A torque and durability test system for a bolt of a new energy vehicle

Abstract

This invention discloses a torque and durability testing system for bolts used in new energy vehicles. The system includes a clamping module for clamping and testing sample bolts. The clamping module includes a clamping tool comprising a main board and a sub-board. It also includes a durability fatigue testing module for simulating the environmental conditions encountered by the battery pack during actual operation of new energy vehicles, thereby improving testing accuracy. The durability fatigue testing module includes a vibration unit, a heating unit, a resonant unit, and a problem collection unit. This solution improves the accuracy of bolt torque and durability testing by simulating the environment encountered by the battery pack during actual operation of new energy vehicles. Furthermore, by separating and integrating these tests, it further improves the accurate identification of bolt defects. The added environmental simulation does not require excessive cost, effectively improving the overall efficiency and accuracy of the testing system.

Description

Technical Field

[0001] This invention relates to the field of bolt torque testers, and more specifically, to a torque and durability testing system for bolts used in new energy vehicles. Background Technology

[0002] High-strength bolts are used to connect battery packs and peripheral accessories in new energy vehicles during installation. Before the bolts are put into actual use, torque and durability tests are required. The existing testing system mainly uses a bolt torque tester. This tester mainly tests the torque and durability by placing the bolt inside two clamping tool plates, positioning the two clamping plates accordingly, and controlling the counter-movement of the clamping plates and the rotation of the nut through the motor output shaft. Among them, the torque and durability testing system for bolts used in new energy vehicles proposed in patent publication number CN218098280U uses a similar principle to perform torque testing.

[0003] However, in actual use, the environment around the battery pack will generate a lot of heat due to its power generation, and there will be a certain degree of bumps during the car's operation, which will cause the bolts to be vibrated. Therefore, the existing testing process cannot effectively simulate the actual environment, resulting in certain deviations in torque and durability testing.

[0004] Therefore, in order to address the above-mentioned technical problems, it is necessary to provide a torque and durability testing system for bolts used in new energy vehicles. Summary of the Invention

[0005] The purpose of this invention is to provide a torque and durability testing system for bolts used in new energy vehicles to solve the above-mentioned problems.

[0006] To achieve the above objectives, an embodiment of the present invention provides the following technical solution: A torque and durability testing system for bolts used in new energy vehicles includes: The clamping module is used to clamp and test sample bolts. The clamping module includes a clamping tool, which includes a main board and a sub-board. The static torque performance testing module includes a torque tester for testing the torque of assembled bolts. The durability fatigue testing module is used to provide environmental simulation effects during bolt testing, thereby improving test accuracy. The durability fatigue testing module includes: A vibration unit, comprising a vibration system, is used to provide a vibration environment for the bolts under test, simulating the bumpy environment of a car driving; A heating unit, comprising a conductive heating system for being inserted into the interior of a clamping tool to provide a high-temperature environment for the bolts during testing; The coordinated resonance unit, controlled by a PLC system, is mainly used to perform coordinated testing on bolts that have undergone two separate tests, thereby further improving the testing accuracy. The problem collection unit is mainly divided into three categories, which collect bolt problems under different testing environments to reflect the trends of bolt problems.

[0007] As a further improvement of the present invention, it also includes a data acquisition module, a judgment module, and a comprehensive data processing module.

[0008] As a further improvement of the present invention, the conductive heating system includes a connecting plate, a connector, and a heat-conducting plug, wherein the bottom end of the connector is connected to the top surface of the connecting plate, and the top end of the heat-conducting plug is connected to the bottom surface of the connecting plate.

[0009] As a further improvement of the present invention, both the main board and the sub-board have bolt placement holes in the middle for bolt installation, and slots are also provided at the top of both. The shape of the slots is adapted to the shape of the heat-conducting rod. The outer periphery of the bolt placement holes is provided with annular grooves inside the main board and the sub-board. A heating resistance wire is installed around the inside of the annular groove. Heat-conducting rods are fixedly connected to the left and right sides of the heating resistance wire. The top end of the heat-conducting rod and the bottom end of the heat-conducting rod are in contact with each other.

[0010] As a further improvement of the present invention, the vibration system includes a sealing tube, with piston rod 1 movably sleeved inside both the left and right sides of the sealing tube, and piston rod 2 movably sleeved inside the upper middle part of the sealing tube. A push plate is fixedly connected to the upper end of piston rod 2, and a cylinder is fixedly connected to the outer end of piston rod 1.

[0011] As a further improvement of the present invention, a rubber coating is fixedly connected to the upper end of the push plate, and the top surface of the rubber coating is in contact with the bottom surface of the main plate and the sub-plate.

[0012] Compared with the prior art, the advantages of this invention are: This solution improves the accuracy of bolt torque and endurance testing by simulating the environment encountered by the battery pack of a new energy vehicle during actual operation. Furthermore, by separating and integrating these tests, it further enhances the accurate identification of bolt defects without incurring excessive costs, effectively improving the efficiency and accuracy of the overall testing system. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the bolt torque and durability testing system of the present invention; Figure 2 This is a schematic diagram of the durability fatigue testing module of the present invention; Figure 3 This is a schematic diagram of a partial assembly structure for bolt testing according to the present invention; Figure 4 This is a partial cross-sectional view of the clamping tool of the present invention; Figure 5 This is a schematic diagram of the vibration system structure of the present invention; Figure 6 This is a schematic diagram illustrating the working principle of the data acquisition module, the judgment module, and the comprehensive data processing module of the present invention. Figure 7 This is a schematic diagram illustrating the linear relationship between torque testing and temperature and vibration according to the present invention; Figure 8 This is a schematic diagram illustrating the relationship between torque testing and temperature and vibration on a three-dimensional slope, as presented in this invention.

[0014] Explanation of the labels in the diagram: 1. Clamping tool; 2. Conductive heating system; 3. Vibration system; 4. Bolt placement hole; 5. Slot; 6. Ring groove; 7. Heating resistance wire; 8. Heat-conducting rod; 9. Sealing tube; 10. Piston rod one; 11. Piston rod two; 12. Push plate. Detailed Implementation

[0015] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0016] Example 1: Please see Figure 1-6 A torque and durability testing system for bolts used in new energy vehicles, comprising: The clamping module is used to clamp and test the sample bolts. The clamping module includes a clamping tool 1, which includes a main board and a sub-board. The static torque performance testing module includes a torque tester for testing the torque of assembled bolts. The durability fatigue testing module is used to provide environmental simulation effects during bolt testing, thereby improving test accuracy. The durability fatigue testing module includes: Vibration unit, which includes vibration system 3, is used to provide a vibration environment for the bolts under test, simulating the bumpy environment of a car driving; A heating unit, comprising a conductive heating system 2, which is inserted into the inside of the clamping tool 1 to provide a high-temperature environment for the bolts during testing; The coordinated resonance unit, controlled by a PLC system, is mainly used to perform coordinated testing on bolts that have undergone two separate tests, thereby further improving the testing accuracy. The problem collection unit is mainly divided into three categories, which collect bolt problems under different testing environments to reflect the trends of bolt problems.

[0017] Specifically, the main equipment used in this application is a torque tester, which is an existing instrument. The drive structure, data acquisition, transmission, and display required for bolt installation and testing are all mature existing technologies, so this application will not elaborate on them. The problem solved by this application is that existing testers cannot simulate the actual use environment of automobiles while performing torque testing, so as to make the bolt test results more realistic and effective. Therefore, this application mainly adds corresponding temperature and vibration simulation at the bolt clamping part, that is, the part of the tester used for bolt installation, to improve the accuracy of the test data and more effectively detect the durability and torque data of the bolt. refer to Figure 6 It also includes a data acquisition module, a judgment module, and a comprehensive data processing module; The data acquisition module is the system's raw signal acquisition unit, operating throughout the entire process of bolt static torque testing, calibration, and alternating durability testing. It continuously acquires instantaneous physical quantities during the test, including mechanical parameters, displacement angle parameters, environmental parameters, and operating status parameters. It simultaneously captures instantaneous changes such as load abrupt changes, parameter decay, and abnormal fluctuations. It does not perform data calculations or logical judgments; it only converts on-site physical signals into electrical signals, providing the raw data source for backend data aggregation and failure determination. Specific acquisition content includes: real-time torque, axial preload clamping force, bolt tightening angle, number of loading cycles, test ambient temperature, loading vibration amplitude, and load loading rate. The judgment module retrieves the standardized test data from the data collection module and compares it against national standards and enterprise bolt performance threshold parameters in real time. On one hand, it monitors whether a single parameter exceeds the limit failure threshold in real time; on the other hand, it analyzes the torque attenuation rate, preload reduction, and parameter fluctuation stability. It determines whether the bolt exhibits failure modes such as thread stripping, fatigue fracture, preload relaxation, or plastic deformation. Once a failure condition is triggered, a stop command is immediately issued, recording the failure time, failure cycle count, and corresponding parameters. If no failure is triggered, the judgment continues until the preset durability cycle limit is reached, ultimately outputting a pass / fail judgment conclusion. The data processing module serves as the core relay and computation unit connecting data acquisition and failure determination. It uniformly receives multiple discrete signals transmitted from the acquisition module, classifies and organizes data of different types and sampling frequencies, aligns their timing, filters out invalid and abnormal data caused by jitter noise and electromagnetic interference, and corrects signal deviations; performs numerical conversion, unit standardization, and curve fitting calculations; and simultaneously calculates derived parameters such as torque attenuation amplitude, preload change rate, and angular deformation difference. The standardized data is stored and archived, and simultaneously output to the determination module in a standardized manner, generating characteristic curves such as torque-angle and load-cycle count, thus transforming raw data into usable analytical data. The working principle of the three modules is as follows: During system operation, the data acquisition module, equipped with a torque sensor, preload sensor, photoelectric angle sensor, and signal conditioning circuit, first converts physical parameters such as torque, preload, angle, and ambient temperature into standard electrical signals based on strain, photoelectric, and piezoelectric physical effects. The signals are then sent to the failure judgment module, which has a built-in main control processor and logic operation circuit. The module retrieves the preset performance critical threshold in the storage chip, compares the instantaneous parameter values ​​in real time, and quickly identifies obvious failure conditions such as bolt breakage and overload. Simultaneously, the control unit issues start / stop commands and triggers audible and visual alarms. All raw monitoring data generated in the judgment stage is then transferred to the data processing module, which is equipped with a high-speed acquisition and analysis instrument, embedded computing chip, and solid-state storage components. The module sequentially completes timing calibration, noise filtering, engineering quantity conversion, synchronous calculation of parameter attenuation rate, fitting of mechanical characteristic curves, and finally organizes and summarizes the test indicators and archives them. The three modules work together in the order of acquisition, judgment, and processing, relying on the dedicated hardware components of each module to realize the complete test process of signal acquisition, failure identification, and in-depth data analysis and archiving.

[0018] See Figure 3-5The conductive heating system 2 includes a connecting plate, a connector, and a heat-conducting rod. The bottom end of the connector is connected to the top surface of the connecting plate, and the top end of the heat-conducting rod is connected to the bottom surface of the connecting plate. Both the main board and the sub-board have bolt holes 4 in their middle sections for bolt installation, and slots 5 are also provided at their tops. The shape of the slots 5 matches the shape of the heat-conducting rod. Annular grooves 6 are formed around the bolt holes 4 inside both the main board and the sub-board. A heating resistance wire 7 is installed around the inside of the annular grooves 6. The left side of the heating resistance wire 7... Heat-conducting rods 8 are fixedly connected to both sides of the right side. The top end of the heat-conducting rod 8 and the bottom end of the heat-conducting plug are in contact with each other. The vibration system 3 includes a sealing tube 9. Piston rod 10 is movably sleeved inside both sides of the sealing tube 9. Piston rod 21 is movably sleeved inside the upper middle part of the sealing tube 9. Push plate 12 is fixedly connected to the upper end of piston rod 21. Cylinder is fixedly connected to the outer end of piston rod 10. Rubber coating is fixedly connected to the upper end of push plate 12. The top surface of rubber coating is in contact with the bottom surface of main plate and sub plate. Specifically, regarding the synergistic resonance unit in the durability fatigue testing module, it should be noted that the power supply first needs to be connected to the connector at the upper end of the conductive heating system 2. One end of the power supply is connected to the controller, and the controller is also electrically connected to the cylinder in the vibration system 3 through PLC technology. Therefore, the controller in the synergistic resonance unit can control the start of both ends simultaneously to ensure synchronous simulation of the environment. In addition, the heating resistance wire 7 adopts a wrap-around design, which can effectively transfer heat to the surface of the bolt placement hole 4. The wrap-around design can ensure that the bolt surface is heated evenly, improving the simulation accuracy. At the same time, the heating resistance wire 7 is positioned at the bolt end and the connection with the nut, which can better test the durability of the connection point. Finally, the piston rod 10 moves towards each other, causing the space inside the sealing tube 9 to decrease instantaneously. The compressed air pressure drives the piston rod 11 to move upward, causing the push plate 12 to be pushed out last, vibrating the bottom of the clamping tool 1. This controls the cylinder to move back and forth, allowing the push plate 12 to frequently strike and vibrate the bottom of the clamping tool 1, simulating the impact test of the bolt connection caused by bumps during car driving, further improving the accuracy of the test. It should be noted that the rubber pad on the top surface of the push plate 12 can provide a certain degree of shock absorption, reduce damage to its body, and improve the overall service life of the device.

[0019] refer to Figure 7-8During the bolt torque test, the test value, temperature, and vibration are all linearly related. As the temperature increases and the vibration frequency increases, the torque value decreases linearly. Therefore, the suitable temperature and vibration frequency for the maximum torque value can be obtained. It can also directly understand the service life and actual stability of the bolt during actual vehicle operation, which is convenient for maintenance personnel to carry out effective and targeted high-efficiency maintenance during vehicle maintenance.

[0020] The working principle of the environmental simulation in the bolt torque tester is as follows: The bolt is placed inside the bolt placement hole 4 and clamped by the clamping tool 1. After clamping, the tester body is started to perform torque testing. Then, the power is turned on to drive the heat-conducting rod in the conductive heating system 2 to heat the heating resistance wire 7 through the heat-conducting rod 8, thereby heating the bolt inside the bolt placement hole 4. Then, the cylinder is started separately to periodically move the piston rod 11, which drives the push plate 12 to continuously strike and vibrate the bottom of the clamping tool 1 to perform a vibration test on the bolt. Finally, the controller simultaneously starts the conductive heating system 2 and the vibration system 3 to perform a final simulated test on the bolt. The final data is then transmitted and displayed on the screen.

[0021] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0022] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style of the specification is merely for clarity. Those skilled in the art should regard the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other implementation methods that can be understood by those skilled in the art.

Claims

1. A torque and durability testing system for bolts used in new energy vehicles, characterized in that: include: The clamping module is used to clamp and test the sample bolts. The clamping module includes a clamping tool (1), which includes a main board and a sub-board. The static torque performance testing module includes a torque tester for testing the torque of assembled bolts. The durability fatigue testing module is used to provide environmental simulation effects during bolt testing, thereby improving test accuracy. The durability fatigue testing module includes: Vibration unit, the vibration unit includes a vibration system (3) for providing a vibration environment to the bolts under test, simulating the bumpy environment of a car driving; The heating unit includes a conductive heating system (2) for inserting into the inside of the clamping tool (1) to provide a high-temperature environment for the bolts during testing; The coordinated resonance unit, controlled by a PLC system, is mainly used to perform coordinated testing on bolts that have undergone two separate tests, thereby further improving the testing accuracy. The problem collection unit is mainly divided into three categories, which collect bolt problems under different testing environments to reflect the trends of bolt problems.

2. The torque and durability testing system for bolts used in new energy vehicles according to claim 1, characterized in that: It also includes a data acquisition module, a judgment module, and a comprehensive data processing module.

3. The torque and durability testing system for bolts used in new energy vehicles according to claim 1, characterized in that: The conductive heating system (2) includes a connecting plate, a connector and a heat-conducting plug, the bottom end of the connector and the top surface of the connecting plate are connected to each other, and the top end of the heat-conducting plug and the bottom surface of the connecting plate are connected to each other.

4. The torque and durability testing system for bolts used in new energy vehicles according to claim 1, characterized in that: Both the main board and the sub-board have bolt placement holes (4) in the middle for bolt installation, and slots (5) are also provided at the top of both. The shape of the slots (5) is adapted to the shape of the heat-conducting plug. The outer periphery of the bolt placement holes (4) is provided with annular grooves (6) inside the main board and the sub-board. Heating resistance wires (7) are installed around the inside of the annular grooves (6). Heat-conducting rods (8) are fixedly connected to the left and right sides of the heating resistance wires (7). The top of the heat-conducting rods (8) and the bottom of the heat-conducting plug are in contact with each other.

5. The torque and durability testing system for bolts used in new energy vehicles according to claim 1, characterized in that: The vibration system (3) includes a sealing tube (9), with piston rod one (10) movably sleeved inside both the left and right sides of the sealing tube (9), and piston rod two (11) movably sleeved inside the upper part of the middle of the sealing tube (9). A push plate (12) is fixedly connected to the upper end of piston rod two (11), and a cylinder is fixedly connected to the outer end of piston rod one (10).

6. The torque and durability testing system for bolts used in new energy vehicles according to claim 5, characterized in that: The upper end of the push plate (12) is fixedly connected with a rubber coating, and the top surface of the rubber coating is in contact with the bottom surface of the main plate and the sub-plate.

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