can be mounted on the rack. In the scheme of the embodiment, the power of the electric drive system to be tested is derived from the input end dynamometer and the motor in the system of the electric drive system to be tested, the energy of the motor is derived from the battery simulator, the power of the electric drive system to be tested is output through the difference subtracting system, and the output power is balanced by means of the wheel end dynamometer. The two sets of power inputs can completely simulate the work of an actual electric drive system, so that the test working condition and the actual operation working condition are kept consistent.
The input end dynamometer is used for torque input and rotation speed control of an electric drive system to be tested. The battery simulator is a metering instrument, can simulate the dynamic characteristics of a vehicle-mounted battery of an electric automobile, supplies power for a bench test of a driving battery system, and is used for inputting energy sources to a motor in an electric driving system to be tested in the testing device. An integrated power unit (Integrate Power Unit, IPU), also called motor controller, is used for power control in the above-described test device. The differential system is a mechanism formed by combining a differential and a speed reducer, and is used for transmitting the power of the electric drive system to be tested to a wheel end half shaft in the testing device, and alternatively, the differential system can be integrated into the electric drive system to be tested. The wheel end dynamometer can be of the same type as the input end dynamometer or of a different type from the input end dynamometer, and in the testing device, the wheel end dynamometer is used for inputting wheel end torque and is used as torque input of a load balance input end dynamometer or a motor. Through the components, the testing device can realize the control of the actual working condition of the electric drive system.
In some embodiments, the apparatus further comprises: the wheel end dynamometer comprises a first wheel end dynamometer connected with a left wheel end half shaft and a second wheel end dynamometer connected with a right wheel end half shaft; the apparatus further comprises: a first torque sensor, a second torque sensor, and a third torque sensor; the first torque sensor is arranged between the electric drive system to be measured and the input end dynamometer and is used for measuring the output torque of the input end dynamometer; the second torque sensor is arranged between the left wheel end half shaft and the first wheel end dynamometer and is used for measuring the output torque of the first wheel end dynamometer; the third torque sensor is arranged between the right wheel end half shaft and the second wheel end dynamometer and is used for measuring the output torque of the second wheel end dynamometer. That is, torque sensors are installed between the electric drive system to be measured and the input end dynamometer and between the differential system and the wheel end dynamometer, and the torque sensors measure the torque of the input end dynamometer and the wheel end dynamometer in real time, so that the input accuracy is ensured.
Further, in some embodiments, the apparatus further comprises: a first battery voltage sensor and a second battery voltage sensor; the first battery voltage sensor is arranged between the battery simulator and the integrated power unit and is used for measuring the output current and voltage of the battery simulator; the second battery voltage sensor is arranged between the integrated power unit and the electric drive system to be tested and is used for measuring the output current and voltage of the integrated power unit. That is, current and voltage sensors are installed between the battery simulator and the integrated power unit, and between the integrated power unit and the electric drive system to be measured, and the current and voltage of the battery simulator and the integrated power unit are measured by the battery voltage sensors in real time, thereby ensuring the accuracy of input.
Still further, in some embodiments, the apparatus further comprises: and the controller is used for acquiring and displaying the measurement results of the first battery voltage sensor and the second battery voltage sensor of the first torque sensor, the second torque sensor and the third torque sensor. That is, the aforementioned torque sensors and battery voltage sensors transmit signals measured in real time to the controller, and the signals are displayed by the controller, so that a tester can determine whether the tester needs to adjust the testing device according to the displayed contents, thereby improving the accuracy of the test.
After the testing working condition is controlled, the stress and strain of the testing position of the shell under the testing working condition can be measured through the strain gauge combination arranged on the shell of the electric drive system. The strain gauge assembly includes a plurality of strain gauges, wherein the strain gauges are elements for measuring strain, and the elements are composed of sensitive grids, and in the embodiment, the selected strain gauges can be resistance strain gauges, and when the strain gauges mechanically deform under the action of external force, resistance values of the resistance strain gauges correspondingly change, and stress of a testing position of the shell can be measured based on the strain effect. Accordingly, in some embodiments, the apparatus further comprises: the data acquisition device is connected with the triaxial strain gauge assembly and is used for measuring the resistance of the strain gauge assembly and calculating the stress of the shell test position where the triaxial strain gauge assembly is located according to the measurement result. That is, the data collector can be additionally arranged to obtain the resistance of the strain gauge combination, which changes due to the stress and strain of the shell test position in the loading process, and the stress of the shell test position can be calculated. Of course, in other embodiments, other types of strain gages and corresponding data collectors may be employed, as the application is not limited in this regard.
Alternatively, the triaxial strain gauge assembly may adopt a triaxial strain gauge assembly with an included angle of 120 °, strain and stress changes in three directions in a plane may be measured, and the measured stress may be Mises stress, which may be calculated based on the following formula:
in the above-mentioned formula(s),is Mises stress; />、/>、/>Respectively refer to a first principal stress, a second principal stress and a third principal stress. Of course, in other embodiments, the strain gauge combination may be a combination of other angles or other forms of combinations, as the application is not limited in this regard.
Further, in some embodiments, the area of the flat surface of the aforementioned housing test site is greater than the area of a circle having a diameter of 5cm, and the stress calculated by simulation of the housing test site is greater than 20MPa, and the number of the housing test sites is 5 or more. That is, the principle of selecting the test position includes the following: the first test position is flat, and the area of the flat surface is larger than the area of a circle with the diameter of 5 cm; secondly, the stress calculated by simulation at the position is larger than 20MPa; thirdly, the number of the selected measuring points is more than or equal to 5. Therefore, a proper test position can be selected on the electric drive system shell, and the accuracy of the stress test of the electric drive system shell is improved.
The embodiment of the application provides a shell stress testing device of an electric drive system, which comprises an input end dynamometer, a battery simulator, an integrated power unit, a difference subtracting system and a wheel end dynamometer, wherein the power of the electric drive system to be tested is derived from the input end dynamometer and a motor in the system of the electric drive system, the energy of the motor is derived from the battery simulator and is subjected to power control through the integrated power unit, the power of the electric drive system to be tested is output through the difference subtracting system, and the output power is balanced by the wheel end dynamometer. The two sets of power inputs can completely simulate the work of an actual electric drive system, so that the test working condition and the actual operation working condition are kept consistent. By the device, the stress of the whole shell of the electric drive system in the actual running process of the system can be tested and obtained, so that the weak point of the stress of the shell is accurately analyzed, the strength design target is rapidly achieved, and meanwhile, the support is provided for the light weight of the shell of the electric drive system.
As shown in fig. 2, fig. 2 is a flowchart of a method for testing stress of a housing of an electric drive system according to an embodiment of the present application, including:
step 201, establishing a complete machine finite element model of an electric drive system according to digital-analog design data of the electric drive system prototype, and submitting the complete machine finite element model of the electric drive system to finite element analysis software for calculation to obtain an analysis result indicating the shell stress distribution of the electric drive system prototype under a target working condition;
step 202, obtaining a test result obtained by performing stress test on the shell of the electric drive system prototype according to the target working condition by using the electric drive system shell stress test device provided by the previous embodiment;
in step 203, by comparing the analysis result with the test result, it is checked whether the complete finite element model of the electric drive system is accurate.
According to the scheme, after the digital-analog design of the prototype is completed, a finite element model of the whole electric drive system is built, simulation analysis is conducted to obtain stress distribution of the shell of the electric drive system, then the stress test device of the shell of the electric drive system provided by the previous embodiment is used for testing the stress of the shell according to the same working condition, the finite element analysis result and the test result are compared one by one, if the finite element analysis result and the test result are basically consistent, the built finite element model of the whole electric drive system can be determined to be accurate, and otherwise, the finite element model needs to be adjusted. Thus, verification of the finite element model is achieved.
Further, in some embodiments, the above method further comprises: and when the complete machine finite element model of the electric drive system is checked to be accurate, analyzing the part of the shell of the electric drive system prototype, which is provided with the stress safety margin exceeding a preset threshold, by utilizing the complete machine finite element model of the electric drive system. That is, the part with larger stress safety margin on the shell of the electric drive system can be analyzed by adopting the scaled finite element model, so that a designer can reduce the weight of the part, thereby improving the light weight level. In addition, the weak part of the electric drive system shell subjected to stress can be analyzed by using the finite element model, so that the structural strength is improved, and various test verification such as driving endurance and the like can be carried out on the optimized prototype, so that the qualification degree of the designed prototype is judged. Thus, blindness of the design of the electric drive system is avoided, the test times are reduced, the development cost is reduced, and the development period is shortened.
For a more detailed description of the solution of the application, a specific embodiment is described below:
as shown in fig. 3, fig. 3 is a schematic diagram of an apparatus for testing stress of a shell of an electric driving system of an electric automobile according to an embodiment of the present application, where the apparatus includes an input dynamometer 31, a first torque sensor 321, a second torque sensor 322, a third torque sensor 323, an electric driving system 33, a first current-voltage sensor 341, a second current-voltage sensor 342, an integrated power unit 35, a battery simulator 36, a first wheel dynamometer 371, a second wheel dynamometer 372, a subtraction system 38, and a data collector 39; wherein:
the input end dynamometer 31 is used for torque input and rotation speed control of the electric drive system 33; the first torque sensor 321, the second torque sensor 322 and the third torque sensor 323 are used for measuring the torque and controlling feedback; the electric drive system 33 is an electric drive integrated system to be tested, and comprises an internal gear, a bearing, a motor and the like; the first current-voltage sensor 341 and the second current-voltage sensor 342 are used for measuring current and voltage and controlling feedback; the integrated power unit 35 is used for power control; the battery simulator 36 is used to input a source of energy for the motor in the electric drive system 33; the first wheel end dynamometer 371 and the second wheel end dynamometer 372 are used for inputting wheel end torque and serve as torque input of the load balancing input end dynamometer 31 or a motor; the subtracting system 38 is used for connecting the electric drive system 33 and the wheel end half shaft, and can be integrated into the electric drive system 33; the data collector 39 is used for acquiring the resistance of the strain gauge assembly 331 installed on the electric drive system 33, and calculating the stress of the test position in the loading process.
Based on the device, the actual working condition control of the electric drive system can be realized, and after the strain gauge combination is installed at the position with a relatively flat surface of the shell of the electric drive system, the stress test can be performed on the shell. As shown in fig. 4, the strain gauge combination is shown in the specification, because the stress of the shell of the electric drive system is complex, the measuring point of the main stress is difficult to judge, the main stress, the shear stress, the main stress and the direction, the equivalent stress and the like of the position can be obtained through the test and calculation of the triaxial strain gauge combination, the strain gauge combination adopts the triaxial strain gauge combination with the included angle of 120 ℃, the strain and the stress variation of three directions in a plane can be measured, and then the stress and the strain of a certain part of the electric drive shell in the loading process can be obtained through calculation.
By utilizing the device, the simulation standard can be combined, and the lightweight design of the electric drive system shell can be realized. As shown in fig. 5, fig. 5 is a schematic diagram of a set of stress testing and contrast optimization flows provided in an embodiment of the present application, where the flow includes:
s501, after the model machine digital-analog design is completed, a complete machine finite element model of the electric drive system is established, finite element analysis software is submitted to calculate, and stress distribution of a shell of the electric drive system is obtained;
s502, carrying out stress test on the shell according to the same working condition by the device shown in FIG. 3;
s503, comparing the finite element analysis result and the test result, namely comparing Mises stress of finite element analysis with stress calculated by strain gauge combination test one by one, and determining the accuracy of finite element calculation;
s504, analyzing weak parts of the shell of the electric drive system subjected to stress by using the opposite-standard finite element model, improving the structural strength, determining the parts with larger stress safety margin of the electric drive system, reducing the weight, and improving the light weight level;
s505, testing and verifying the optimized prototype, including driving endurance test and the like;
s506, judging whether the design of the prototype is qualified or not according to the test and verification result, if so, executing S507, otherwise, returning to S504;
s507, ending the flow.
The scheme of the embodiment has at least the following advantages:
first, emulation contrast precision is high: only the characteristics of the material are provided through the stress test of the sample, and the strain under the real load of the system is provided through the stress test of the whole shell of the electric drive system, so that the simulation contrast precision is high; secondly, development cost is reduced: the development of the traditional electric drive system requires more than 3 rounds of test verification, but the design target can be achieved by only 1 round of test through the whole simulation calibration of the electric drive system, the test times are reduced, and the development cost is effectively reduced; third, product performance promotes: the weight of the electric drive is reduced through simulation, the light weight level of the electric drive system is improved, and the energy density of the electric drive system is improved.
Corresponding to the embodiments of the aforementioned method, the present application also provides embodiments of a storage medium and an electronic device implementing the aforementioned method:
the present application provides a computer readable storage medium, on which a computer program is stored, which when executed by a processor implements a method as described in the method embodiments, and in order to avoid repetition, a description is omitted here.
The application also provides an electronic device, which comprises a processor, a memory and a computer program stored in the memory and capable of running on the processor, wherein the processor executes the method described in the method embodiment, and in order to avoid repetition, the description is omitted here.
The above description is only an example of the present application and is not intended to limit the scope of the present application, and various modifications and variations will be apparent to those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application should be included in the protection scope of the present application. It should be noted that: like reference numerals and letters denote like items in the following figures, and thus once an item is defined in one figure, no further definition or explanation thereof is necessary in the following figures.
The foregoing is merely illustrative of the present application, and the present application is not limited thereto, and any person skilled in the art will readily recognize that variations or substitutions are within the scope of the present application. Therefore, the protection scope of the present application shall be subject to the protection scope of the claims.
It is noted that relational terms such as first and second, and the like are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Moreover, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one … …" does not exclude the presence of other like elements in a process, method, article, or apparatus that comprises the element.
Claims (10)
1. The utility model provides an electric drive system casing stress testing arrangement which characterized in that, including input dynamometer, battery simulator, integrated power unit, subtracting system and wheel end dynamometer, wherein: the input end dynamometer is connected with a motor input shaft of the electric drive system to be tested, and is used for providing a power source for the electric drive system to be tested and controlling the input torque and the rotating speed of the electric drive system to be tested; a strain gauge combination is arranged on the shell of the electric drive system to be tested; the battery simulator is connected with a motor of the electric drive system to be tested and is used for inputting a power supply to the motor; the integrated power unit is arranged between the electric drive system to be tested and the battery simulator and is used for controlling the battery simulator to input the power of the power supply of the motor; the difference subtracting system is respectively connected with the electric drive system to be tested and the wheel end half shaft and is used for transmitting the power of the motor output shaft of the electric drive system to be tested to the wheel end half shaft; the wheel end dynamometer is connected with the wheel end half shaft and used for balancing the power of the motor output shaft.
2. The apparatus of claim 1, wherein the wheel end dynamometer comprises a first wheel end dynamometer coupled to a left wheel end half shaft and a second wheel end dynamometer coupled to a right wheel end half shaft; the apparatus further comprises: a first torque sensor, a second torque sensor, and a third torque sensor; the first torque sensor is arranged between the electric drive system to be measured and the input end dynamometer and is used for measuring the output torque of the input end dynamometer; the second torque sensor is arranged between the left wheel end half shaft and the first wheel end dynamometer and is used for measuring the output torque of the first wheel end dynamometer; the third torque sensor is arranged between the right wheel end half shaft and the second wheel end dynamometer and is used for measuring the output torque of the second wheel end dynamometer.
3. The apparatus as recited in claim 2, further comprising: a first battery voltage sensor and a second battery voltage sensor; the first battery voltage sensor is arranged between the battery simulator and the integrated power unit and is used for measuring the output current and voltage of the battery simulator; the second battery voltage sensor is arranged between the integrated power unit and the electric drive system to be tested and is used for measuring the output current and voltage of the integrated power unit.
4. A device according to claim 3, further comprising: and the controller is used for acquiring and displaying the measurement results of the first torque sensor, the second torque sensor, the third torque sensor, the first battery voltage sensor and the second battery voltage sensor.
5. The apparatus as recited in claim 1, further comprising: the data acquisition device is connected with the strain gauge combination and is used for measuring the resistance of the strain gauge combination and calculating the stress of the shell test position where the strain gauge combination is located according to the measurement result.
6. The device of claim 5, wherein the flat surface of the housing test site has an area greater than a circular area having a diameter of 5cm, and the stress calculated by simulation of the housing test site is greater than 20MPa, and the number of the housing test sites is 5 or more.
7. The method for testing the stress of the shell of the electric drive system is characterized by comprising the following steps of:
establishing a complete machine finite element model of the electric drive system according to digital-analog design data of the electric drive system prototype, and submitting the complete machine finite element model of the electric drive system to finite element analysis software for calculation to obtain an analysis result indicating the shell stress distribution of the electric drive system prototype under a target working condition;
obtaining a test result obtained by carrying out stress test on the shell of the electric drive system prototype according to the target working condition by the electric drive system shell stress test device according to any one of claims 1 to 6;
and comparing the analysis result with the test result to check whether the complete finite element model of the electric drive system is accurate.
8. The method as recited in claim 7, further comprising:
and when the complete machine finite element model of the electric drive system is checked to be accurate, analyzing the part of the shell of the electric drive system prototype, which is provided with the stress safety margin exceeding a preset threshold, by utilizing the complete machine finite element model of the electric drive system.
9. A computer readable storage medium, characterized in that a computer program is stored thereon, which computer program, when being executed by a processor, implements the method according to any of claims 7 to 8.
10. An electronic device comprising a processor, a memory and a computer program stored on the memory and executable on the processor, wherein the processor implements the method of any one of claims 7 to 8 when the computer program is executed by the processor.
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