为解决某型车辆在试验过程中出现的车架开裂问题，提出一种基于实测试验载荷谱与数值仿真分析相结合的车架结构优化方法，并在试验中得到应用验证。主要内容包括：首先建立集六分力传感器、加速度传感器、位移传感器、应变传感器为一体的多通道数据采集系统，获取实际行驶试验底盘载荷谱原始数据，利用零点漂移、去趋势项、去噪等信号处理技术得出载荷谱分析数据，采用定性与定量相结合的方法分析车架结构开裂的故障原因。其次，建立车架有限元仿真模型，基于试验载荷谱分析数据，在不影响整体结构的基础上提出优化方案，计算比较优化前后的车架结构在典型受力工况下的力学特性，保证优化后受力满足要求。再次，利用RPC迭代技术，基于实测载荷谱数据迭代计算得到响应驱动信号，应用于整车道路模拟试验台，开展台架试验，验证车架设计优化的有效性。最后对优化后的车架进行完整的可靠性行驶试验，结果表明：优化后的车架未发生故障且满足可靠性指标。该研究以解决实际问题为出发点，为整车高可靠性设计技术提供了有效、可行的方法。
Abstract
In order to solve the vehicle frame fractures happened during the reliability running test, an optimization method for vehicle frames based on measured test road load spectrum and numerical simulation analysis was given, and the method was applied and verified in the test. The main contents include: firstly, a multi-channel data acquisition system integrating six component force sensor, acceleration sensor, displacement sensor and strain sensor is established to obtain the original data of chassis load spectrum of actual driving test, and the load spectrum analysis data is obtained by using signal processing technologies such as zero drift, trend term removal and noise removal. The failure causes of frame structure cracking are analyzed by the combination of qualitative and quantitative methods. Secondly, through the establishment of vehicle frame simulation finite element model, the optimization scheme was proposed without affecting the overall structure, the mechanical characteristics of the frame structure before and after optimization under typical stress conditions were calculated and compared to ensure that the stress after optimization meets the requirements. Meanwhile, the RPC iterative technology was used, and the response driving signal is obtained by iterative calculation based on the measured load spectrum data, which is applied to the vehicle road simulation test-bed to carry out bench test to verify the effectiveness of frame design optimization. In the end, through the reliability running test of the optimized frame, the results showed that the optimized frame did not fail and met the reliability index. The research provides the most effective and feasible method for vehicle high reliability design technology.
关键词
车架 /
载荷谱 /
仿真 /
台架试验 /
优化分析
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Key words
vehicle frame /
load spectrum /
numerical simulation /
bench test /
optimization analysis
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