路面不平度垂向传递机理及其对车辆结构疲劳损伤的影响研究
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摘要
路面不平度是造成车辆结构或零部件疲劳损伤的主要输入之一,是影响汽车疲劳寿命的根本因素。为揭示汽车运行过程中随机路面不平度的传递机理及其对车辆结构产生的损伤,本文通过实测路面不平度高程,等效重构了符合实际运行条件的各等级路面；通过建立车路垂向耦合模型,分析了路面不平度传递特性；通过疲劳损伤理论和实测载荷谱,分析了试验场路面对车辆结构产生疲劳损伤的影响规律,对副车架、控制臂等结构进行了寿命预测。
(1)基于实测道路谱的路面不平度等效重构
应用课题组开发的路面不平度激光测试系统,测取不同等级公路路面和试验场路面的高程数据。利用经验模态分解提取并去除路面高程数据趋势项,利用基于固定门限准则的经验模态分解小波硬阈值法,进行数据去噪。选择典型路面数据进行功率谱分析,获得各类等级路面的路面不平度功率谱。利用二维AR模型对各等级路面进行了虚拟重构,利用F检验法和相关指数法对重构路面进行检验与分析。利用VC++和Matlab混合编程技术,开发了基于实测高程数据的路面虚拟重构软件系统,生成CarSim、VPG、ADAMS动力学仿真软件使用的虚拟路面文件。结果表明,重构谱与实测谱重合度较高,为车路耦合系统动力学仿真试验和车辆疲劳耐久性分析提供准确的路面激励。
(2)路面不平度垂向传递特性分析与试验
应用1/4车辆子系统模型、考虑路面变形的欧拉-贝努力道路模型、考虑包容特性的垂向耦合弹性轮胎模型,建立车路垂向耦合系统动力学模型。对某SUV型样车的悬架和轮胎性能参数进行识别。解析求解并仿真分析了路面垂向位移,进行了车路垂向耦合系统中车轮、车身处加速度、位移等参数的仿真,分析了路面不平度的垂向传递特性。通过实车试验,验证了悬架位移、车轮垂向加速度等参数特征,分析了复合路面不平度在车轮-车身子系统的动力传递特性。结果表明,随车速的提高和路面等级的降低,路面激励引起的路面动位移逐渐增加,增加趋势为非线性；复合路面不平度不改变车轮-车身系统频响特性,与车辆结构载荷具有一致的随机性,是车辆结构产生疲劳损伤的根本原因。
(3)不同路面不平度引起的车辆结构疲劳损伤分析与寿命预测
为分析路面不平度激励下车辆结构的疲劳损伤,建立了前述试验车前、后悬等重要结构总成的三维实体模型,根据有限元分析结果,确定了车辆前悬控制臂、副车架,后悬纵臂、横臂等重要结构件疲劳损伤危险点,确定载荷谱测试点位置。制定载荷谱测试方案,在某汽车试验场完成载荷谱测试。利用雨流计数法,编制了车辆结构各测点载荷谱,载荷谱均值符合正态分布、幅值服从威布尔分布。利用ncode8.0glyphworks软件,分析了车辆结构(副车架、控制臂等)在试验场路各强化路面激励下的疲劳损伤分布规律,并进行了寿命预估,提出了表示车辆结构疲劳损伤的网状图法和当量系数法。结果表明,车辆结构疲劳损伤随路面等级降低而增加,同时受车辆加减速、转弯等使用工况的影响较显著。
本文的创新之处在于：
(1)提出一种基于实测道路谱的路面等效重构方法,在车辆动力学仿真应用中,针对不同用户的使用目的和需求,在实测高程数据的基础上,重构了与实测路面谱等效的虚拟路面,并开发了路面重构软件,为整车与零部件的疲劳耐久试验研究提供准确的路面激励,使车辆动力学仿真更准确可靠。
(2)建立了考虑轮胎包容特性的车路垂向耦合动力学模型,分析了车路垂向耦合作用过程中车辆结构对复合路面不平度的响应特性,为疲劳耐久性研究提供了更准确的动力学求解方法。
(3)提出了表征组合路况引起车辆结构疲劳损伤状况的网状图法和基于损伤等效的当量系数法。网状图法用圆心角表示各路面产生损伤的贡献率、半径表示损伤密度,形成网状图封闭面积表示结构的疲劳损伤状况。当量系数法根据疲劳损伤等效原则,计算任意路面相对于某一关注路面的当量里程及当量系数。为车辆道路试验规范修订提供了重要的方法依据,降低车辆疲劳耐久试验成本。
本文以路面不平度研究为基础,开展了路面不平度对车辆疲劳耐久性影响的应用研究,为车路耦合动力学和车辆疲劳耐久性研究提供了重要的基础理论与有效方法。
Road roughness is one of primary input that caused to damage on the vehicle structure or component, and is a fundamental factor that impact on the vehicle fatigue life. To reveal the transfer mechanism on random road roughness and the vehicle structure damage by it caused, in this paper, each grade road is reconstructed equivalently based on the measured road roughness. Road roughness transfer mechanism is analyzed by established the model of vehicle and pavement coupled. Through fatigue damage theoretical and measured load spectrum, the law of vehicle structure fatigue damage is analysis under the condition of proving ground road, and subframe, control arm and other structures life are predicted.
(1) Road roughness equivalent reconstruction based on measured road spectrum
Elevation data on different level pavement and proving ground is tested by applying road roughness laser test systems that project team developed. The data trend term is extracted by using the empirical mode decomposition, and data is removed the noise by using the of empirical mode decomposition wavelet hard threshold method based on fixed threshold criteria. Power spectral density of typical pavement data is analyzed. Each class of virtual pavement is reconstructed by two-dimensional AR model, and reconstruction results are tested and analyzed by using the F-test and associated index method. A software on pavement virtual reconstruction based on measured elevation data is developed by using the hybrid programming technology on VC++and Matlab, and can generate virtual road files applied to the CarSim, VPG, ADAMS dynamics simulation software. The results show that the reconstruction accuracy are high between reconstruction spectrum and measured spectrum. It provides accurate road excitation for the vehicle road coupling system dynamics simulation and vehicle fatigue durability analysis.
(2) Road roughness vertical transfer characteristics simulation and experiment
Vehicle and road vertical coupling dynamics model is built by three subsystem models including on1/4vehicle models, Euler-Bernoulli road model considered pavement deformation, vertical coupling elastic tire model considered the inclusive features. Some performance parameters are for recognized on a sport utility vehicle suspension and tire. Pavement vertical displacement is resolved by analytical method and simulation analysis, on this basis. Then acceleration and displacement parameters in wheels and body are simulated in the vehicle and road vertical coupling system, and road roughness vertical transfer mechanism is analyzed. Vehicle tests verify the suspension displacement and wheel vertical acceleration parameters characteristics, and dynamic transfer characteristics of complex road roughness are analyzed in wheel-body subsystems. The results show that with increased speed and reduced road grade, dynamic displacement caused by road excitation induced increased gradually, and increasing trend is nonlinear. And complex road roughness couldn't change the wheel-body system frequency response characteristics, and its stochastic characteristic is consistent with vehicle structural load, and it is the root cause of vehicle structure fatigue damage.
(3) Fatigue damage analysis and life prediction of vehicle structure caused by different road roughness
In order to analyze fatigue damage of vehicle structure under the road roughness, some important structure three dimension models such as front suspension and rear suspension are built. According to the FEA result, and the key points in the structures including front suspension control arm, subframe, rear suspension arm and cross arm are determined, then load test points are determined. According to the project, the load spectrum test in a vehicle test field is finished. By rain flow count method, the load spectrum of all test points is drawn up, its mean values are in line with normal distribution, and amplitude values are in line with Weibull distribution. By ncode8.0glyphworks software, the fatigue damage distribution laws of vehicle structures (subframe and control arm etc.) are analyzed under the strengthened test field road pavement, and the life prediction is done, then the network diagram and equivalent coefficient method indicting vehicle structure fatigue damage are proposed. The results show that vehicle structure fatigue damage increases with road grade decreasing, which can be affected drastically by the conditions such as vehicle acceleration and turning.
The innovations lie in:
(1) Road equivalent reconstruction method based on the measured spectrum is proposed. During the process of vehicle dynamics simulation, aimed to the using purposes and requirements of the different users, the virtual road pavements equivalent with measured road spectrum are reconstructed, and the road reconstruction software is exploited, which can provide accurate road roughness for fatigue tests of the whole vehicle and parts, make vehicle dynamics simulation be more accurate and reliable.
(2) Vehicle-road vertical coupling dynamics model considering tire enveloping property is built, then the vehicle structures response properties for complex road roughness under the action of vehicle-road vertical coupling. It provides a more accurate solving method for vehicle fatigue durability research.
(3) Network diagram method of evaluating vehicle structure fatigue damage caused by combination roads and equivalent coefficient method based on damage equivalent are proposed. The method of using central angle indicating damage contribution rate caused by different roads and radius indicating damage density, the forming network diagram envelop area indicting fatigue damage is referred as network diagram method. By the rule of fatigue damage equivalence, the equivalent mileage and factor of any road compared with focused road are calculated, which is the damage equivalent method. It provides important methods for the vehicle road test specification revision, can cut test cost greatly.
Taken road roughness as basis, the effect research of vehicle fatigue duration is developed, which provides important basic theory and effective method for the research of vehicle-road coupling dynamics and fatigue duration performance.
(1)基于实测道路谱的路面不平度等效重构
应用课题组开发的路面不平度激光测试系统,测取不同等级公路路面和试验场路面的高程数据。利用经验模态分解提取并去除路面高程数据趋势项,利用基于固定门限准则的经验模态分解小波硬阈值法,进行数据去噪。选择典型路面数据进行功率谱分析,获得各类等级路面的路面不平度功率谱。利用二维AR模型对各等级路面进行了虚拟重构,利用F检验法和相关指数法对重构路面进行检验与分析。利用VC++和Matlab混合编程技术,开发了基于实测高程数据的路面虚拟重构软件系统,生成CarSim、VPG、ADAMS动力学仿真软件使用的虚拟路面文件。结果表明,重构谱与实测谱重合度较高,为车路耦合系统动力学仿真试验和车辆疲劳耐久性分析提供准确的路面激励。
(2)路面不平度垂向传递特性分析与试验
应用1/4车辆子系统模型、考虑路面变形的欧拉-贝努力道路模型、考虑包容特性的垂向耦合弹性轮胎模型,建立车路垂向耦合系统动力学模型。对某SUV型样车的悬架和轮胎性能参数进行识别。解析求解并仿真分析了路面垂向位移,进行了车路垂向耦合系统中车轮、车身处加速度、位移等参数的仿真,分析了路面不平度的垂向传递特性。通过实车试验,验证了悬架位移、车轮垂向加速度等参数特征,分析了复合路面不平度在车轮-车身子系统的动力传递特性。结果表明,随车速的提高和路面等级的降低,路面激励引起的路面动位移逐渐增加,增加趋势为非线性；复合路面不平度不改变车轮-车身系统频响特性,与车辆结构载荷具有一致的随机性,是车辆结构产生疲劳损伤的根本原因。
(3)不同路面不平度引起的车辆结构疲劳损伤分析与寿命预测
为分析路面不平度激励下车辆结构的疲劳损伤,建立了前述试验车前、后悬等重要结构总成的三维实体模型,根据有限元分析结果,确定了车辆前悬控制臂、副车架,后悬纵臂、横臂等重要结构件疲劳损伤危险点,确定载荷谱测试点位置。制定载荷谱测试方案,在某汽车试验场完成载荷谱测试。利用雨流计数法,编制了车辆结构各测点载荷谱,载荷谱均值符合正态分布、幅值服从威布尔分布。利用ncode8.0glyphworks软件,分析了车辆结构(副车架、控制臂等)在试验场路各强化路面激励下的疲劳损伤分布规律,并进行了寿命预估,提出了表示车辆结构疲劳损伤的网状图法和当量系数法。结果表明,车辆结构疲劳损伤随路面等级降低而增加,同时受车辆加减速、转弯等使用工况的影响较显著。
本文的创新之处在于：
(1)提出一种基于实测道路谱的路面等效重构方法,在车辆动力学仿真应用中,针对不同用户的使用目的和需求,在实测高程数据的基础上,重构了与实测路面谱等效的虚拟路面,并开发了路面重构软件,为整车与零部件的疲劳耐久试验研究提供准确的路面激励,使车辆动力学仿真更准确可靠。
(2)建立了考虑轮胎包容特性的车路垂向耦合动力学模型,分析了车路垂向耦合作用过程中车辆结构对复合路面不平度的响应特性,为疲劳耐久性研究提供了更准确的动力学求解方法。
(3)提出了表征组合路况引起车辆结构疲劳损伤状况的网状图法和基于损伤等效的当量系数法。网状图法用圆心角表示各路面产生损伤的贡献率、半径表示损伤密度,形成网状图封闭面积表示结构的疲劳损伤状况。当量系数法根据疲劳损伤等效原则,计算任意路面相对于某一关注路面的当量里程及当量系数。为车辆道路试验规范修订提供了重要的方法依据,降低车辆疲劳耐久试验成本。
本文以路面不平度研究为基础,开展了路面不平度对车辆疲劳耐久性影响的应用研究,为车路耦合动力学和车辆疲劳耐久性研究提供了重要的基础理论与有效方法。
Road roughness is one of primary input that caused to damage on the vehicle structure or component, and is a fundamental factor that impact on the vehicle fatigue life. To reveal the transfer mechanism on random road roughness and the vehicle structure damage by it caused, in this paper, each grade road is reconstructed equivalently based on the measured road roughness. Road roughness transfer mechanism is analyzed by established the model of vehicle and pavement coupled. Through fatigue damage theoretical and measured load spectrum, the law of vehicle structure fatigue damage is analysis under the condition of proving ground road, and subframe, control arm and other structures life are predicted.
(1) Road roughness equivalent reconstruction based on measured road spectrum
Elevation data on different level pavement and proving ground is tested by applying road roughness laser test systems that project team developed. The data trend term is extracted by using the empirical mode decomposition, and data is removed the noise by using the of empirical mode decomposition wavelet hard threshold method based on fixed threshold criteria. Power spectral density of typical pavement data is analyzed. Each class of virtual pavement is reconstructed by two-dimensional AR model, and reconstruction results are tested and analyzed by using the F-test and associated index method. A software on pavement virtual reconstruction based on measured elevation data is developed by using the hybrid programming technology on VC++and Matlab, and can generate virtual road files applied to the CarSim, VPG, ADAMS dynamics simulation software. The results show that the reconstruction accuracy are high between reconstruction spectrum and measured spectrum. It provides accurate road excitation for the vehicle road coupling system dynamics simulation and vehicle fatigue durability analysis.
(2) Road roughness vertical transfer characteristics simulation and experiment
Vehicle and road vertical coupling dynamics model is built by three subsystem models including on1/4vehicle models, Euler-Bernoulli road model considered pavement deformation, vertical coupling elastic tire model considered the inclusive features. Some performance parameters are for recognized on a sport utility vehicle suspension and tire. Pavement vertical displacement is resolved by analytical method and simulation analysis, on this basis. Then acceleration and displacement parameters in wheels and body are simulated in the vehicle and road vertical coupling system, and road roughness vertical transfer mechanism is analyzed. Vehicle tests verify the suspension displacement and wheel vertical acceleration parameters characteristics, and dynamic transfer characteristics of complex road roughness are analyzed in wheel-body subsystems. The results show that with increased speed and reduced road grade, dynamic displacement caused by road excitation induced increased gradually, and increasing trend is nonlinear. And complex road roughness couldn't change the wheel-body system frequency response characteristics, and its stochastic characteristic is consistent with vehicle structural load, and it is the root cause of vehicle structure fatigue damage.
(3) Fatigue damage analysis and life prediction of vehicle structure caused by different road roughness
In order to analyze fatigue damage of vehicle structure under the road roughness, some important structure three dimension models such as front suspension and rear suspension are built. According to the FEA result, and the key points in the structures including front suspension control arm, subframe, rear suspension arm and cross arm are determined, then load test points are determined. According to the project, the load spectrum test in a vehicle test field is finished. By rain flow count method, the load spectrum of all test points is drawn up, its mean values are in line with normal distribution, and amplitude values are in line with Weibull distribution. By ncode8.0glyphworks software, the fatigue damage distribution laws of vehicle structures (subframe and control arm etc.) are analyzed under the strengthened test field road pavement, and the life prediction is done, then the network diagram and equivalent coefficient method indicting vehicle structure fatigue damage are proposed. The results show that vehicle structure fatigue damage increases with road grade decreasing, which can be affected drastically by the conditions such as vehicle acceleration and turning.
The innovations lie in:
(1) Road equivalent reconstruction method based on the measured spectrum is proposed. During the process of vehicle dynamics simulation, aimed to the using purposes and requirements of the different users, the virtual road pavements equivalent with measured road spectrum are reconstructed, and the road reconstruction software is exploited, which can provide accurate road roughness for fatigue tests of the whole vehicle and parts, make vehicle dynamics simulation be more accurate and reliable.
(2) Vehicle-road vertical coupling dynamics model considering tire enveloping property is built, then the vehicle structures response properties for complex road roughness under the action of vehicle-road vertical coupling. It provides a more accurate solving method for vehicle fatigue durability research.
(3) Network diagram method of evaluating vehicle structure fatigue damage caused by combination roads and equivalent coefficient method based on damage equivalent are proposed. The method of using central angle indicating damage contribution rate caused by different roads and radius indicating damage density, the forming network diagram envelop area indicting fatigue damage is referred as network diagram method. By the rule of fatigue damage equivalence, the equivalent mileage and factor of any road compared with focused road are calculated, which is the damage equivalent method. It provides important methods for the vehicle road test specification revision, can cut test cost greatly.
Taken road roughness as basis, the effect research of vehicle fatigue duration is developed, which provides important basic theory and effective method for the research of vehicle-road coupling dynamics and fatigue duration performance.
引文
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