Accelerated Service Life Testing of Automotive Vehicles on a Test Course

SUMMARY

The accelerated service life testing of automotive vehicles for durability to road roughness induced dynamic loads is often accomplished in the laboratory using road roughness simulation facilities [1–5]. However, such tests can also be accomplished by a carefully designed field operation on a test course [6], where both the speed of the vehicle and the roughness of die test course become variables that control the degree of the test acceleration. Field tests are generally harder to control than laboratory tests, but offer a greater degree of realism since the vehicle is fully operational during the test exactly as it will be in service. This paper formulates the criteria for accelerated service life tests on a test course, evaluates the assumptions that must be enforced to obtain valid results, and explores the sensitivity of the results to the critical test parameters, namely, the vehicle speed and the road roughness severity of the test course relative to the service environment.     

远程参数控制技术在轿车车身结构动强度试验中的应用

远程参数控制技术（RPC）是一种在室内台架复现实际道路行驶状况的试验手段。通过对轿车车身实际道路载荷的采集，采用电液伺服道路模拟系统和远程参数控制系统进行迭代（迭代控制目标为轴头加速度信号，对不同路面的载荷谱分别进行迭代，最后将迭代的结果合并），得到用于台架试验的加载谱。在此结果上实现室内轿车车身结构动强度试验。由此对远程参数控制技术在汽车试验中的应用进行了一定的研究和探索。     

汽车驾驶员车速控制模式的模拟研究

系统地对汽车驾驶员在一定行车环境中的安全性认知与车速控制的决策、推理过程进行了定量研究,通过进行一系列勘测、测试和心理评价试验,应用模糊集合、模糊统计试验、模糊控制和模糊逻辑推理等分析方法,建立了描述汽车驾驶员在既定道路条件下行车时基于安全性考量的逻辑推理规则和车速控制模型,最后进行了相应的实测验证。模拟预测结果与实测结果吻合较好,证明了研究所采用方法和建立模型的正确性。     

Road Surface Correction o f Tire Test Data

Most tire data used for vehicle simulations is measured on laboratory test facilities. An investigation showed that the frictional properties of these laboratory machines can be quite different from actual road conditions. This paper describes a method to correct laboratory tire test data to be more like road data in order to achieve a higher degree of correlation between instrumented test- and simulation results.     

Road Surface Correction o f Tire Test Data

SUMMARY

Most tire data used for vehicle simulations is measured on laboratory test facilities. An investigation showed that the frictional properties of these laboratory machines can be quite different from actual road conditions. This paper describes a method to correct laboratory tire test data to be more like road data in order to achieve a higher degree of correlation between instrumented test- and simulation results.     

基于汽车车身垂直加速度的典型道路路面谱识别研究

以1/4汽车振动模型为研究对象,推导出以汽车车身垂直振动加速度作为输入信号、路面不平度作为输出信号的数学模型及其模拟图,并利用MATLAB/SIMULINK搭建系统模型求解路面不平度,对路面不平度进行谱估计完成路谱的识别。通过实际测试和数据处理分析,说明该方法理论依据正确可行,可以为虚拟样机仿真路面的生成提供数据支持。     

基于径向刚度法的车辆翻新轮胎使用寿命判定

为了有效判定车辆翻新轮胎的剩余使用寿命，需要科学确定废旧轮胎胎体橡胶老化程度对翻新轮胎使用寿命的影响。在分析废旧轮胎胎体橡胶老化规律的基础上，通过橡胶老化试验测试及回归分析，确定了胎体弹性模量随着橡胶老化年限增加近似线性增大的影响规律；结合计算机仿真技术及试验测试技术，基于轮胎径向刚度法提出了翻新轮胎剩余使用寿命不安全系数计算方法，其计算数值大小与翻新轮胎径向刚度和新轮胎径向刚度之差成正比，与新轮胎径向刚度值成反比；构建了由橡胶加速老化系统、弹性模量测取系统、承载-变形计算机模拟系统和承载-变形测试系统等组成的翻新轮胎剩余使用寿命判定系统；基于径向刚度法和判定系统提出了车辆翻新轮胎剩余使用寿命判定规则，确定了翻新轮胎胎体剩余使用寿命判定具体流程；根据剩余使用寿命不安全系数计算方法和判定规则，将翻新轮胎确定为可正常使用、需降速使用和需报废处理3个级别，并利用11.00R22.5载重车辆翻新轮胎进行了剩余使用寿命判定与评价，依据判定规则分别计算了不同使用年限3条翻新轮胎的剩余使用寿命不安全系数，确定出3条翻新轮胎所对应的级别，判定与评价结论与实际使用情况相吻合。研究结果表明：废旧轮胎胎体橡胶老化程度对翻新轮胎剩余使用寿命影响显著，翻新轮胎径向刚度与剩余使用寿命之间存在较大影响关系；废旧轮胎胎体橡胶老化程度越严重和径向刚度越大，翻新轮胎的剩余使用寿命将会越短。     

考虑弹性支撑边界条件的电动汽车-路面系统机电耦合振动特性分析

轮毂电机驱动电动汽车的簧下质量大导致轮胎动载荷增加,并且电机电磁力和转矩波动对车轮造成电机激励,进一步加剧车轮振动引起垂向振动负效应的问题。鉴于此,考虑电机的电磁激励,建立了电动汽车-路面系统的机电耦合动力学模型,推导了弹性支撑边界条件下路面结构的模态频率和振型表达式,以及路面振动引起的二次激励。计算了简支与弹性支撑边界条件下的路面模态频率,根据频率分布进行了截断阶数选取,并分析了边界条件、电机激励和车速对路面响应的影响。在此基础上,研究了不同行驶速度、路基反应模量及路面不平顺幅值下,激励形式对汽车车身加速度、悬架动挠度和轮胎动载荷的影响。结果表明：路面不平顺幅值越小,弹性支撑对路面响应的影响越大,弹性支撑边界条件下的路面响应较小,电机激励会引起路面响应的增加;弹性支撑边界条件下,路面不平顺幅值和路基反应模量越小,考虑路面不平顺、路面二次激励和电机激励的三重综合激励对电动汽车响应的影响越大,激励形式对轮胎动载荷的影响最大,对车身加速度的影响次之,对悬架动挠度的影响最小;电机激励导致轮胎动载荷增加,对路面破坏和寿命产生的负效应不容忽视。所建电动汽车-路面系统机电耦合模型及研究思路可为电动汽车垂向动力学分析提供参考与理论支持。     

Vehicle Energy Dissipation Due to Road Roughness

Road roughness and surface texture are known to affect tire rolling resistance; however, little emphasis has been placed on the consequent changes in total vehicle energy dissipation due to road roughness. Thus, tire rolling resistance, in isolation from vehicle contributed losses such as dissipation in the suspension, appears to be a weakness in present evaluation procedures as they relate to fuel economy and pollution level testing: Recent work by Funfsinn and Korst has shown that substantial and measurable increases in energy losses occur for vehicles traveling on rough roads. The present investigation uses vehicle axle accelerations as a means of examining various road surfaces. Correlation with computer simulations has allowed the development of a deterministic road roughness model which permits the prediction of energy dissipation in both the tire and suspension as functions of road roughness, tire pressure, and vehicle speed. Comparison to the experiments of Korst and Funfsinn results in good agreement and shows that total rolling loss increases of up to 20 percent compared to ideal smooth roads are possible. The aerodynamic drag coefficient is also found to increase while driving on rough roads.     

Vehicle Energy Dissipation Due to Road Roughness

SUMMARY

Road roughness and surface texture are known to affect tire rolling resistance; however, little emphasis has been placed on the consequent changes in total vehicle energy dissipation due to road roughness. Thus, tire rolling resistance, in isolation from vehicle contributed losses such as dissipation in the suspension, appears to be a weakness in present evaluation procedures as they relate to fuel economy and pollution level testing: Recent work by Funfsinn and Korst has shown that substantial and measurable increases in energy losses occur for vehicles traveling on rough roads. The present investigation uses vehicle axle accelerations as a means of examining various road surfaces. Correlation with computer simulations has allowed the development of a deterministic road roughness model which permits the prediction of energy dissipation in both the tire and suspension as functions of road roughness, tire pressure, and vehicle speed. Comparison to the experiments of Korst and Funfsinn results in good agreement and shows that total rolling loss increases of up to 20 percent compared to ideal smooth roads are possible. The aerodynamic drag coefficient is also found to increase while driving on rough roads.     

汽车试验场搓板路强化系数的研究

通过对试验车辆的疲劳寿命估算,利用道路强化系数计算方法,研究汽车试验场搓板路强化系数,为汽车可靠性强化道路试验规范的制定、验证和优化提供依据。采用有限元动态仿真技术模拟汽车在试验场搓板路的试验过程,仿真与试验结果进行对比验证,对应的特征参数基本一致。利用有限元仿真的结果对样车关键部件进行疲劳寿命分析和预测,求取试验场搓板路面的强化系数,并得到搓板路强化曲线。研究的结果应用于指导汽车路试规范的准确制定,减少试验的盲目性,增强试验的可信度,缩短研发周期和试验成本。     

发动机制动、排气制动与缓速器联合作用时的非连续线性控制系统的研究

针对客车发动机制动、排气制动的制动扭矩比较小的问题,提出采用发动机制动、排气制动与缓速器联合作用的持续制动方式,并且针对汽车在山区道路下坡行驶过程中对稳定车速的要求,进行了相应的控制系统设计。模拟分析结果表明:该控制系统可以保证汽车在不采用行车制动器的条件下,利用发动机制动、排气制动与缓速器联合作用的持续制动方式,在各种坡度的坡道上以希望的车速稳定下坡行驶,为汽车在山区道路连续下坡行驶的制动安全性提供了一个合理的解决方案。     

车辆噪声与城市道路路面平整度关系的试验研究

主要研究了城市道路平整度可能对机动车辆噪声级产生的影响。采用IRI作为道路平整度的计量单位,并在上海的一些城市道路上组织了沥青路面和水泥路面两类试验。首先,在满足试验条件的道路上进行平整度的量测;其次,在试验道路的测点上采集车辆以特定速度驶过的最大噪声级。通过对试验数据的分析,发现车辆以相同速度行驶在平整度不同的城市道路上时,其噪声级是不同的,而且随着平整度指数的增加,机动车辆噪声级也呈上升趋势,因此城市道路平整度确实会对机动车辆噪声级产生影响。在20~50 km/h速度范围内,对于平整度相同的水泥路面和沥青路面,前者的车辆匀速行驶噪声要高于后者。     

Road roughness estimation based on discrete Kalman filter with unknown input

ABSTRACT

The road roughness acts as a disturbance input to the vehicle dynamics, and causes undesirable vibrations associated with the ride and handing characteristics. Furthermore, the accurate measurement of road roughness plays a key role in better understanding a vehicle dynamic behaviour and active suspension control systems. However, the direct measurement by laser profilometer or other distance sensors are not trivial due to technical and economic issues. This study proposes a new road roughness estimation method by using the discrete Kalman filter with unknown input (DKF-UI). This algorithm is built on a quarter-car model and uses the measurements of the wheel stroke (suspension deflection), and the acceleration of the sprung mass and unsprung mass. The estimation results are compared to the measurements by laser profilometer in-vehicle test.     

汽车前后轴台架疲劳试验与海南汽车试验场的疲劳寿命当量关系

以某轻型汽车后桥壳为例，运用工程疲劳寿命估算与道路模型疲劳试验相结合的方法，给出了该后桥壳基于海南汽车试验场可靠性试验的道路行驶载荷条件下所得到的疲劳寿命概率分布。     

桥面不平顺对下承式系杆拱桥振动影响的试验和模拟研究

为了获得下承式系杆拱桥的汽车荷载冲击系数，在桥面间隔布置橡胶减速条带以形成周期性的不平顺输入，对下承式钢管混凝土系杆拱桥的动挠度进行现场实测。结合自编的车桥耦合（VBI）单元，建立车-桥耦合振动三维有限元分析模型，通过与实测结果对比验证VBI单元的正确性。在此基础上，引入另外3座标准拱桥以形成涵盖4种跨径的下承式系杆拱桥研究对象，输入规范规定的A~D级不平顺，研究车速、车重和桥梁基频对系梁冲击系数的影响。研究结果表明：汽车通过周期间隔布置的减速带时会形成稳态激振，当激振频率接近桥梁的前2阶基频时，引起的系梁动挠度响应最大；系梁的汽车荷载冲击系数随着桥梁基频的增加呈现出先增大后减小的趋势，当小汽车（总重低）行驶于差桥面（D级不平顺）时，规范值明显低估了系梁的冲击系数。     

车轮随机动载特性的Simulink仿真分析

利用汽车的两自由度模型，应用Simulink软件仿真分析了车速与路面不平度对车轮随机动载变化趋势的影响。同时也分析了车轮随机动载的大小对路面疲劳应力的影响，指出了不同车速和路面不平度引起的路面动力反应及损伤变化规律，即车速和路面不平度的增加将导致汽车动载的增加，从而加速路面的损伤。提出了针对路面状况调整车速可以降低车轮随机动载，从而达到减轻路面损伤的要求。     

Evaluation and Measurement the Recovered Energy from Automobile Suspension in the Operation Conditions

The purpose of this paper is to verify if it is possible to recover the energy from automobile suspensions, using a system who replace the shock absorber. The system consists of an electric generator, a mechanical system for transforming the translation of body car in rotational movement and an electronic control system. The tests were made on three road types, according to ISO 8608/1995 with four different driving speeds. The results showed that a significant quantity of energy was recovered during the test on inferior type of road, even at reduced speed. For the superior type of the road, the energy can be recovered only at high speed. The parameters that influences the system capacity of recovering energy are gross weight of the vehicle, road type and the vehicle speed.     

基于整车模型的车-路耦合作用仿真分析

为研究车‐路系统耦合作用下汽车行驶平顺性,运用车辆动力学仿真软件CarSim建立整车模型,并采用傅里叶逆变换法对 GB7031中规定的A~D级路面进行数值仿真与验证,分析了车辆以不同速度行驶在不同等级路面上的加速度和车轮法向动载系数。结果表明:①随着路面等级的降低和车辆行驶速度的提高,车身加速度显著增大,由50 km/h、A级路面上的0.2599 m/s2变化为120 km/h、D级路面上的1.6889m/s2,增加了5.5倍,车辆行驶平顺性下降;②车‐路耦合产生的动载作用受路面工况和车速的影响也较大,由50 km/h、A级路面上的0.0833变化为120 km/h、D级路面上的0.7754,增大8.3倍。路面等级越低,车速越高,动载系数越大,对路面的破坏作用越严重。      

Optimal Preview Control of a Two-dof Vehicle Model Using Stochastic Optimal Control Theory

An optimal preview control algorithm is applied to a two degree of freedom(dof) vehicle model travelling with constant velocity on a randomly profiled road. The road roughness is modelled as a homogeneous random process being the output of a linear first order filter to white noise. The input from the road irregularity is assumed to be measured at some distance in front of the vehicle and this measured infonnation is utilized by the active controller to prepare the system for the ensuing input. The preview control algorithm is obtained by minimizing a quadratic performance index and by describing the average behaviour of the system by the covariance matrix of the vehicle response state vector. Results are presented for full state feedback and significant improvements in sprung mass acceleration, suspension working space and road holding are observed.