DE102021131262A1 - Procedure for conducting a durability test and test bench system - Google Patents

Abstract

The present invention relates to a method (200) for carrying out an operational stability test on an energy assembly (110) for a motor vehicle, having the following method steps: - providing (202) the energy assembly (110) and an overall vehicle structure (150), the energy assembly (110) is integrated in the overall vehicle structure (150), - determining (204) at least one integration boundary condition (170) for the energy assembly (110) in the overall vehicle structure (150) with at least one first measuring device (10), - installing (206) the overall vehicle structure (150 ) in a first test stand (50), the first test stand (50) being arranged in contact with the overall vehicle structure (150) and in particular with the energy assembly (110) in order to introduce at least one load variable (172),- subjecting (208) the overall vehicle structure ( 150) with the at least one load variable (172) by the first test bench (50), - measuring (210) load parameters (180) of the energy assembly (110) and/or the overall vehicle structure (150) with at least one second measuring device (20) of the first test bench (50) during the loading (208),- arranging (212) the energy assembly (110) in a second test bench (60) such that the arrangement of the energy assembly (110) in the second test bench (60) of the at least one specific Integration boundary condition (170) corresponds to - subjecting (214) the energy assembly (110) to at least the measured load parameters (180) by the second test stand (60), and - carrying out (216) the durability test. The invention also relates to a test stand system (80) comprising a first test stand (50) and a second test stand (60).

Description

The present invention relates to a method for carrying out an operational stability test on an energy assembly for a motor vehicle. Furthermore, the invention relates to a test bench system comprising a first test bench and a second test bench.

In the known state of the art, to ensure the operational stability of vehicle structure-integrated energy assemblies and/or structure-integrated high-voltage storage devices for battery-electric vehicles and plug-in hybrids, a stress-related operational stability test is only possible in the overall vehicle context, since adequate load application to the vehicle structure-integrated energy assemblies to be secured is only ensured under boundary conditions close to the entire vehicle. In the known state of the art, to ensure the operational stability of assemblies integrated into the vehicle structure, either complete vehicle tests are carried out with a complete structural integration environment of the energy assemblies integrated into the vehicle structure, or component tests are carried out using test devices which, at the load application points of the energy assemblies integrated into the vehicle structure, map the entire vehicle body structure as closely as possible to the entire vehicle with regard to the integration boundary conditions relevant to operational stability. In both cases, an overall vehicle test bench is required to introduce the necessary structural loads at the overall vehicle or component level into the respective test network.

The test methods known in the prior art are very time-consuming and correspondingly expensive due to the high demands on the test environment, which require either an overall vehicle body structure or an optimized test frame, and the complex test concept in the overall vehicle context. In addition, due to the high complexity of the scope of testing, there is only a limited range on the market for testing service providers, with correspondingly high prices. A desired aim of the invention is therefore to eliminate or at least partially eliminate the shortcomings known in the prior art and to specify an optimized method and a test bench arrangement for carrying out damage-equivalent fatigue strength tests on energy assemblies integrated in the vehicle structure.

It is therefore the object of the present invention to at least partially eliminate the disadvantages described above in a method for carrying out an operational stability test on an energy assembly for a motor vehicle. In particular, the object of the present invention is to create a method and a test bench system for carrying out an operational stability test on an energy assembly for a motor vehicle, which enables structural data of an energy assembly and/or an overall vehicle structure to be determined in a simple and cost-effective manner by means of an operational stability test .

The above object is achieved by a method for carrying out an operational stability test on an energy assembly for a motor vehicle with the features of claim 1 and by a test bench system with the features of claim 14. Further features and details of the invention result from the dependent claims, the description and the Drawings. Features and details that are described in connection with the method for carrying out an operational stability test on an energy assembly for a motor vehicle also apply, of course, in connection with the test bench system according to the invention and vice versa, so that the disclosure of the individual aspects of the invention is always referred to alternately will or can become.

• - Bereitstellen der Energiebaugruppe und einer Gesamtfahrzeugstruktur, wobei die Energiebaugruppe in der Gesamtfahrzeugstruktur integriert ist,
• - Bestimmen wenigstens einer Integrationsrandbedingung für die Energiebaugruppe in der Gesamtfahrzeugstruktur mit wenigstens einem ersten Messmittel,
• - Einbauen der Gesamtfahrzeugstruktur in einen ersten Prüfstand, wobei der erste Prüfstand mit der Gesamtfahrzeugstruktur und insbesondere mit der Energiebaugruppe kontaktierend zur Einleitung wenigstens einer Belastungsgröße angeordnet ist,
• - Beaufschlagen der Gesamtfahrzeugstruktur mit der wenigstens einen Belastungsgröße durch den ersten Prüfstand,
• - Messen von Belastungsparametern der Energiebaugruppe und/oder der Gesamtfahrzeugstruktur mit wenigstens einem zweiten Messmittel des ersten Prüfstands während des Beaufschlagens,
• - Anordnen der Energiebaugruppe in einem zweiten Prüfstand derart, dass die Anordnung der Energiebaugruppe in dem zweiten Prüfstand der wenigstens einen bestimmten Integrationsrandbedingung entspricht,
• - Beaufschlagen der Energiebaugruppe wenigstens mit den gemessenen Belastungsparametern durch den zweiten Prüfstand, und
• - Durchführen der Betriebsfestigkeitsprüfung.

According to the first aspect of the invention, the object is achieved by a method for carrying out an operational stability test on an energy assembly for a motor vehicle. The process has the following process steps:

• - Providing the energy assembly and an overall vehicle structure, the energy assembly being integrated in the overall vehicle structure,
• - Determining at least one integration boundary condition for the energy assembly in the overall vehicle structure with at least one first measuring device,
• - installing the overall vehicle structure in a first test stand, the first test stand being arranged in contact with the overall vehicle structure and in particular with the energy assembly in order to introduce at least one load variable,
• - Applying the at least one load variable to the overall vehicle structure by the first test bench,
• - Measuring load parameters of the energy assembly and/or the overall vehicle structure with at least one second measuring device of the first test bench during the loading,
• - arranging the energy assembly in a second test bench in such a way that the arrangement of the energy assembly in the second test bench corresponds to at least one specific integration boundary condition,
• - subjecting the energy assembly to at least the measured load parameters by the second test bench, and
• - Carrying out the durability test.

Unless explicitly stated otherwise, the method steps described above and below can be carried out individually, together, once, multiple times, at the same time and/or one after the other in any order. A designation as, for example, “first procedural step” and “second procedural step” does not require any chronological order and/or prioritization. As part of the method, an energy assembly is preferably designed as an energy store for storing energy, in particular for a drive device of a motor vehicle. The energy assembly is preferably designed as a high-voltage storage device. The energy assembly is integrated into the overall vehicle structure. In the context of the invention, the overall vehicle structure is preferably to be understood as a vehicle structure with all structurally relevant components. The overall vehicle structure preferably includes all structurally relevant motor vehicle devices. The overall vehicle structure is preferably to be understood as a complete motor vehicle, as can also be found in real sales and/or on the road, for example. An integration of the energy assembly in the overall vehicle structure is preferably to be understood as a constructive and/or structural integration of the energy assembly in the overall vehicle structure. The power assembly is preferably fastened in the overall vehicle structure, in particular in a detachable manner. The constructive and/or structural interaction between the energy assembly and the overall vehicle structure are referred to as integration boundary conditions within the scope of the invention. For example, an integration constraint includes the load magnitude introduction points, contact surfaces or points, and/or attachment points between the power assembly and the overall vehicle structure. The at least one integration boundary condition for the energy assembly in the overall vehicle structure is determined, recorded, measured and/or ascertained with at least one first measuring device. The durability test is preferably a damage-equivalent durability test, with an equivalent stress test of the energy assembly being carried out in comparison to one or more exemplary damage situations. The essence of the invention is to determine realistic load data, strength data and/or structural data for the energy assembly. In other words, the method according to the invention preferably enables at least one structural load path to be introduced into the energy assembly for simulating practical motor vehicle loading and motor vehicle use.

The first test bench is used to measure load parameters, in particular acceleration parameters, of the energy assembly and/or the overall vehicle structure with at least one second measuring device of the first test bench while the energy assembly and/or the overall vehicle structure is subjected to the at least one load variable, in particular at least one test force Test acceleration and / or a test torque through the first test bench. The energy assembly is integrated into the overall vehicle structure and is arranged and/or mounted together on the first test bench. The first test stand preferably serves to check legal and/or industry-specific targets for test forces that the energy assembly in the overall vehicle structure should be able to withstand or which the energy assembly in the overall vehicle structure should survive without damage. Material use, material aging, material fatigue and/or other structural changes in the material of the energy assembly and/or the overall vehicle structure are clearly simulated by introducing at least one load variable on the first and/or second test stand. At least one load variable is specified as a default value for the test on the first test stand, for example by said standards, laws, regulations and/or operating processes of the motor vehicle manufacturer. For example, a simulation of thousands of kilometers of motor vehicle use is generated on the first test stand by the at least one load variable. Furthermore, a simulation for stresses caused by a normal driving style and/or by a sporty driving style can be generated. The load parameters on the energy assembly and/or the overall vehicle structure are measured on the first test stand as a result of the application of the at least one load variable. The at least one load variable is preferably introduced via at least one wheel suspension of the motor vehicle.

The second test stand differs from the first test stand in such a way that no overall vehicle structure is arranged and/or assembled on the second test stand. The energy assembly is arranged and/or mounted directly or indirectly on the second test bench. When arranging and/or assembling the energy assembly on the second test stand, the little tens generates an integration boundary condition. For example, the at least one integration boundary condition is generated by installing the energy assembly in the second test stand. The constructive and structural integration boundary conditions of the overall vehicle structure for the energy assembly are clearly described on the second test bench, but without the need for the overall vehicle structure. On the second test bench, the previously measured load parameters of the energy assembly and/or the overall vehicle structure serve as input variables for loading the energy assembly. The arrangement and/or assembly of the energy assembly on the second test bench thus simulates the conditions of the overall vehicle structure for the energy assembly. According to the invention, the second test stand is used to test the actual structural forces, accelerations and/or loads that the energy assembly can withstand. In this case, the energy assembly on the second test bench is preferably subjected to at least the load parameters up to structural failure and/or damage, as will be explained in detail in a later section of the description.

The first and the second measuring means can be a wide variety of devices for determining the at least one integration boundary condition and for measuring the load parameters, which are defined in more detail in the further sections.

A method configured in this way for carrying out an operational stability test on an energy assembly for a motor vehicle is particularly advantageous, since an operational stability test is made possible with simple and inexpensive means, in particular with structural data of the energy assembly and/or the overall vehicle structure being determined in a simple and inexpensive manner made possible by the fatigue strength test.

According to a preferred further development of the invention, it can be provided in a method that the at least one integration boundary condition includes structural mechanical parameters, in particular local static and/or dynamic stiffness conditions, between the energy assembly and the overall vehicle structure. The first test stand is preferably designed as a complete vehicle test stand with the option of introducing loads that are specific to individual wheels. Alternatively or additionally, the first test stand is designed as a modular frame construction. A variation of the static and/or dynamic rigidity in the connection area of the energy assembly integrated into the vehicle structure can preferably be set in a temporally correlated dependency according to specifications of the first measuring means. Within the scope of the invention, the at least one integration boundary condition is preferably to be understood as a constructive and/or structural interaction between the energy assembly and the overall vehicle structure. For example, an integration constraint includes the load magnitude introduction points, contact surfaces or points, and/or attachment points between the power assembly and the overall vehicle structure.

According to a preferred further development of the invention, it can be provided in a method that the overall vehicle structure is designed as a structural-mechanical simulation model and includes the energy assembly, with the structural-mechanical simulation model generating the at least one integration boundary condition, in particular in the same way as a motor vehicle, and for determining the at least one Integration boundary condition is suitable when the structural-mechanical simulation model is subjected to the at least one load variable.

• - Klimatisieren der Energiebaugruppe und/oder der Gesamtfahrzeugstruktur durch eine Klimatisierungsvorrichtung des ersten Prüfstands und/oder zweiten Prüfstands.

According to a preferred further development of the invention, it can be provided in a method that the method further comprises:

• - Air conditioning the energy assembly and / or the overall vehicle structure by an air conditioning device of the first test bench and / or second test bench.

The method according to the invention preferably simulates material use, material aging, material fatigue and/or other structural changes in the material of the energy assembly and/or the overall vehicle structure by introducing at least one load variable on the first and/or second test stand. Additionally or alternatively, air conditioning of the energy assembly and/or the overall vehicle structure by an air conditioning device of the first test bench and/or second test bench enables the energy assembly and/or the overall vehicle structure to be advantageously influenced in order to reduce material use, material aging, material fatigue and/or other structural changes to the material to simulate the energy assembly and / or the overall vehicle structure through various uses of the energy assembly and / or the overall vehicle structure. An air conditioning device advantageously enables the influence of environmental influences, such as changes in ambient temperature, to be simulated. In this case, air conditioning potentially includes both an increase and a decrease in the temperature of the energy assembly and/or the overall vehicle structure on the first and/or second test stand.

• - Variieren der beaufschlagten Belastungsparameter durch den zweiten Prüfstand,
• - Variieren des Klimatisierens der Energiebaugruppe durch die Klimatisierungsvorrichtung des zweiten Prüfstands,
• - Variieren einer Frequenz des Beaufschlagens,
• - Variieren einer Dauer des Beaufschlagens.

According to a preferred further development of the invention, it can be provided in a method that the performance of the durability test comprises at least one of the following method steps:

• - Varying of the applied load parameters by the second test bench,
• - varying the air conditioning of the energy assembly by the air conditioning device of the second test bench,
• - varying a frequency of impingement,
• - varying a duration of impingement.

On the second test bench, the previously measured load parameters of the energy assembly and/or the overall vehicle structure serve as input variables for loading the energy assembly. The arrangement and/or assembly of the energy assembly on the second test bench thus simulates the conditions of the overall vehicle structure for the energy assembly. According to the invention, the second test stand is used to test the actual structural forces, accelerations and/or loads that the energy assembly can withstand. In this case, the energy assembly on the second test stand is preferably subjected to the load parameters up to structural failure and/or damage. On the second test stand, the load parameters applied, the air conditioning of the energy assembly, the frequency of the impact and/or the duration of the impact are varied. In particular, the above variables are at least temporarily increased compared to the first test stand and the applied test forces.

Test cycles and/or test programs are preferably made possible on the second test bench, which include a large number of variations over time in the said variables. A method designed in this way is particularly advantageous since real strength data of the energy assembly can be recorded by the fatigue strength test according to the invention using simple and inexpensive means. The applied load parameters are preferably varied in such a way that load-compacted and/or damage-equivalent and/or dynamic loads and/or damage-equivalent emissions are taken into account.

• - Erfassen wenigstens eines Festigkeitsparameters und/oder wenigstens eines Strukturparameters der Energiebaugruppe durch den zweiten Prüfstand, insbesondere durch ein drittes Messmittel des zweiten Prüfstands,
• - Festlegen eines kritischen Werts für den wenigstens einen Festigkeitsparameter und/oder wenigstens einen Strukturparameter der Energiebaugruppe, insbesondere wobei eine Dauer des Beaufschlagens bis zum Erreichen des kritischen Werts und/oder ein beaufschlagter Belastungsparameter bei Erreichen des kritischen Werts und/oder eine Frequenz des Beaufschlagens bei Erreichen des kritischen Werts erfasst wird.

According to a preferred further development of the invention, it can be provided in a method that the performance of the durability test comprises at least one of the following method steps:

• - detecting at least one strength parameter and/or at least one structural parameter of the energy assembly by the second test bench, in particular by a third measuring device of the second test bench,
• - Defining a critical value for the at least one strength parameter and/or at least one structural parameter of the energy assembly, in particular with a duration of the application until the critical value is reached and/or an applied load parameter when the critical value is reached and/or a frequency of the application Reaching the critical value is recorded.

The fatigue strength test preferably includes detecting at least one strength parameter and/or at least one structural parameter of the energy assembly by the second test bench, in particular by a third measuring device of the second test bench. For example, the at least one strength parameter and/or the at least one structural parameter includes a parameter for the flexural rigidity, for the elongation and/or for the torsional rigidity of the energy assembly. It is particularly advantageous if a critical value is specified for the structural parameter and/or strength parameter of the energy assembly, in particular with a duration of the application until the critical value is reached and/or an applied load parameter when the critical value is reached and/or a frequency of the Acting upon reaching the critical value is recorded. Thus, a method according to the invention advantageously enables an operational stability test with simple and inexpensive means, in particular structural data of an energy assembly and/or an overall vehicle structure being determined by an operational stability test in a simple and inexpensive manner.

According to a preferred further development of the invention, a method can provide for the first test bench to be designed as a frame construction, in particular as a modular frame construction with variable length and/or width, and/or the first test bench being designed with fastening devices for fastening the overall vehicle structure and/or having the energy assembly on the first test stand with variable static and/or dynamic stiffness. According to this embodiment, the overall vehicle structure is designed as a frame construction and the motor vehicle is thus replaced at least in sections by this frame construction. The frame construction advantageously enables a simulation of the at least one integration condition of the overall vehicle structure for the energy assembly. Such a designed method is particularly advantageous because a first Test bench is thus preferably adaptable to different overall vehicle structures and/or the application of the at least one load variable and/or its initiation point or initiation points are adjustable.

According to a preferred further development of the invention, a method can provide for the at least one first measuring device and/or the at least one second measuring device to be designed as an acceleration sensor, load cell, strain gauge and/or displacement transducer. The first and the second measuring means can be a wide variety of devices for determining the at least one integration boundary condition and for measuring the load parameters. The first measuring device and/or the second measuring device are preferably designed as strain gauges on the overall vehicle structure and/or the energy assembly. A method designed in this way is particularly advantageous since real strength data of the energy assembly can be recorded by the fatigue strength test according to the invention using simple and inexpensive means.

According to a preferred further development of the invention, it can be provided in a method that the energy assembly and/or the overall vehicle structure is subjected to the at least one load variable by the first test bench using a stress-time function, in particular one that is temporally correlated to one another. As described above, the first and/or the second test bench allow forces, loads and/or accelerations to be applied to the energy assembly and/or the overall vehicle structure, in particular over time, particularly preferably varying over time. Thus, stress cycles and/or stress programs are preferably made possible as stress-time functions for the energy assembly and/or the overall vehicle structure by the method according to the invention. With a method designed in this way, real conditions of use and/or loads on a motor vehicle are preferably simulated or even exceeded with regard to values for forces and/or acceleration.

According to a preferred further development of the invention, it can be provided in a method that the energy module is subjected to at least the measured load parameters by the second test bench using a stress-time function, in particular one that is correlated in terms of time, and/or by means of, in particular, uncorrelated in terms of time, power density spectra. As described above, the first and/or the second test bench allow forces, loads and/or accelerations to be applied to the energy assembly and/or the overall vehicle structure, in particular over time, particularly preferably varying over time. Thus, stress cycles and/or stress programs are preferably made possible as stress-time functions for the energy assembly and/or the overall vehicle structure by the method according to the invention. With a method designed in this way, real conditions of use and/or loads on a motor vehicle are preferably simulated or even exceeded with regard to values for forces and/or acceleration.

According to a preferred further development of the invention, it can be provided in a method that the second test bench is an assembly of the first test bench and/or that the second test bench is designed as a part vehicle test bench, in particular as an, in particular uniaxial, shaker or multi-axial oscillating table. An embodiment of the second test bench as an assembly of the first test bench is preferably to be understood in such a way that the second test bench is arranged and/or installed within the first test bench as part of the first test bench. The second test stand is preferably removed and/or expanded from the first test stand so that the energy assembly can be subjected to at least the measured load parameters by the second test stand. In a method designed in this way, the second test bench is, clearly described, a smaller unit and/or subassembly of the first test bench the durability test is made possible.

According to a preferred further development of the invention, a method can provide for the energy assembly to be subjected to at least the measured load parameters by the second test stand for carrying out the durability test until the energy assembly yields structurally and/or is destroyed. Test cycles and/or test programs are preferably tested by the second test stand until structural failure and/or until the energy assembly is destroyed. With reference to the first test stand, the load parameters applied are increased for this purpose, for example, applied for longer and/or applied with a different frequency. A method designed in this way is particularly advantageous, since real strength data up to structural failure can be obtained with simple and inexpensive means gene and / or to the destruction of the energy module can be detected by the durability test according to the invention. The second test stand is preferably designed in such a way that it carries out a confirmation test of the system requirements.

According to a preferred further development of the invention, it can be provided in a method that the energy assembly is installed in the second test stand using a test stand, with the test stand generating the at least one determined integration boundary condition. The energy assembly is arranged and/or mounted indirectly on the second test stand by means of the test stand. When arranging and/or assembling the energy assembly on the second test stand, the at least one integration boundary condition is generated, in particular by the test stand. For example, the at least one integration boundary condition is generated by installing the energy assembly using the test frame in the second test bench. The constructive and structural integration boundary conditions of the overall vehicle structure for the energy assembly are clearly described on the second test bench, but without the need for the overall vehicle structure. On the second test bench, the previously measured load parameters of the energy assembly and/or the overall vehicle structure serve as input variables for loading the energy assembly. The arrangement and/or assembly of the energy assembly on the second test bench thus simulates the conditions of the overall vehicle structure for the energy assembly. According to the invention, the second test stand is used to test the actual structural forces, accelerations and loads that the energy assembly can withstand. In this case, the energy assembly on the second test stand is preferably subjected to the load parameters up to structural failure and/or damage. A method designed in this way advantageously enables structural data of the energy assembly and/or the overall vehicle structure to be determined in a simple and cost-effective manner by means of the fatigue strength test and the test frame according to the invention.

According to a second aspect of the invention, the object is achieved by a test bench system having a first test bench and a second test bench, the test bench system being designed to carry out the method according to the first aspect. All the advantages that have already been described for the method for carrying out an operational stability test on an energy assembly for a motor vehicle according to the first aspect of the invention result from the described test stand system.

• 1 in einer Vorderansicht einen ersten Prüfstand eines Prüfstandsystems mit einer Gesamtfahrzeugstruktur und einer Energiebaugruppe,
• 2 in einer Vorderansicht einen zweiten Prüfstand eines Prüfstandsystems mit einer Energiebaugruppe, und
• 3 in einem Flussdiagramm ein erfindungsgemäßes Verfahren.

A method according to the invention for carrying out an operational stability test on an energy assembly for a motor vehicle and a test bench system are explained in more detail below with reference to drawings. They each show schematically:

• 1 in a front view, a first test bench of a test bench system with an overall vehicle structure and an energy assembly,
• 2 in a front view, a second test stand of a test stand system with an energy assembly, and
• 3 in a flowchart, a method according to the invention.

Elements with the same function and mode of action are in the 1 until 3 each provided with the same reference numerals.

In 1 a first test bench 50 of a test bench system 80 with an overall vehicle structure 150 and an energy assembly 110 is shown schematically in a front view. The energy assembly 110 is integrated into the overall vehicle structure 150 . An integration boundary condition 170 for the energy assembly 110 in the overall vehicle structure 150 can be determined by means of a first measuring device 10 . The overall vehicle structure 150 is installed in the first test stand 50 , the first test stand 50 being arranged in contact with the overall vehicle structure 150 in order to introduce a load variable 172 . The first test bench is designed to apply the load variable 172 to the energy assembly 110 and the overall vehicle structure 150 . Furthermore, in the first test stand according to the invention, load parameters 180 of the energy assembly 110 are measured with a second measuring device 20 of the first test stand 50 while the load variable 172 is applied. The integration boundary condition 170 includes structural-mechanical parameters for local static and dynamic stiffness conditions between the energy assembly 110 and the overall vehicle structure 150. The first test bench 50 also has an air conditioning device 40 for air conditioning the energy assembly 110 and the overall vehicle structure 150. The first test stand 50 is designed as a modular frame construction with variable length and width, the first test stand 50 having fastening devices 54 for fastening the overall vehicle structure 150 to the first test stand 50 with variable static and dynamic rigidity. The first measuring device 10 and the second measuring device 20 are designed as an acceleration sensor, load cell, strain gauge and/or displacement sensor. The test bench system 80 and the method 200 according to the invention (not shown) enable It is also advantageous to introduce at least one structural load path into the energy assembly 110 for simulating practical motor vehicle loading and motor vehicle use.

In 2 a second test bench 60 of a test bench system 80 with an energy assembly 110 is shown schematically in a front view. After the load parameter 180 has been measured according to the above description, the energy assembly 110 is installed in the second test bench 60 in such a way that the arrangement of the energy assembly 110 in the second test bench 60 corresponds to the specific integration boundary condition 170 . The arrangement and / or assembly of the energy assembly 110 on the second test bench 60 thus simulates the conditions of the overall vehicle structure 150 (not shown) for the energy assembly 110. The energy assembly 110 is then subjected to at least the measured load parameters 180 by the second test bench 60 and the durability test carried out. According to the invention, the second test stand 60 is used to test the actual structural forces, accelerations and/or loads that the energy assembly 110 can withstand. In this case, the energy assembly 110 on the second test stand 60 is preferably subjected to at least the load parameters 180 or beyond until structural failure and/or damage and/or destruction occurs.

In 3 a method 200 according to the invention is shown schematically in a flow chart. In a first method step, method 200 includes providing 202 energy assembly 110 and an overall vehicle structure 150 , energy assembly 110 being integrated in overall vehicle structure 150 . In a further method step, the method 200 includes the determination 204 of at least one integration boundary condition 170 for the energy assembly 110 in the overall vehicle structure 150 with at least one first measuring device 10. In a further method step, the method 200 includes the installation 206 of the overall vehicle structure 150 in a first test bench 50, first test stand 50 being arranged in contact with overall vehicle structure 150 and/or energy assembly 110 in order to introduce at least one load variable 172. In a further method step, method 200 comprises subjecting 208 energy assembly 110 and/or the overall vehicle structure 150 to the at least one load variable 172 by first test bench 50. In a further method step, method 200 comprises measuring 210 load parameters 180 of energy assembly 110 and / or the overall vehicle structure 150 with at least one second measuring device 20 of the first test bench 50 during the loading 208. The method 200 comprises in a further method step arranging 212 the energy assembly 110 in a second test bench 60 such that the arrangement of the energy assembly 110 in the second Test bench 60 which corresponds to at least one specific integration boundary condition 170. In a further method step, the method 200 comprises subjecting 214 the energy assembly 110 to at least the measured load parameters 180 by the second test bench 60. In a further method step, the method 200 comprises carrying out 216 the durability test. In a further method step, the method 200 comprises the air conditioning 218 of the energy assembly 110 and/or the overall vehicle structure 150 by an air conditioning device 40 of the first test bench 50 and/or second test bench 60.

Reference List

10

first measuring device

20

second measuring device

30

third measuring device

40

air conditioning device

50

first test stand

54

fastening devices

60

second test stand

64

test stand

80

test bench system

110

power assembly

150

overall vehicle structure

170

integration boundary condition

172

load size

180

load parameters

190

strength parameters

192

structural parameters

200

Proceedings

202

Provide

204

Determine

206

build in

208

pressurize

210

Measure

212

arrange

214

pressurize

216

Carry out

218

air conditioning

Claims (14)

Method (200) for carrying out an operational stability test on an energy assembly (110) for a motor vehicle, having the following method steps: - Providing (202) the energy assembly (110) and an overall vehicle structure (150), wherein the energy assembly (110) is integrated in the overall vehicle structure (150), - Determining (204) at least one integration boundary condition (170) for the energy assembly (110) in the overall vehicle structure (150) with at least one first measuring means (10), - Installing (206) the overall vehicle structure (150) in a first test stand (50), the first test stand (50) being arranged in contact with the overall vehicle structure (150) and in particular with the energy assembly (110) in order to introduce at least one load variable (172). , - applying (208) the overall vehicle structure (150) to the at least one load variable (172) by the first test stand (50), - Measuring (210) load parameters (180) of the energy assembly (110) and/or the overall vehicle structure (150) with at least one second measuring device (20) of the first test bench (50) during the loading (208), - Arranging (212) the energy assembly (110) in a second test bench (60) such that the arrangement of the energy assembly (110) in the second test bench (60) corresponds to the at least one specific integration boundary condition (170), - Applying (214) the energy assembly (110) at least with the measured load parameters (180) by the second test stand (60), and - Carrying out (216) the durability test. Method (200) according to claim 1 , characterized in that the at least one integration boundary condition (170) structural mechanical parameters, in particular local static and / or dynamic stiffness conditions, between the energy assembly (110) and the overall vehicle structure (150). Method (200) according to at least one of the preceding claims, characterized in that the overall vehicle structure (150) is designed as a structural-mechanical simulation model and includes the energy assembly (110), the structural-mechanical simulation model generating the at least one integration boundary condition (170) and for determining the at least one integration boundary condition (170) is suitable when the at least one load variable (172) is applied to the structural-mechanical simulation model. Method (200) according to at least one of the preceding claims, characterized in that the method (200) further comprises: - Air conditioning (218) of the energy assembly (110) and / or the overall vehicle structure (150) by an air conditioning device (40) of the first test bench (50) and/or second test stand (60). Method (200) according to at least one of the preceding claims, characterized in that the implementation (216) of the operational stability test comprises at least one of the following method steps: - Varying the load parameters (180) applied by the second test bench, - Varying the air conditioning (218) of the Energy assembly (110) by the air conditioning device (40) of the second test bench (60), - varying a frequency of the application (208, 214), - varying a duration of the application (208, 214), - varying a load density of the application (208, 214) Method (200) according to at least one of the preceding claims, characterized in that the performance (216) of the fatigue strength test comprises at least one of the following method steps: - detecting at least one strength parameter (190) and/or at least one structural parameter (192) of the energy assembly (110 ) by the second test stand (60), in particular by a third measuring device (30) of the second test stand (60), - determining a critical value for the at least one strength parameter (190) and/or at least one structural parameter (192) of the energy assembly (110 ); ) is recorded when the critical value is reached. Method (200) according to at least one of the preceding claims, characterized in that the overall vehicle structure (150) is designed as a frame construction, in particular as a modular frame construction with variable length and/or width, and/or wherein the overall vehicle structure (150) has fastening devices (54 ) for fastening the energy assembly (110) to the overall vehicle structure (150) with variable static and/or dynamic rigidity. Method (200) according to one of the preceding claims, characterized in that the at least one first measuring device (10) and/or the at least one second measuring device (20) and/or the at least one third measuring device (30) as an acceleration sensor, load cell, strain gauge , Force measuring foil, expansion shaft screw and/or displacement transducer are designed. Method (200) according to one of the preceding claims, characterized in that the loading (208) of the energy assembly (110) and / or the overall vehicle structure (150) with the at least one load variable (172) by the first test bench (50) using a in particular, stress-time function correlated in time with one another. Method (200) according to one of the preceding claims, characterized in that the loading (214) of the energy assembly (110) with at least the measured load parameters (180) by the second test bench (60) using a stress time, in particular one that is temporally correlated to one another -Function and/or by means of power density spectra, in particular which are uncorrelated in terms of time. Method (200) according to one of the preceding claims, characterized in that the second test stand (60) is designed as a part vehicle test stand, in particular as an, in particular uniaxial, shaker or multi-axial oscillating table. Method (200) according to at least one of the preceding claims, characterized in that the loading (214) of the energy assembly (110) with at least the measured load parameters (180) by the second test bench for carrying out the fatigue strength test until structural yielding and/or until the Destruction of the energy assembly (110) and/or until the critical value of the at least one strength parameter (190) is reached. Method (200) according to at least one of the preceding claims, characterized in that the energy assembly (110) is installed in the second test stand (60) by means of a test stand (64), the test stand (64) fulfilling the at least one determined integration boundary condition (170) generated. Test bench system (80) comprising a first test bench (50) and a second test bench (60), characterized in that the test bench system (80) is designed to carry out the method according to one of the preceding claims.

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