汽车耐久性试验技术

六分力 车身扭曲 应力集中点的应变信号

典型通道

减震器安装座 控制臂球头 转向横拉杆及连接杆


减震器及螺旋弹簧
发动机悬臵
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开发运转工况及进行试验场测量
S. R.
M. R.
E. R.
客户调查 试验场程序 公共道路数据
失效及统计分析
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Steering
Body 100 80 60
Trim A/C Electric
Full load Peak Torsional 6
Peak Crankshaft Torsional RPM WOT
Full load Power Peak
No Load to Full Lo
Idle to Power Peak +
R e peat 7 t i mes
5
Power Peak WOT
试验场试验
Brakes Fuel system
40 20
Suspension
极端客户
Base engine
0
Drive Shafts
Clutch
FEAD
Manual Transm. Automatic Transm. Mounts
90%-ile
CAE/试验 室试验
Fuel Injection
Exhaust
Idle, 20%, 40%, 60%, 80%, WOT (Peak Tq-500) to (Peak Hp+10%)
Cycle includes the following speed/load pts:
Percent of WOT Torque RPM N/L 20% 40% 60% 80% WOT Idle X Pk Tq - 500 X X X X X Pk Tq X X X X X 1/2(PkTq+PkPow) X X X X X Pk Pow X X X X X Pk Pow + 10% X X
RPM RPM RPM
To generate high mileage/tim failure modes associated wit head joint and gasket service yr/150,000 mile lifespan.
Structural Fatigue Piston & Rod, Crankshaft, Camdrive
客户1
客户2 客户3
…
客户???
…
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市场调查
目的：确定特定市场的路面状况

高速公路比例 一般公路比例 坏路比例
乘客数量以及行李重量
各种典型道路

选定特定市场有代表性的车型 调查方法

电子邮件 电话 面谈

每个特定市场至少1000名客户
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数据采集
通道选择

PASCAR
Fra Baidu bibliotek
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第三部分：耐久性DVP矩阵
任何一种试验都有其局限性。
为了建立足够Robust的耐久性DVP计划，必须建立耐久性DVP矩阵，考 虑所有的Noise factor。
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零部件
强度试验
系统
整车
结构耐久性试验
PT耐久性试验 抗腐蚀性试验
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Road Cycle Dynamometer Durability Test
Cycle contains 250 speed/load points and 1) 30 min - Idle / No Load a 1 hr soak period.. The speed/loads listed 2) 5 hr 45 min, Torque Peak / WOT above are used to make up the 250 points. 3) 20 min, Pwr Peak+6% / No Load 4) 10 min, Pwr Peak+12% / No Load Total cycle = 9 hours 5) 3 hr 45 min, Power Peak / WOT (includes 1 hour soak) 6) 2 hr, Power Peak+6% / WOT Total cycle = 12.5 hours
Car/Light Truck: 50 x 10 WOT engine cycles (100 x 106 WOT revs) Over 8500 GVW Truck: 75 x 106 WOT engine cycles (150 x 106 WOT revs) Determine RPM of highest crankshaft torsional vibration and run continuously at that RPM WOT. Measure and adjust RPM every 20 hours. 1) 17 min - Idle 2) 60 min - Power Peak WOT 3) 3 min - Max. Intermittent Spd WOT 4) 17 min - Power Peak WOT 5) 60 min - Max. Continuous Spd WOT Total cycle = 180 minutes All: 100 test hours All: 180 test hours (60 cycles) All: 100 test hours
制定DVP
执行DVP
1. 2. 3. 4.
产品寿命 驾驶习惯 路面 环境
1. 2. 3. 4.
设计 材料 加工制造 质量控制
第二部分：客户关联（公共道路数据库）
客户关联用来定义了客户使用车辆过程中的操作频率，载荷以及环境 。 它界定了系统/子系统/部件必须服从的操作状况分布。
客户关联可以是针对整车，也可以针对系统、部件，它的输出物是客户 使用应力分布，整车试验场耐久性试验程序，关键寿命试验方法等等
Coolant Temp.
2
1
3 4 3 4
3
RPM
1 2 1 2
3
2
Test Pattern
7 3
6
Time
1
Time
1
Time Time
6
Time
Time
Test Duration
1000 test hours = 890 hours running (1000 cycles)
Car/Light Truck: 675 test hours = 596.2 hours running (75 cycles) over 8500 lb Truck: 990 test hours = 874.5 hours running (110 cycles)
Time depends on heat-up tim Min: 485.3 hrs total = 390.5 hrs running = 273.8 Max: 532.0 hrs total = 437.2 hrs running = 273.8
Cycle Description
1) 3 min - 60 km/hr equivalent 2) 4 min 12 sec - Torque Peak WOT 3) 15 min - 110 km/hr equivalent 4) 3 min - Power Peak WOT 5) 1 min 12 sec - Power Peak/ No Load 6) 3 min - Normal Idle 7) 3 min 36 sec - 105 km/hr equivalent 8) 15 min - 120 km/hr equivalent 9) 5 min 24 sec - High Idle (forced cooling) 10) 6 min 36 sec - Cold Soak (12° C/54° F) Total cycle = 60 minutes 140° C (284° F) max. Cycles between 12 ±3° C (54 ±5° F) and 95 ±3° C (203 ±5° F) 50 gly / 50 H20 mix Orifice plates to match vehicle backpressure Pending Derived from Volvo test procedure.
Structural Fatigue Blocks, Cylinder Heads, Lubrication, Valvetrain, Piston&Rod, Crankshaft, Bearings Idle and Full load Idle to Max. Intermittent Spd 5
To evaluate the durability and reliability characteristics of an engine at speeds and loads typical of customer use. Accessories Test Purpose are loaded and engine coolant is forcecooled. System Test Test Classification All
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公共道路数据库是指通过一种或者几种基准载荷谱采集样 车，对公共道路进行载荷谱采集，从而形成整车结构强度 基准数据库；
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客户需求 Required 设计验证 Test 设计
客户需求 设计验证 设计
客户需求 设计验证 设计验证
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客户需求
设计验证
设计验证

采集样车
公共道路
客户需求
设计强度
验证方法
Cylinder Head Joint Ke (KLT)
To investigate the durability and reliability To investigate the structural integrity of an To evaluate the durability of To investigate the structural fatigue To investigate the endurance quality of of the entire engine system at speed and engine at sustained high speed and high engine components while running durability of an engine (and/or component an engine and/or component parts at load conditions derived from an Autobahn load conditions. with maximum crankshaft parts) at high engine speeds. high speed operation. drive cycle. torsional vibration amplitudes. Structural / System Test ALL, this is an engine system test Structural Fatigue Blocks, Cylinder Heads, Intake Manifold, Lubrication, Valvetrain, Piston & Rod, Crankshaft, Bearings Idle, No load and Full load Idle to Power Peak + 12% 34 2
第三开发部

结构耐久性在整车开发中的应用
客户关联（公共道路数据库）
耐久性DVP矩阵 可靠性的18种工具
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第一部分：结构耐久在整车开发过程中的应用
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设计验证 CAE 客户需求 设计 试验室
道路
公共道路
客户关联
整车
载荷谱采集
道路（试验场）试验
里程累积试验
系统
CAE分析
试验室试验
部件
定义客户需求
Structural Fatigue Piston&Rod, Crankshaft
Thermal Fatigue
Components On Test* Load Range RPM Range
2
RPM
Cylinder Head (surface), Cy Gasket, Block (deck
Idle to Full Load Idle to Peak Power 45 8 9 10
Dearborn-Cologne Durability Cycle - No Thermal Overlay
FIE Dynamometer Test
Crankshaft Durability Test
180 Hour High Speed Durability Cycle
100 Hour High Speed Endurance