A battery valve support strength endurance performance prediction method based on simulation analysis

Abstract

This invention discloses a simulation-based method for predicting the strength and durability performance of a battery valve bracket, belonging to the field of battery valve bracket performance testing technology. The method includes: establishing a finite element model and assembly model; defining contacts; defining the materials of the finite element model; defining boundaries; applying bolt axial force loads; applying cylinder oil passage working hydraulic loads; coupling inertial force loads in various directions; solving the finite element model using ABAQUS software; and calculating the static strength safety factor and fatigue strength safety factor of the battery valve bracket using Femfat software. Based on the safety factors of the battery valve bracket, it is determined whether its structure meets the strength and durability requirements, and the rubber sealing performance is determined based on the rubber contact pressure and slippage. This method improves simulation accuracy by using refined modeling, considering the rubber elastic modulus, the clearance fit between the battery valve and the cylinder, the hydraulic loading method, and coupling the working hydraulic pressure and inertial loads. It also effectively avoids repetitive work caused by low-level errors or incomplete consideration of influencing factors.

Description

Technical Field

[0001] This invention belongs to the field of battery valve bracket performance testing technology, specifically relating to a method for predicting the strength and durability performance of battery valve brackets based on simulation analysis. Background Technology

[0002] Solenoid valves, as automated actuators for controlling fluids, are widely used in industrial control systems to adjust parameters such as the direction and flow rate of the medium. Engines commonly use solenoid valves to control the supply and return of oil in the oil passages to ensure the normal and safe operation of the engine. Solenoid valves are generally mounted to the engine via integrated brackets. The strength and durability of the brackets directly affect the lifespan of the solenoid valve. Under certain extreme operating conditions, if the bracket breaks, it will directly cause the solenoid valve to fail during operation, leading to the risk of oil leakage or even engine shutdown. Therefore, a simulation analysis method is needed to predict the strength and durability performance of the solenoid valve and determine the strength and durability performance of the bracket in advance.

[0003] The strength and durability of the battery valve bracket directly affect whether the battery valve can work safely. The verification of the battery valve bracket is usually divided into test verification and simulation verification.

[0004] The testing and verification process involves conducting component-level strength and durability tests according to relevant testing standards. The battery valve bracket is fixed on a test bench, and the test is carried out according to established standards. The bracket is deemed to meet the strength and durability requirements based on the absence of cracks or other defects after the test. However, in the early stages of product development, the test bench conditions could not fully replicate the vehicle's condition, and the testing cycle was too long, which could not meet the needs of rapid development.

[0005] Simulation verification: Current simulation analysis methods suffer from many problems affecting simulation accuracy, such as insufficient modeling accuracy, inaccurate simulation of battery valve-cylinder contact, inaccurate simulation of rubber state and elastic modulus, and incomplete definition of working conditions. Low-precision simulation cannot provide quantitative guidance for product design, but can only give a general trend, and cannot meet the effective iteration needs of product design. Summary of the Invention

[0006] To overcome the shortcomings of existing methods for testing the strength and durability of battery valve brackets, this invention provides a method for predicting the strength and durability of battery valve brackets based on simulation analysis. This prediction method relies on finite element analysis for fast and accurate calculations, and can predict the strength and durability of the brackets in the early stages of structural design, thus saving product development and testing costs.

[0007] This invention is achieved through the following technical solution:

[0008] A method for predicting the strength and durability performance of a battery valve bracket based on simulation analysis includes the following steps:

[0009] S1. Establish a finite element model through a geometric model, and analyze and determine the dangerous stress location of the battery valve bracket before modeling.

[0010] S2. Assemble the model according to the actual structural installation method;

[0011] S3, Define the contact, specifically including:

[0012] The rubber, battery valve, and cylinder are assembled using a geometric interference fit, and the outer edge of the battery valve in the sealing area is defined as having clearance contact with the cylinder.

[0013] The initial geometric position of the rubber ring is interference-fitted by defining finite sliding contact, and the contact type is set to surface to surface; the clearance fit between the solenoid valve and the cylinder is achieved by defining clearance.

[0014] S4. Define the materials of the finite element model, and define the elastic modulus E, Poisson's ratio μ and density ρ of the finite element model materials of each component.

[0015] S5. Define the boundary, constrain the cylinder block X-axis tangent plane in directions 1 and 2, constrain the cylinder block Y-axis tangent plane in directions 2 and 3, and constrain the cylinder block Z-axis tangent plane in directions 1 and 3.

[0016] S6. Apply bolt axial load, the axial force is calculated from the bolt torque using an empirical formula;

[0017] S7. Apply hydraulic load to the cylinder block oil passage. The hydraulic loading method is simulated by applying a concentrated force on the equivalent force section of the battery valve.

[0018] The equivalent stress section is defined as: the area of ​​maximum oil pressure action intercepted on the projection of the main view along the axis of the battery valve as the equivalent stress section;

[0019] S8. Couple the inertial force loads in all directions. The maximum hydraulic load is coupled in the same direction as the lateral, longitudinal, and vertical directions that cause the battery valve bracket to deform, and the minimum hydraulic load is coupled in the opposite direction to the lateral, longitudinal, and vertical directions that cause the battery valve bracket to deform.

[0020] S9. Use ABAQUS software to solve the finite element model, and use Newton's method to perform nonlinear statics solution to calculate and analyze the stress, strain, contact pressure and slip of the part.

[0021] S10. The static strength safety factor and fatigue strength safety factor of the battery valve bracket are calculated using Femfat software.

[0022] S11. Based on the safety factor of the battery valve bracket obtained in step S10, determine whether its structure meets the strength and durability requirements. Based on the rubber contact pressure and slippage obtained in step S9, determine the rubber sealing performance.

[0023] Furthermore, in step S1, the dangerous location area is modeled with a 0.5mm hexahedral mesh for fine detailing, ensuring that the mesh is uniform and has a regular shape.

[0024] Furthermore, in step S1, the size of the rubber mesh is greater than or equal to 1 mm, and a single hexahedral hybrid unit is used for simulation. If there are sharp geometric features, they are equivalent to a width of 0.5 mm. The size of the rubber groove and the rubber should be consistent.

[0025] Furthermore, the dangerous locations mentioned in step S1 are located around the support fixing point, at the root of the reinforcing rib, or at the bend and chamfer.

[0026] Furthermore, the assembly model components in step S2 include: a battery valve, a battery valve bracket, a cut-off cylinder body, sealing rubber, and solid bolts.

[0027] Further, step S2 specifically includes the following: the sealing rubber is in an uncompressed state, the model interferes with the solenoid valve and cylinder; the solid bolt engagement area is simulated using rigid elements, wherein the top and bottom rigid elements of the engagement area are constrained in 3 directions, the remaining rigid elements are constrained in 1 to 3 directions, and all nodes of the engagement area are constrained in 4 to 6 directions.

[0028] Furthermore, the elastic modulus of the rubber in step S4 is calculated using the following formula:

[0029]

[0030] In the formula, E EPDM d2 is the elastic modulus of the rubber; K1 is the elastic modulus correction factor, which is taken as 0.9-1.2; d2 is the outer diameter of the rubber ring; d1 is the inner diameter of the rubber ring; h is the rubber thickness; and HS is the rubber hardness.

[0031] Furthermore, in step S7, the maximum hydraulic load is in the battery valve open state, and the maximum value is obtained by the following formula.

[0032]

[0033] In the formula, F MAX For minimum hydraulic load; p MAX Minimum oil pressure; R MAX The minimum effective radius at which the most hydraulic pressure acts on the solenoid valve;

[0034] The minimum load for hydraulic pressure is when the solenoid valve is closed, and the minimum value is obtained by the following formula.

[0035]

[0036] In the formula, F MINFor minimum hydraulic load; p MIN Minimum oil pressure; R MIN The minimum effective radius at which the most hydraulic pressure acts on the battery valve.

[0037] Compared with the prior art, the advantages of the present invention are as follows:

[0038] The present invention provides a method for predicting the strength and durability of a battery valve bracket based on simulation analysis. By employing methods such as refined modeling, consideration of rubber elastic modulus, clearance fit between the battery valve and cylinder, hydraulic loading method, and coupling of working hydraulic pressure and inertial load, the simulation accuracy is greatly improved and more consistent with reality. At the same time, it can effectively avoid repetitive work caused by low-level errors or incomplete consideration of influencing factors. Attached Figure Description

[0039] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the accompanying drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, the elements or parts are not necessarily drawn to scale.

[0040] Figure 1 This is a flowchart illustrating a method for predicting the strength and durability performance of a battery valve bracket based on simulation analysis, according to the present invention. Detailed Implementation

[0041] To clearly and completely describe the technical solution and its specific working process of the present invention, the specific embodiments of the present invention are as follows, in conjunction with the accompanying drawings:

[0042] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0043] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0044] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0045] Example 1

[0046] This embodiment provides a method for predicting the strength and durability performance of a battery valve bracket based on simulation analysis, specifically including the following steps:

[0047] S1. Import the geometric model for finite element modeling. Before modeling, analyze and determine the critical stress location of the support. For the critical location area, use a 0.5mm hexahedral mesh for fine modeling and ensure that the mesh is uniform and regular in shape.

[0048] S2. Assemble the model according to the actual structural installation method;

[0049] S3, Define the contact, specifically including:

[0050] The rubber, battery valve, and cylinder are assembled using a geometric interference fit, and the outer edge of the battery valve in the sealing area is defined as having clearance contact with the cylinder.

[0051] The initial geometric position of the rubber ring is interference-fitted by defining finite sliding contact, and the contact type is set to surface to surface; the clearance fit between the solenoid valve and the cylinder is achieved by defining clearance.

[0052] S4. Define the materials of the finite element model, and define the elastic modulus E, Poisson's ratio μ and density ρ of the finite element model materials of each component.

[0053] S5. Define the boundary, constrain the cylinder block X-axis tangent plane in directions 1 and 2, constrain the cylinder block Y-axis tangent plane in directions 2 and 3, and constrain the cylinder block Z-axis tangent plane in directions 1 and 3.

[0054] S6. Apply bolt axial load, the axial force is calculated from the bolt torque using an empirical formula;

[0055] S7. Apply working hydraulic load to the cylinder block oil passage. The hydraulic loading method is simulated by applying a concentrated force on the equivalent stress section of the battery valve. The equivalent stress section is defined as: the maximum range of hydraulic pressure applied on the projection along the axis of the battery valve in the main view.

[0056] S8. Couple the inertial force loads in all directions. The maximum hydraulic load is coupled in the same direction as the lateral, longitudinal, and vertical directions that cause the battery valve bracket to deform, and the minimum hydraulic load is coupled in the opposite direction to the lateral, longitudinal, and vertical directions that cause the battery valve bracket to deform.

[0057] S9. Use ABAQUS software to solve the finite element model, and use Newton's method to perform nonlinear statics solution to calculate and analyze the stress, strain, contact pressure and slip of the part.

[0058] S10. The static strength safety factor and fatigue strength safety factor of the battery valve bracket are calculated using Femfat software.

[0059] S11. Based on the safety factor of the battery valve bracket obtained in step S10, determine whether its structure meets the strength and durability requirements. Based on the rubber contact pressure and slippage obtained in step S9, determine the rubber sealing performance.

[0060] Example 2

[0061] like Figure 1 The diagram shown is a flowchart illustrating a method for predicting the strength and durability of a battery valve bracket based on simulation analysis, according to this embodiment. The prediction method includes the following steps:

[0062] S1. Import the geometric model for finite element modeling. The main dangerous position of the support is determined to be the chamfer position of the bolt flange face pressing. This area is modeled with a 0.5mm uniform regular hexahedral mesh. The rubber is simulated with a 1mm single hexahedral hybrid element.

[0063] S2. Assemble the model according to the actual assembly;

[0064] The assembly model components include: solenoid valve, solenoid valve bracket, cut-off cylinder body, sealing rubber, and solid bolts, etc.

[0065] The sealing rubber should be in an uncompressed state, and the model should not interfere with the solenoid valve and cylinder. The solid bolt engagement area is simulated using rigid elements, and the top and bottom rigid elements of the engagement area are constrained in three directions, while the remaining rigid elements are constrained in one to three directions. At the same time, all nodes in the engagement area are constrained in four to six directions.

[0066] S3, Define contact;

[0067] Specifically, the initial geometric position of the rubber ring is interference-fitted by defining finite sliding contact, and the contact type is set to surface to surface; the clearance fit between the battery valve and the cylinder is achieved by defining clearance.

[0068] S4. Define the materials for the finite element model:

[0069] Define the elastic modulus E, Poisson's ratio μ, and density ρ of the materials in the finite element model of each component. Typically, for steel, E = 210000 MPa, μ = 0.30, and ρ = 7.89 kg / dm³; for aluminum alloy, E = 70000 MPa, μ = 0.33, and ρ = 2.70 kg / dm³. The elastic modulus E of rubber is calculated using the following formula. EPDM =10MPa,

[0070]

[0071] In the formula, E EPDM d2 is the elastic modulus of the rubber; K1 is the elastic modulus correction factor, generally taken as 0.9 to 1.2; d2 is the outer diameter of the rubber ring; d1 is the inner diameter of the rubber ring; h is the rubber thickness; and HS is the rubber hardness.

[0072] S5. Define the boundaries, constraining the cylinder block's X-axis tangent plane in directions 1 and 2, constraining the cylinder block's Y-axis tangent plane in directions 2 and 3, and constraining the cylinder block's Z-axis tangent plane in directions 1 and 3.

[0073] S6. Apply bolt axial load. The axial force of the M8 bolt is calculated from its torque using an empirical formula and is 8000N.

[0074] S7. Apply hydraulic load to the cylinder block oil passage. The hydraulic loading method is simulated by applying a concentrated force on the equivalent force section of the battery valve.

[0075] The equivalent stress section is defined as the projection of the main view along the battery valve axis, and the maximum range of oil pressure is intercepted on the projection as the equivalent stress section.

[0076] The maximum load is when the solenoid valve is open, and the maximum value is obtained by the following formula: F MAX =300N,

[0077]

[0078] In the formula, F MAX For minimum hydraulic load; p MAX Minimum oil pressure; R MAX The minimum effective radius at which the most hydraulic pressure acts on the battery valve.

[0079] The minimum load is calculated with the solenoid valve closed, and the minimum value is obtained from the following formula: F MIN =50N,

[0080]

[0081] In the formula, F MIN For minimum hydraulic load; p MIN Minimum oil pressure; R MIN The minimum effective radius at which the most hydraulic pressure acts on the battery valve.

[0082] S8, Couples inertial force loads in all directions.

[0083] The maximum hydraulic load is coupled in the same direction as the deformation of the battery valve bracket caused by the lateral, longitudinal, and vertical directions, respectively, while the minimum hydraulic load is coupled in the opposite direction to the deformation of the battery valve bracket caused by the lateral, longitudinal, and vertical directions, respectively.

[0084] Inertial load Hydraulic load Longitudinal impact 1 +8G 600kPa Longitudinal impact 2 -8G 270 kPa Vertical impact 1 +8G 270 kPa Vertical impact 2 -16G 600kPa Lateral impact 1 +8G 600kPa Lateral impact 2 -8G 270 kPa

[0085] S9. Solve the finite element model using ABAQUS software:

[0086] Nonlinear statics were performed using Newton's method to calculate and analyze the stress, strain, contact pressure, and slip of the parts, including the minimum contact pressure P at the rubber contact surface. press =8MPa, maximum slippage S at the rubber contact surface slip =1.3e -3 mm.

[0087] S10. The static strength safety factor and fatigue strength safety factor of the battery valve bracket are calculated using Femfat software. 静 =4.3 and S 疲劳 =3.3.

[0088] S11. Based on the safety factor of the battery valve bracket obtained in step S10, determine that its structure meets the strength and durability requirements. Based on the minimum contact pressure and maximum slip of the rubber obtained in step S9, determine that it meets the sealing requirements.

[0089] The preferred embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the specific details of the above embodiments. Within the scope of the technical concept of the present invention, various simple modifications can be made to the technical solution of the present invention, and these simple modifications all fall within the protection scope of the present invention.

[0090] It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. In order to avoid unnecessary repetition, the present invention will not describe the various possible combinations separately.

[0091] Furthermore, various different embodiments of the present invention can be combined in any way, as long as they do not violate the spirit of the present invention, they should also be regarded as the content disclosed by the present invention.

Claims

1. A method for predicting the strength endurance performance of a battery valve holder based on simulation analysis, characterized by, Specifically, the steps include the following: S1. Establish a finite element model through a geometric model, and analyze and determine the dangerous stress location of the battery valve bracket before modeling. S2. Assemble the model according to the actual structural installation method; S3, Define the contact, specifically including: The rubber, battery valve, and cylinder are assembled using a geometric interference fit, and the outer edge of the battery valve in the sealing area is defined as having clearance contact with the cylinder. The initial geometric position of the rubber ring is interference-fitted by defining finite sliding contact, and the contact type is set to surface to surface; the clearance fit between the solenoid valve and the cylinder is achieved by defining clearance. S4, define the material of the finite element model, define the elastic modulus E, Poisson's ratio and density of the material of each component finite element model and density ; S5. Define the boundary, constrain the cylinder block X-axis tangent plane in directions 1 and 2, constrain the cylinder block Y-axis tangent plane in directions 2 and 3, and constrain the cylinder block Z-axis tangent plane in directions 1 and 3. S6. Apply bolt axial load, the axial force is calculated from the bolt torque using an empirical formula; S7. Apply hydraulic load to the cylinder block oil passage. The hydraulic loading method is simulated by applying a concentrated force on the equivalent force section of the battery valve. The equivalent stress section is defined as: the area of ​​maximum oil pressure action intercepted on the projection of the main view along the axis of the battery valve as the equivalent stress section; S8. Couple the inertial force loads in all directions. The maximum hydraulic load is coupled in the same direction as the lateral, longitudinal, and vertical directions that cause the battery valve bracket to deform, and the minimum hydraulic load is coupled in the opposite direction to the lateral, longitudinal, and vertical directions that cause the battery valve bracket to deform. S9. Use ABAQUS software to solve the finite element model, and use Newton's method to perform nonlinear statics solution to calculate and analyze the stress, strain, contact pressure and slip of the part. S10. The static strength safety factor and fatigue strength safety factor of the battery valve bracket are calculated using Femfat software. S11. Based on the safety factor of the battery valve bracket obtained in step S10, determine whether its structure meets the strength and durability requirements. Based on the rubber contact pressure and slippage obtained in step S9, determine the rubber sealing performance.

2. The method for predicting the strength and durability performance of a battery valve bracket based on simulation analysis as described in claim 1, characterized in that, In step S1, the dangerous location area is modeled with a fine-grained hexahedral mesh of 0.5mm size, ensuring that the mesh is uniform and has a regular shape.

3. The method for predicting the strength and durability performance of a battery valve bracket based on simulation analysis as described in claim 1, characterized in that, In step S1, the size of the rubber mesh is greater than or equal to 1 mm, and a single hexahedral hybrid unit is used for simulation. If there are sharp geometric features, they are equivalent to a width of 0.5 mm. The size of the rubber groove and the rubber should be consistent.

4. The method for predicting the strength and durability performance of a battery valve bracket based on simulation analysis as described in claim 1, characterized in that, The dangerous locations mentioned in step S1 are located around the support fixing point, at the root of the reinforcing rib, or at the bend and chamfer.

5. The method for predicting the strength and durability performance of a battery valve bracket based on simulation analysis as described in claim 1, characterized in that, The assembly model components in step S2 include: battery valve, battery valve bracket, cut-off cylinder body, sealing rubber, and solid bolts.

6. The method for predicting the strength and durability performance of a battery valve bracket based on simulation analysis as described in claim 1, characterized in that, Step S2 specifically includes the following: the sealing rubber is in an uncompressed state, and the model interferes with the solenoid valve and cylinder; the solid bolt engagement area is simulated using rigid elements, wherein the top and bottom rigid elements of the engagement area are constrained in 3 directions, the remaining rigid elements are constrained in 1 to 3 directions, and all nodes of the engagement area are constrained in 4 to 6 directions.

7. The method for predicting the strength and durability performance of a battery valve bracket based on simulation analysis as described in claim 1, characterized in that, The elastic modulus of the rubber in step S4 is calculated using the following formula: （1） In the formula, It is the elastic modulus of rubber; This is the elastic modulus correction factor, ranging from 0.9 to 1.2; The outer diameter of the rubber ring. The inner diameter of the rubber ring. For rubber thickness, This refers to the hardness of the rubber.

8. The method for predicting the strength and durability performance of a battery valve bracket based on simulation analysis as described in claim 1, characterized in that, In step S7, the maximum hydraulic load is in the solenoid valve open state, and the maximum value is obtained by the following formula. ……………（2） In the formula, This represents the maximum hydraulic load. Maximum oil pressure; The maximum effective radius of the hydraulic pressure acting on the solenoid valve; The minimum load for hydraulic pressure is when the solenoid valve is closed, and the minimum value is obtained by the following formula. ……………（3） In the formula, Minimum load for hydraulic pressure; Minimum oil pressure; This is the minimum effective radius of the hydraulic pressure acting on the battery valve.

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