Module tester
By designing the frame, fixtures, and actuators of the modular testing machine, and using adjustable arms and actuators to vector-replicate road load data from the strut module, the problem of inaccurate simulation of vehicle forces and torques in existing testing methods is solved, thus achieving precise strut module testing.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- GM GLOBAL TECHNOLOGY OPERATIONS LLC
- Filing Date
- 2021-05-14
- Publication Date
- 2026-07-21
AI Technical Summary
Existing bench testing methods cannot accurately simulate vehicle forces and torques when testing strut modules, and require the combination of total suspension components or comprehensive load input, resulting in insufficient test accuracy.
A modular testing machine was designed, comprising a frame, fixtures, and actuators, which replicates road load data of a strut module through adjustable lengths and actuator vectors. Multiple adjustable arms and actuators apply loads on six force axes, combined with a controller for precise control.
It enables accurate testing of vehicle forces and moments of the strut module without relying on the main suspension components, providing representative multi-axle vehicle inputs that can closely reproduce vehicle geometry and load behavior.
Smart Images
Figure CN114689428B_ABST
Abstract
Description
[0001] introduction. Technical Field
[0002] This disclosure relates to systems and methods for use with module test machines. Background Technology
[0003] To simplify test setups, current bench testing methods often sacrifice some of the vehicle inputs experienced by the strut module. Two current styles of test benches used for testing strut modules are the quarter-car rig and the linear damper machine. The quarter-car rig utilizes factory suspension components to control the conical motion of the strut module. The quarter-car rig occupies a large floor space to apply forces on more than one axle and implements actuators for each force applied to the tire patch. Body-driven inertial forces are often neglected. The linear damper machine is limited to lateral load mechanisms that apply representative lateral loads or moment loads.
[0004] The desired technology is to construct a modular testing machine for accurately testing strut modules in terms of vehicle forces and moments, without combining the overall suspension components or combined load inputs. Summary of the Invention
[0005] This document provides a modular testing machine. The modular testing machine includes a frame, a fixture, up to two actuators coupled to the fixture, and a controller. The frame is coupled to a first end of a support module. The fixture is coupled to a second end of the support module. The fixture includes multiple arms having multiple adjustable lengths. The up to two actuators are coupled to two of the multiple arms and configured to apply multiple loads along six force axes at the second end of the support module. The controller is configured to control up to two actuators in response to up to two actuator vectors. The multiple adjustable lengths and the up to two actuator vectors are configured to replicate road load data at the second end of the support module during testing.
[0006] In one or more embodiments of the module tester, the fixture includes a first swing arm pivotally coupled to a second swing arm. The first swing arm includes a first arm having a first adjustable length and coupled to a frame, and a second arm having a second adjustable length and coupled to the frame. The second swing arm includes a third arm having a third adjustable length and coupled to a first actuator of up to two actuators, and a fourth arm having a fourth adjustable length and coupled to a second actuator of up to two actuators.
[0007] In one or more embodiments of the module tester, a frame defines an x-axis, a y-axis, and a z-axis. A first arm is connected to the frame at a first offset angle, and this first offset angle is adjustable in the xz plane. A second arm is connected to the frame at a second offset angle, and this second offset angle is adjustable in the xy plane.
[0008] In one or more embodiments of the module tester, a first actuator is coupled to a third arm at a third offset angle, which is adjustable in the xz plane and configured to move the fixture at least along the z-axis. A second actuator is coupled to a fourth arm at a fourth offset angle, which is adjustable in the xy plane and configured to move the fixture at least along the x-axis.
[0009] In one or more embodiments of the module tester, each of the first adjustable length, the second adjustable length, the third adjustable length, the fourth adjustable length, the first offset angle, the second offset angle, the third offset angle, and the fourth offset angle is manually adjustable.
[0010] In one or more embodiments of the module tester, each of the at most two actuators is a single-axis actuator.
[0011] In one or more embodiments of the module tester, the fixture and the at most two actuators are configured to provide a variable motion ratio.
[0012] In one or more embodiments of the module tester, the fixture and the at most two actuators are configured to provide a variable torque arm and torque arm torque ratio.
[0013] In one or more embodiments of the module tester, the module tester is configured to: calculate multiple geometric parameters of the strut module based on multiple geometries of a vehicle configured to incorporate the strut module; determine road load data of the strut module along six force axes; calculate multiple adjustable lengths of multiple arms of a fixture in the module tester based on the multiple geometric parameters; calculate multiple torque parameters based on the road load data; calculate at most two actuator vectors controlling at most two actuators based on the multiple geometric parameters and the multiple torque parameters; adjust the multiple arms to the multiple adjustable lengths; and load the at most two actuator vectors into a controller.
[0014] This document provides a method for configuring a modular test machine. The method includes calculating multiple geometric parameters of the strut module based on multiple geometries of a vehicle configured to incorporate the strut module, determining road load data of the strut module along six force axes, and calculating multiple adjustable lengths of multiple arms of a fixture in the modular test machine based on the multiple geometric parameters. The fixture is coupled to a frame of the modular test machine and up to two actuators. A first end of the strut module is coupled to the frame. A second end of the strut module is coupled to the fixture. The up to two actuators are configured to apply multiple loads along six force axes at the second end of the strut module. The method further includes calculating multiple moment parameters based on the road load data, calculating up to two actuator vectors controlling the up to two actuators based on the multiple geometric parameters and the multiple moment parameters, adjusting the multiple arms to multiple adjustable lengths, and loading the up to two actuator vectors into a controller of the modular test machine. The multiple adjustable lengths and the up to two actuator vectors are configured to replicate the road load data at the second end of the strut module during testing.
[0015] In one or more embodiments, the method further includes calculating a plurality of offset angles of a subset of the plurality of arms relative to the frame, and adjusting the subset of the plurality of arms to the plurality of offset angles.
[0016] In one or more embodiments, the method further includes calculating at most two offset angles of the at most two actuators relative to a subset of the plurality of arms, and adjusting the at most two actuators to the at most two offset angles.
[0017] In one or more embodiments of the method, the calculation of the plurality of geometric parameters includes calculating the conical moment of the camber angle in response to a plurality of vehicle geometries.
[0018] In one or more embodiments of the method, the calculation of the plurality of geometric parameters includes calculating the conical torque of the caster in response to the plurality of geometries of the vehicle.
[0019] In one or more embodiments of the method, the calculation of the plurality of geometric parameters includes calculating wheel offset torque in response to the vehicle's geometry.
[0020] In one or more embodiments of the method, the calculation of the plurality of moment parameters includes calculating the front / rear lateral ratio of the bump in response to road load data.
[0021] In one or more embodiments of the method, the calculation of the plurality of torque parameters includes calculating the bump force / torque ratio in response to road load data.
[0022] In one or more embodiments, the method further includes determining multiple geometries of the vehicle relative to the strut module by measuring the vehicle.
[0023] In one or more embodiments, the method further includes determining multiple geometries of the vehicle relative to the strut module from a simulation model of the vehicle.
[0024] This document provides a modular testing machine. The modular testing machine includes a frame connectable to a first end of a support module, up to two actuators applying multiple loads at a second end of the support module, a first swing arm, a second swing arm, and a controller. The first swing arm has a first arm connected to the frame and having a first adjustable length, and a second arm connected to the frame and having a second adjustable length. The second swing arm is connected to the first swing arm and connectable to the second end of the support module. The second swing arm has a third arm and a fourth arm, the third arm having a third adjustable length connected to the first actuator of the up to two actuators, and the fourth arm having a fourth adjustable length connected to the second actuator of the up to two actuators. The first and second actuators are configured to apply multiple loads along six force axes at the second swing arm. The controller is configured to control the up to two actuators in response to vectors of the up to two actuators. The first, second, third, and fourth adjustable lengths and the up to two actuator vectors are configured to replicate road load data at the second end of the support module during testing.
[0025] This invention provides the following technical solutions:
[0026] 1. A module testing machine, comprising:
[0027] A frame that can be connected to the first end of the support module;
[0028] A clamp that can be connected to the second end of the support module, wherein the clamp includes multiple arms having multiple adjustable lengths;
[0029] Up to two actuators, coupled to two of the plurality of arms, and configured to apply a plurality of loads along six force axes at the second end of the support module; and
[0030] A controller configured to control the up to two actuators in response to up to two actuator vectors, wherein the plurality of adjustable lengths and the up to two actuator vectors are configured to replicate road load data at the second end of the strut module during testing.
[0031] 2. The module testing machine according to technical solution 1, wherein:
[0032] The clamp includes a first swing arm pivotally connected to a second swing arm;
[0033] The first swing arm includes a first arm having a first adjustable length and connected to the frame, and a second arm having a second adjustable length and connected to the frame; and
[0034] The second swing arm includes a third arm having a third adjustable length and connected to a first actuator of the at most two actuators, and a fourth arm having a fourth adjustable length and connected to a second actuator of the at most two actuators.
[0035] 3. The module testing machine according to technical solution 2, wherein:
[0036] The frame defines the x-axis, y-axis, and z-axis;
[0037] The first arm is connected to the frame at a first offset angle;
[0038] The first offset angle is adjustable in the xz plane;
[0039] The second arm is connected to the frame at a second offset angle; and
[0040] The second offset angle is adjustable in the xy plane.
[0041] 4. The module testing machine according to technical solution 3, wherein:
[0042] The first actuator is coupled to the third arm at a third offset angle;
[0043] The third offset angle is adjustable in the xz plane and is configured to move the clamp at least along the z-axis;
[0044] The second actuator is coupled to the fourth arm at a fourth offset angle; and
[0045] The fourth offset angle is adjustable in the xy plane and is configured to move the clamp at least along the x-axis.
[0046] 5. The module testing machine according to technical solution 4, wherein each of the first adjustable length, the second adjustable length, the third adjustable length, the fourth adjustable length, the first offset angle, the second offset angle, the third offset angle, and the fourth offset angle is manually adjustable.
[0047] 6. The module testing machine according to technical solution 1, wherein each of the at most two actuators is a single-axis actuator.
[0048] 7. The module testing machine according to technical solution 1, wherein the fixture and the at most two actuators are configured to provide a variable motion ratio.
[0049] 8. The module testing machine according to technical solution 1, wherein the fixture and the at most two actuators are configured to provide a variable torque arm and a torque arm torque ratio.
[0050] 9. The module testing machine according to technical solution 1, wherein the module testing machine is configured with the following:
[0051] Multiple geometric parameters of the strut module are calculated based on multiple geometries of the vehicle configured to incorporate the strut module.
[0052] Determine the road load data of the support module along the six force axes;
[0053] The multiple adjustable lengths of the multiple arms of the fixture in the module testing machine are calculated based on the multiple geometric parameters.
[0054] Multiple torque parameters are calculated based on the road load data;
[0055] The at most two actuator vectors controlling the at most two actuators are calculated based on the plurality of geometric parameters and the plurality of torque parameters;
[0056] Adjust the plurality of arms to the plurality of adjustable lengths; and
[0057] The at most two actuator vectors are loaded into the controller.
[0058] 10. A method for configuring a module test machine, comprising:
[0059] Multiple geometric parameters of the strut module are calculated based on multiple geometries of the vehicle configured to incorporate the strut module.
[0060] Determine the road load data of the support module along the six force axes;
[0061] The plurality of adjustable lengths of the plurality of arms of the fixture in the module testing machine are calculated based on the plurality of geometric parameters, wherein the fixture is connected to the frame of the module testing machine and at most two actuators, a first end of the support module is connectable to the frame, a second end of the support module is connectable to the fixture, and the at most two actuators are configured to apply a plurality of loads along six force axes at the second end of the support module;
[0062] Multiple torque parameters are calculated based on the road load data;
[0063] The at most two actuator vectors controlling the at most two actuators are calculated based on the plurality of geometric parameters and the plurality of torque parameters;
[0064] Adjust the plurality of arms to the plurality of adjustable lengths; and
[0065] The at most two actuator vectors are loaded into the controller of the module test machine, wherein the plurality of adjustable lengths and the at most two actuator vectors are configured to replicate road load data at the second end of the strut module during testing.
[0066] 11. The method according to technical solution 10 further includes:
[0067] Calculate multiple offset angles of a subset of the plurality of arms relative to the frame; and
[0068] Adjust a subset of the plurality of arms to the plurality of offset angles.
[0069] 12. The method according to technical solution 10 further includes:
[0070] Calculate at most two offset angles of the at most two actuators relative to a subset of the plurality of arms; and
[0071] Adjust the at most two actuators to the at most two offset angles.
[0072] 13. The method according to technical solution 10, wherein the calculation of the plurality of geometric parameters includes:
[0073] In response to the various geometries of the vehicle, the conical moment of the camber angle is calculated.
[0074] 14. The method according to technical solution 10, wherein the calculation of the plurality of geometric parameters includes:
[0075] In response to the various geometries of the vehicle, the conical torque of the caster is calculated.
[0076] 15. The method according to technical solution 10, wherein the calculation of the plurality of geometric parameters includes:
[0077] Calculate wheel offset torque in response to vehicle geometry.
[0078] 16. The method according to technical solution 10, wherein the calculation of the plurality of torque parameters includes:
[0079] Calculate the front / rear lateral ratio of the bump in response to road load data.
[0080] 17. The method according to technical solution 10, wherein the calculation of the plurality of torque parameters includes:
[0081] Calculate the bump force / moment ratio in response to road load data.
[0082] 18. The method according to technical solution 10 further includes:
[0083] The vehicle's geometry relative to the strut module is determined by measuring the vehicle.
[0084] 19. The method according to technical solution 10 further includes:
[0085] The vehicle's geometric structures relative to the strut modules are determined from a simulation model of the vehicle.
[0086] 20. A module testing machine, comprising:
[0087] A frame that can be connected to the first end of the support module;
[0088] Up to two actuators apply multiple loads at the second end of the support module;
[0089] The first swing arm has a first arm with a first adjustable length connected to the frame, and a second arm with a second adjustable length connected to the frame.
[0090] A second swing arm, connected to the first swing arm and connectable to a second end of the support module, has a third arm of a third adjustable length connected to a first actuator of the at most two actuators, and a fourth arm of a fourth adjustable length connected to a second actuator of the at most two actuators, wherein the first and second actuators are configured to apply the plurality of loads along six force axes at the second swing arm; and
[0091] A controller is configured to control the most two actuators in response to at most two actuator vectors, wherein a first adjustable length, a second adjustable length, a third adjustable length, a fourth adjustable length, and the most two actuator vectors are configured to replicate road load data at a second end of the strut module during testing.
[0092] The above features and advantages of this disclosure, as well as other features and advantages, will become apparent from the following detailed description of the best mode for carrying out this disclosure when considered in conjunction with the accompanying drawings. Attached Figure Description
[0093] Figure 1 This is a schematic diagram of the system environment.
[0094] Figure 2 This is a schematic diagram of a module test machine in a system according to one or more exemplary embodiments.
[0095] Figure 3This is a simplified schematic diagram of the mechanism of the test bench in a module tester according to one or more exemplary embodiments.
[0096] Figure 4 It is a flowchart of a parameterized process method for setting up a module test machine according to one or more exemplary embodiments. Detailed Implementation
[0097] Embodiments of this disclosure provide a modular test machine and a parameterization method capable of testing strut modules using in-vehicle conditions and without in conjunction with other components of the vehicle. The modular test machine includes a test bench and a controller. The test bench is configured using the geometry of the vehicle's front axle and front suspension. The controller is programmed with road load data and / or standard test datasets taken from the vehicle. The parameterization method for configuring the modular test machine enables it to apply forces to the strut module under test to provide representative multi-axle vehicle inputs. The modular test machine is also configured to measure the output response of the strut module during testing.
[0098] This parametric method generates a parametric dataset determined by measurements taken from the vehicle and / or extracted from a computerized simulation model of the vehicle. The test bench can be adjustable to match the parametric dataset and closely reproduce vehicle geometry and compliance. The modular test machine uses two single-axis actuators and two geometrically adjustable swing arms to accurately reproduce in-vehicle load behavior in six degrees of freedom. The modular test machine's adjustability provides variable motion ratios and independent variable torque arms and torque arm motion ratios.
[0099] refer to Figure 1 The diagram illustrates a schematic of the environment of system 70. System 70 typically includes a vehicle and / or vehicle model 80 and a module testing machine 100. The vehicle / model 80 defines wheels 82 and a chassis 84. A strut module 90 is mounted between the wheels 82 and the chassis 84. A first end 92 of the strut module 90 is typically attached to the chassis 84. A second end 94 of the strut module 90 is typically attached to an axle near the wheels 82. The module testing machine 100 includes a test bench 102. The strut module 90 may be mounted in the test bench 102 during one or more tests.
[0100] The parameter dataset and road load data experienced by strut module 90 can be transmitted to module test machine 100 in a parameter signal (e.g., PAR). Parameters typically include vehicle geometry and road load data. Vehicle geometry can be measured from the front axle and front suspension of an actual vehicle 80 utilizing strut module 90 and / or from a computer model of vehicle 80. Road load data can be measured from an actual vehicle 80 and / or obtained from a standard dataset. For example, road load data can be Road Load Data Acquisition (RLDA) load data for tire patching and / or Virtual Road Load Data Acquisition (VRLDA) load data. When mounted in test bench 102, module test machine 100 can replicate the road load data at strut module 90.
[0101] Vehicle 80 can be implemented as a moving object or a simulated model of a moving object. In various embodiments, vehicle 80 can be, but is not limited to, moving objects such as cars, trucks, motorcycles, boats, trains, and / or aircraft. Other types of vehicle 80 can be implemented to meet design criteria for specific applications. The geometry of vehicle 80 and road load data applied to strut module 90 when vehicle 80 is in motion can be recorded and / or simulated, and subsequently transmitted to module test machine 100 in parameter signal PAR.
[0102] Wheel 82 may be implemented as a road wheel or a simulated model of a road wheel. Wheel 82 is generally operable to provide input loads to strut module 90. In the case of being implemented as a real road wheel, wheel 82 generally provides movement of vehicle 80 around the ground. In various embodiments, wheel 82 may include tires mounted on a rim.
[0103] The chassis 84 can be implemented as the load-bearing frame of the vehicle 80. In various embodiments, the chassis 84 includes the front axle and front suspension of the vehicle 80, or a simulated model of the front axle and front suspension. The chassis 84 is generally operable to provide support for the first end 92 of the strut module 90.
[0104] The strut module 90 can be implemented as an automotive suspension component providing spring and damper units. The strut module 90 typically operates as a suspension mount for the upper steering pivot and wheel 82. In various embodiments, the strut module 90 can be a MacPherson strut module. Other types of damper modules can be implemented to meet design criteria for specific applications.
[0105] The first end 92 of the support module 90 can be implemented as an upper support plate. The first end 92 is operable to provide a steering pivot point for attachment to the chassis 84 or the test bench 102.
[0106] The second end 94 of the strut module 90 can be implemented as an undermount assembly. The second end 94 is operatively attached to the suspension steering knuckle of the wheel 82 or a movable clamp in the test bench 102.
[0107] The modular tester 100 can be implemented as a test component suitable for testing the strut module 90. The modular tester 100 can be parameterized using the geometry of the vehicle 80 and measured / simulated road load data received in the parameter signal PAR. The modular tester 100 can replicate road load data at the second end 94 of the strut module 90 while it is under test, utilizing the geometry and parameters. Testing typically loads the strut module 90 with six degrees of freedom.
[0108] Test bench 102 is implemented as an automotive test bench, lacking the actual vehicle 80 surrounding the strut module 90. Test bench 102 is operable to support the strut module 90 during testing and drive the strut module 90 on six degrees of freedom axes.
[0109] refer to Figure 2 A schematic diagram of an example embodiment of a module testing machine 100 is shown, according to one or more exemplary embodiments. The module testing machine 100 includes a test bench 102 and a controller 104. The test bench 102 typically includes a frame 106, a fixture 108, and two actuators 110 and 112. The fixture 108 is directly coupled to the frame 106 at multiple adjustable positions. A first actuator 110 and a second actuator 112 are coupled between the fixture 108 and the frame 106. During testing, a support module 90 under test is positioned between the frame 106 and the fixture 108.
[0110] The parameter signal PAR can be received by the controller 104. A first actuator signal (e.g., A1) can be generated by the controller 104 and transmitted to the first actuator 110. A second actuator signal (e.g., A2) can also be generated by the controller 104 and transmitted to the second actuator 112. Actuator signals A1 and A2 typically convey actuator vectors used to control the movement of the gripper 108. Sensor signals (e.g., SEN) can be generated by one or more sensors in the module tester 100 and received by the controller 104. The sensor signal SEN can convey sensor data collected from the support module 90 during testing.
[0111] Test bench 102 may include a first actuator 110, a second actuator 112, and one or more sensors. In various embodiments, additional actuators may be included to provide other motions, such as steering motions. Sensors measure the strut module 90 during testing. Sensors are operable to measure the response of the strut module 90. These responses may be transmitted to controller 104 in sensor signals SEN.
[0112] The controller 104 is implemented as one or more computers. The controller 104 is operable to control the test applied to the strut module 90 and record the performance of the strut module 90 based on data in the sensor signal SEN. Control of the test is accomplished by presenting commands to the first actuator 110 and the second actuator 112 in response to the actuator vector set loaded into the controller 104. The multiple adjustable arm lengths of the clamp 108 and the actuator vectors are configured to replicate road load data at the second end 94 of the strut module 90 during the test.
[0113] Frame 106 can be implemented as a support structure. Frame 106 is operable to support the first end 92 of the support module 90, the multiple arms of the clamp 108, the first actuator 110, the second actuator 112, and the sensor.
[0114] The clamp 108 may be implemented as a two-part assembly that can be coupled to the support module 90 during testing. The clamp 108 is operable to apply loads along six axes of the support module 90 in response to forces applied relative to the frame 106 by at most the first actuator 110 and the second actuator 112. The clamp 108 typically includes multiple (e.g., four) arms. The arms typically have variable lengths. Some arms may be directly coupled to the frame 106. Other arms may be coupled to the first actuator 110 and the second actuator 112.
[0115] The first actuator 110 is implemented as a single-axis actuator. The first actuator 110 is operable to apply a first force to the clamp 108. The first force is controlled by a first actuator signal A1. The first actuator 110 is disposed between the arm of the clamp 108 and the frame 106.
[0116] The second actuator 112 is also implemented as a single-axis actuator. The second actuator 112 is operable to apply a second force to the clamp 108 independently of the first force. The second force is controlled by the second actuator signal A2. The second actuator 112 is disposed between the other arm of the clamp 108 and the frame 106.
[0117] refer to Figure 3 A simplified schematic diagram of an example embodiment of the mechanism of test bench 102 is shown according to one or more exemplary embodiments. Frame 106 may include a rigid base 126 and a ground plane 128. Clamp 108 may include a first swing arm 130, a second swing arm 140, and a ball joint 150. The first swing arm 130 may include a first arm 132, a second arm 134, and a first component 136. The second swing arm 140 may include a third arm 142, a fourth arm 144, and a second component 146. The first component 136 is connected to the second component 146 via the ball joint 150. A support module 90 may be mounted between the rigid base 126 of frame 106 and the second component 146 of clamp 108.
[0118] The movement of the second end 94 of the support module 90 within the test bench 102 can be defined along three axes. These three axes of motion can be defined by Cartesian coordinates, with the origin at the second end 94. The Cartesian coordinates have an x-axis defining the first axis of motion 120, a y-axis defining the second axis of motion 122, and a z-axis defining the third axis of motion 124. The x, y, and z axes can be orthogonal to each other. The load applied to the second end 94 of the support module 90 within the test bench 102 can be defined along six axes. Three force axes can be defined by Cartesian coordinates, with the origin at the second end 94. These Cartesian coordinates have an x-axis defining the first force Fx axis, a y-axis defining the second force Fy axis, and a z-axis defining the third force Fz axis. The x, y, and z axes can be orthogonal to each other. A fourth force axis can be a rotational torque Mx about the x-axis. A fifth force axis can be a rotational torque My about the y-axis. A sixth force axis can be a rotational torque Mz about the z-axis. The xy plane is defined by the x and y axes. The x-axis and z-axis define the xz plane. The yz plane is defined by the y-axis and z-axis.
[0119] The first swing arm 130 may be implemented as a first link connecting the ground plane 128 to the moving part of the clamp 108. The first swing arm 130 includes a first arm 132 connected to the first part 136 and a second arm 134 connected to the first part 136.
[0120] The first arm 132 is coupled to the ground plane 128 via a ball joint and a connection to the first component 136. In various embodiments, this connection may be another ball joint or bushing. In some embodiments, the connection may be a rigid connection. The first arm 132 has a manually adjustable first length L1. A first offset angle in the xz plane... Created between the first arm 132 and the ground plane 128. First offset angle. The angle can be adjusted manually or automatically within a range of approximately 10 to 80 degrees.
[0121] The second arm 134 is coupled to the ground plane 128 via a ball joint and a connection to the first component 136. In some embodiments, this connection may be another ball joint or bushing. In other embodiments, the connection may be a rigid connection. The second arm 134 has a manually adjustable second length L2. A second offset angle in the xy plane... Created between the second arm 134 and the ground plane 128. Second offset angle. The angle can be adjusted manually or automatically within a range of approximately 10 to 80 degrees.
[0122] The second control arm 140 may be implemented as a second link that connects the first actuator 110 and the second actuator 112 to a moving part of the clamp 108. The second control arm 140 is controlled to act as a suspension steering knuckle of the vehicle 80. The second control arm 140 typically includes a third arm 142 connected to the second part 146 and a fourth arm 144 connected to the second part 146.
[0123] The third arm 142 is rigidly connected to the second component 146 and pivotally connected to one end of the first actuator 110 via a ball joint. The third arm 142 has a manually adjustable third length L3 and a third offset angle in the xy-plane. Created between the third arm 142 and the first actuator 110. Third offset angle. The angle can be adjusted manually or automatically within a range of approximately 10 degrees to 170 degrees.
[0124] The fourth arm 144 of the second swing arm 140 is rigidly connected at one end to the second component 146 and pivotally connected to one end of the second actuator 112 via a ball joint. The fourth arm 144 has a manually adjustable fourth length L4. A fourth offset angle in the xz plane... Created between the fourth arm 144 and the second actuator 112. Fourth offset angle. It can be adjusted manually or automatically within an angle range of approximately 10 degrees to 170 degrees.
[0125] The first actuator 110 is pivotally connected to the third arm 142 and pivotally connected to the frame 106. The second actuator 112 is pivotally connected to the fourth arm 144 and pivotally connected to the frame 106.
[0126] Two separate adjustable lengths L1 and L2 and two adjustable arm offset angles along the ground plane 128 and Approximate single and multiple lower control arms are typically allowed for various types of vehicles. This includes arm lengths L3 and L4, and two adjustable actuator offset angles. and The adjustment allows the forces applied by the first actuator 110 and the second actuator 112 to closely approximate one or more riding events. In various embodiments, the first actuator 110 and the second actuator 112 may be pivotally coupled to the frame 106 to align the input force with measured road load data received in the parameter signal PAR. In some embodiments, the road load data may be road load data measured from a vehicle or vehicle model or virtual road load data.
[0127] refer to Figure 4A flowchart of an example parameterization process method 160 for setting up a module test machine 100 according to one or more exemplary embodiments is shown. Method (or process) 160 may be implemented by system 70. Method 160 typically includes steps 162, 164, 166, 168, 170, 172, 174, 176, 178, and 180. Step 166 may include steps 182, 184, and 186. Step 168 may include steps 188 and 190. Step 170 may include steps 192 and 194. Step 172 may include steps 196 and 198. Step 174 may include steps 200 and 202. The sequence of steps is shown as a representative example. Other step sequences may be implemented to meet application-specific criteria.
[0128] In step 162, the geometry of vehicle 80 relative to strut module 90 can be measured and / or extracted from the simulation model. The geometry may include, but is not limited to, control arm length, static angle, kingpin size, and wheel center. The vehicle geometry data can be provided to step 166. In step 164, six-axle road load data applied to strut module 90 when mounted in vehicle 80 can optionally be measured. Alternatively, the road load data can be obtained from a simulation using a standard input model. The road load data can be provided to step 168.
[0129] Step 166 may calculate the geometric parameters of the strut module 90 based on the vehicle geometry data received from step 162. The calculation of the geometric parameters may include calculating the conical moment of the camber angle data in step 182, calculating the conical moment of the caster data in step 184, and calculating the wheel offset moment data in step 186. The conical moment of the camber angle data and the conical moment of the caster data may be provided to step 170. The wheel offset moment data may be provided to steps 170, 172, and 174.
[0130] In step 168, moment parameters can be calculated based on the road load data received from step 164. The calculation of moment parameters may include the front-to-back / lateral ratio data of the bump calculated in step 188, and the force / moment ratio data of the bump calculated in step 190. The moment parameters can be provided to steps 172 and 174.
[0131] In step 170, geometric data for the first swing arm 130 and the second swing arm 140 can be calculated based on the geometric parameters received from step 166. The swing arm geometric data can be presented to step 176. The calculation of the geometric data may include, in step 192, calculating first geometric data for the first swing arm 130 based on the conical torque from the camber angle data from step 182 and the conical torque from the caster data from step 184. The first geometric data may include a first arm length L1, a second arm length L2, and a first offset angle. Second offset angle The calculation of geometric data may further include, in step 194, calculating second geometric data for the second swing arm 140 based on the wheel offset torque data from step 186. The second geometric data may include the third arm length L3 and the fourth arm length L4. This geometric data may be presented to step 176.
[0132] In step 172, the actuator offset vectors of the first actuator 110 and the second actuator 112 can be calculated based on the geometric parameters from step 166 and the torque parameters from step 168. The first actuator vector data of the first actuator 110 can be calculated in step 196 based on the wheel offset torque data from step 186. The second actuator vector data of the second actuator 112 can be calculated in step 198 based on the front-to-rear / lateral ratio data of the bump received from step 188. The actuator vector data can be presented to step 178.
[0133] In step 174, the third offset angle of the first actuator 110 can be calculated based on the geometric parameters from step 166 and the torque parameters from step 168. The fourth offset angle of the second actuator 112 Third offset angle The fourth offset angle can be calculated in step 200 based on the wheel offset torque data from step 186 and the bump force / torque ratio data from step 190. The actuator offset angle can be calculated in step 202 based on the bump front-to-back / lateral ratio data from step 188 and the bump force / torque ratio data from step 190. and This can be presented to step 180.
[0134] In step 176, the arm lengths L1, L2, L3, and L4 can be adjusted to the calculated lengths. This adjustment can be accomplished manually and / or automatically by adjusting the clamps in the corresponding arms 132, 134, 142, and 144. Other mechanisms for adjusting the arm lengths can be implemented to meet design criteria for specific applications.
[0135] In step 178, the actuator vector can be loaded into the controller 104. In various embodiments, the actuator vector can be included in the parameters received by the controller 104 in the parameter signal PAR. In other embodiments, the actuator vector can be calculated based on a standard load curve and subsequently loaded into the controller 104.
[0136] In step 180, the arm offset angle can be set in the test bench 102. and and actuator offset angle and In various embodiments, the offset angle , , and The positions of the first arm 132, the second arm 134, the first actuator 110, and the second actuator 112 connected to the frame 106 can be manually adjusted. The arm lengths L1, L2, L3, and L4 are already set, and the offset angles are... , , and After the actuator vectors have been set up, loaded into the controller 104, and the support module 90 has been installed in the test bench 102, the controller 104 can execute the actuator vectors to test the support module 90. During testing, control of the fixture 108 on the six axes can be accomplished by at most two actuators (e.g., first actuator 10 and second actuator 12) for every two actuator vectors in the first actuator signal A1 and the second actuator signal A2. Test data collected during testing can be presented to and stored in the controller 104.
[0137] Embodiments of System 70 typically include a module tester 100 that uses up to two single-axis actuators 110 and 112 and two geometrically adjustable swing arms 130 and 140 to reproduce six-axis strut module input loads. System 70 may include a method that converts the six force axes of strut module input loads from vehicle data and / or simulations into a parametric dataset that the module tester 100 can use to test one or more strut modules 90. The strut module test bench / parametric method can test the strut module 90 using in-vehicle conditions without any other components of the vehicle 80.
[0138] While the best mode of implementing this disclosure has been described in detail, those skilled in the art to which this disclosure pertains will recognize various alternative designs and embodiments for practicing this disclosure within the scope of the appended claims.
Claims
1. A module testing machine, comprising: A frame that can be connected to the first end of the support module; A clamp that can be connected to the second end of the support module, wherein the clamp includes multiple arms having multiple adjustable lengths; Up to two actuators, coupled to two of the plurality of arms, and configured to apply a plurality of loads along six force axes at the second end of the support module; and A controller configured to control the up to two actuators in response to up to two actuator vectors, wherein the plurality of adjustable lengths and the up to two actuator vectors are configured to replicate road load data at the second end of the strut module during testing; The clamp includes a first swing arm pivotally connected to a second swing arm; The first swing arm includes a first arm having a first adjustable length and connected to the frame, and a second arm having a second adjustable length and connected to the frame, and has a first component, wherein the first arm and the second arm are connected to a ground plane via a ball joint and a connection to the first component; and The second swing arm includes a third arm having a third adjustable length and coupled to a first actuator of the at most two actuators, and a fourth arm having a fourth adjustable length and coupled to a second actuator of the at most two actuators, and has a second component that couples the first and second actuators to a moving component of the clamp, the first and second actuators being pivotally coupled to the frame to align the input force with measured road load data received in the parameter signal PAR.
2. The module testing machine according to claim 1, wherein: The frame defines the x-axis, y-axis, and z-axis; The first arm is connected to the frame at a first offset angle; The first offset angle is adjustable in the xz plane; The second arm is connected to the frame at a second offset angle; and The second offset angle is adjustable in the xy plane.
3. The module testing machine according to claim 2, wherein: The first actuator is coupled to the third arm at a third offset angle; The third offset angle is adjustable in the xz plane and is configured to move the clamp at least along the z-axis; The second actuator is coupled to the fourth arm at a fourth offset angle; and The fourth offset angle is adjustable in the xy plane and is configured to move the clamp at least along the x-axis.
4. The module testing machine according to claim 3, wherein, Each of the first adjustable length, the second adjustable length, the third adjustable length, the fourth adjustable length, the first offset angle, the second offset angle, the third offset angle, and the fourth offset angle is manually adjustable.
5. The module testing machine according to claim 1, wherein, Each of the at most two actuators is a single-axis actuator.
6. The module testing machine according to claim 1, wherein, The clamp and the at most two actuators are configured to provide a variable motion ratio.
7. The module testing machine according to claim 1, wherein, The clamp and the at most two actuators are configured to provide a variable torque arm and torque arm torque ratio.
8. The module testing machine according to claim 1, wherein, The module testing machine is configured with the following features: Multiple geometric parameters of the strut module are calculated based on multiple geometries of the vehicle configured to incorporate the strut module. Determine the road load data of the support module along the six force axes; The multiple adjustable lengths of the multiple arms of the fixture in the module testing machine are calculated based on the multiple geometric parameters. Multiple torque parameters are calculated based on the road load data; The at most two actuator vectors controlling the at most two actuators are calculated based on the plurality of geometric parameters and the plurality of torque parameters; Adjust the plurality of arms to the plurality of adjustable lengths; as well as The at most two actuator vectors are loaded into the controller.
9. A method for configuring a module test machine, comprising: Multiple geometric parameters of the strut module are calculated based on multiple geometries of the vehicle configured to incorporate the strut module. Determine the road load data of the support module along the six force axes; The plurality of adjustable lengths of the plurality of arms of the fixture in the module testing machine are calculated based on the plurality of geometric parameters, wherein the fixture is connected to the frame of the module testing machine and at most two actuators, a first end of the support module is connectable to the frame, a second end of the support module is connectable to the fixture, and the at most two actuators are configured to apply a plurality of loads along six force axes at the second end of the support module; Multiple torque parameters are calculated based on the road load data; The at most two actuator vectors controlling the at most two actuators are calculated based on the plurality of geometric parameters and the plurality of torque parameters; Adjust the plurality of arms to the plurality of adjustable lengths; and The at most two actuator vectors are loaded into the controller of the module test machine, wherein the plurality of adjustable lengths and the at most two actuator vectors are configured to replicate road load data at the second end of the strut module during testing; The clamp includes a first swing arm pivotally connected to the second swing arm; The first swing arm includes a first arm having a first adjustable length and connected to the frame, and a second arm having a second adjustable length and connected to the frame, and has a first component, wherein the first arm and the second arm are connected to a ground plane via a ball joint and a connection to the first component; and The second swing arm includes a third arm having a third adjustable length and coupled to a first actuator of the at most two actuators, and a fourth arm having a fourth adjustable length and coupled to a second actuator of the at most two actuators, and has a second component that couples the first and second actuators to a moving component of the clamp, the first and second actuators being pivotally coupled to the frame to align the input force with measured road load data received in the parameter signal PAR.
10. The method of claim 9, further comprising: Calculate multiple offset angles of a subset of the plurality of arms relative to the frame; and Adjust a subset of the plurality of arms to the plurality of offset angles.
11. The method of claim 9, further comprising: Calculate at most two offset angles of the at most two actuators relative to a subset of the plurality of arms; as well as Adjust the at most two actuators to the at most two offset angles.
12. The method according to claim 9, wherein, The calculation of the plurality of geometric parameters includes: In response to the various geometries of the vehicle, the conical moment of the camber angle is calculated.
13. The method according to claim 9, wherein, The calculation of the plurality of geometric parameters includes: In response to the various geometries of the vehicle, the conical torque of the caster is calculated.
14. The method according to claim 9, wherein, The calculation of the plurality of geometric parameters includes: Calculate wheel offset torque in response to vehicle geometry.
15. The method according to claim 9, wherein, The calculation of the plurality of torque parameters includes: Calculate the front / rear lateral ratio of the bump in response to road load data.
16. The method according to claim 9, wherein, The calculation of the plurality of torque parameters includes: Calculate the bump force / moment ratio in response to road load data.
17. The method of claim 9, further comprising: The vehicle's geometry relative to the strut module is determined by measuring the vehicle.
18. The method of claim 9, further comprising: The vehicle's geometric structures relative to the strut modules are determined from a simulation model of the vehicle.
19. A module testing machine, comprising: A frame that can be connected to the first end of the support module; Up to two actuators apply multiple loads at the second end of the support module; A first swing arm has a first arm with a first adjustable length connected to a frame, and a second arm with a second adjustable length connected to a frame, and has a first component, wherein the first arm and the second arm are connected to a ground plane via a ball joint and through a connection to the first component; A second swing arm, pivotally connected to the first swing arm and connectable to a second end of the support module, has a third arm of a third adjustable length connected to the first actuator of the at most two actuators, and a fourth arm of a fourth adjustable length connected to the second actuator of the at most two actuators. The second swing arm also has a second component that connects the first and second actuators to a moving component of the clamp. The first and second actuators are pivotally connected to the frame to align the input force with measured road load data received in the parameter signal PAR. The first actuator and the second actuator are configured to apply the plurality of loads along six force axes at the second swing arm; and A controller is configured to control the most two actuators in response to at most two actuator vectors, wherein a first adjustable length, a second adjustable length, a third adjustable length, a fourth adjustable length, and the most two actuator vectors are configured to replicate road load data at a second end of the strut module during testing.