Test apparatus and method of making same

Abstract

The present application relates to the technical field of bench test, and particularly provides a test device and a manufacturing method thereof, aiming at solving the problem of test failure caused by false high stress in the test process of the existing test device. To this end, the test device comprises: a plurality of clamping tools for clamping a test piece, the clamping tool comprising a rigid piece and a flexible clamping piece, the flexible clamping piece being arranged on the rigid piece, the flexible clamping piece being in contact with the test piece, and the constraint of the flexible clamping piece on the test piece being the same as the constraint of the whole vehicle on the test piece; and a loading system for loading a load on the test piece to perform a bench test. The flexible contact does not have the phenomenon of being too "rigid"; the constraint of the flexible clamping piece on the test piece is the same as the constraint of the whole vehicle on the test piece, so that the stress state around the concerned area during the loading of the load is the same as the state of the whole vehicle, and then the stress and strain in the test process are consistent with the real vehicle test, thereby ensuring the accuracy of the results.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of bench test, and particularly provides a test device and a manufacturing method thereof. BACKGROUND

[0002] The integrated die casting of the vehicle body structural member can reduce the assembly steps and the use of connecting members, reduce the weight of the vehicle body structural member, and reduce the manufacturing cost. Therefore, the integrated die casting of the vehicle body structural member is an inevitable choice for the lightweight and cost reduction of the automobile industry.

[0003] The so-called "integrated die casting" is to manufacture large aluminum parts through a large-tonnage die casting machine, mainly refers to the integrated processing of the automobile body structural member, the originally designed multiple separate and scattered small parts are highly integrated through re-design, and then are formed into a complete large part through one-time forming die casting by using the die casting machine, thereby omitting the welding and assembly process, so as to reduce the manufacturing cost.

[0004] As the main structural member of the vehicle body, the integrated die casting part needs to meet various performance requirements in the design of the vehicle body, and the strength of the casting is a key index. The traditional vehicle body strength test methods include vehicle road test verification and bench test verification. The vehicle road test is an indispensable verification link in vehicle research and development, has the advantages of real test environment and close to the actual use of the vehicle by the user, and has the disadvantage of long test period and high test cost. The bench test is to build a test bench in the test room, fix the tested part on the test bench through a tool fixture, load through a hydraulic cylinder, simulate the stress scene of the real vehicle, has the advantages of convenient and fast test process, and has the disadvantage that the real working state of the part is "secondarily simulated" by the test bench fixture, and the test result is limited by the design accuracy of the test bench fixture.

[0005] In the existing bench test, the assembly including the tested part is placed on the test bench, and the other parts are clamped by the tool fixture away from the tested part, so as to avoid that the clamping point is too close to the concerned area, changes the stress state of the tested part, and affects the accuracy of the test result.

[0006] Since the integrated die casting part is huge and integrates dozens of parts together, it is equivalent to an assembly itself, and the entire die casting part belongs to the concerned area, and the clamping point can only be fixed on the structure of the die casting part, so it is impossible to be away from the concerned area. If the traditional tool is used for fixation, the position of the clamping point will be too "rigid", which does not conform to the stress of the part on the real vehicle, and false high stress will occur in the test process, resulting in test failure.

[0007] Therefore, there is an urgent need in the related field for a test device and a manufacturing method thereof to solve the above technical problems. SUMMARY

[0008] The present invention aims to solve the above-mentioned technical problems, namely, to solve the problem of false high stress causing test failure during the testing process of existing testing equipment.

[0009] In a first aspect, the present invention provides a testing apparatus, comprising:

[0010] Multiple clamping fixtures are used to clamp the test piece. The clamping fixtures include rigid components and flexible clamping components. The flexible clamping components are disposed on the rigid components and are in contact with the test piece. The constraint of the flexible clamping components on the test piece is the same as the constraint of the vehicle on the test piece.

[0011] A loading system for applying loads to the test specimen for bench testing.

[0012] In a specific embodiment of the above-mentioned test equipment, the test equipment further includes a base, and the loading system and rigid components are both disposed on the base.

[0013] In a specific embodiment of the above-mentioned test equipment, the loading system includes a gantry support and a servo actuator. The gantry support is mounted on the base, and the servo actuator is movably mounted on the gantry support. The servo actuator is used to apply a load to the test piece.

[0014] In a specific embodiment of the above-mentioned test equipment, the gantry support includes at least two columns and a crossbeam disposed on the columns, and the servo actuator is slidably disposed on the crossbeam and can be locked on the crossbeam.

[0015] In the specific implementation of the above-mentioned test equipment, the servo actuator is an electro-hydraulic servo actuator.

[0016] In the specific implementation of the above-mentioned test equipment, the flexible clamping component is made of rubber, silicone, nylon, or composite material.

[0017] In a specific embodiment of the above-mentioned test equipment, the flexible clamping member and the rigid member are connected by a connector.

[0018] In a second aspect, the present invention provides a method for manufacturing the experimental device as described above, comprising the following steps:

[0019] The elastic modulus E of the flexible clamping component was determined through simulation. n The flexible clamping member provides the same constraint on the test piece as the vehicle provides on the test piece.

[0020] Choose the elastic modulus as E n Materials for preparing flexible clamping components;

[0021] The rigid piece is prepared, and the flexible clamping piece and the rigid piece are connected;

[0022] The rigid piece is fixed on the base;

[0023] The gantry is built on the base;

[0024] The servo actuator is loaded on the gantry.

[0025] In the embodiment of the method for manufacturing the test equipment, the step of "determining the elastic modulus E of the flexible clamping piece through simulation" includes: n

[0026] S1, simulating the stress state of the test piece on the whole vehicle structure and outputting the stress and strain nephogram of the test piece on the whole vehicle structure as a target value;

[0027] S2, setting the initial elastic modulus of the flexible clamping piece as E0 in the simulation model;

[0028] S3, simulating the installation of the test piece on the test bench, simulating the external load applied by the loading system, and outputting the stress and strain nephogram of the test piece on the test bench as a simulation result;

[0029] S4, comparing the simulation result and the target value, if the two do not match, adjusting the elastic modulus of the flexible clamping piece to E i , and performing step S3, if the two match, the elastic modulus E n is the current elastic modulus of the flexible clamping piece in the simulation model.

[0030] In the embodiment of the method for manufacturing the test equipment, the stress and strain nephogram includes one or more of the deformation nephogram and the stress nephogram, the stress nephogram and the strain nephogram, the stress / strain energy nephogram and the strain nephogram, and the stress / strain energy nephogram and the deformation nephogram.

[0031] In the case of adopting the above technical scheme, the clamping tool of the test equipment is used to clamp the test piece, the flexible clamping piece is in contact with the test piece, the clamping point is a flexible contact, and the phenomenon of being too "rigid" does not occur; the constraint of the flexible clamping piece on the test piece is the same as the constraint of the whole vehicle on the test piece, which can ensure that the stress state around the concerned area during loading is the same as that of the whole vehicle, and both are flexible constraints, thereby ensuring that the stress and strain during the test process are consistent with those of the real vehicle test, thereby ensuring the accuracy of the results. The existence of the rigid piece can ensure that the test piece is effectively constrained during the test, avoiding the test piece from being knocked off during loading, which causes the test to fail.

[0032] Furthermore, through simulation calculation, the elastic modulus of the flexible clamping piece in the simulation model is adjusted to be consistent with the stress and strain nephogram of the design target.​Figure One Therefore, the elastic modulus of the flexible holder is calculated in this way, and the flexible holder is selected according to the elastic modulus, so that the constraint of the flexible holder on the test piece is the same as the constraint of the whole vehicle on the test piece, and the accuracy of the test result is ensured. BRIEF DESCRIPTION OF DRAWINGS

[0033] The preferred embodiments of the present application will be described below with reference to the accompanying drawings, in which:

[0034] Figure 1 is a front view of the test equipment provided by the present application;

[0035] Figure 2 is a top view of the test equipment provided by the present application;

[0036] Figure 3 is a structural schematic view of the test equipment provided by the present application;

[0037] Figure 4 is a partial enlarged view of the test equipment provided by the present application;

[0038] Figure 5 is a main step flowchart of the manufacturing method of the test equipment provided by the present application;

[0039] Figure 6 is a flowchart of determining the elastic modulus of the flexible holder provided by the present application;

[0040] Figure 7 is a detailed step flowchart of the manufacturing method of the test equipment provided by the present application.

[0041] LIST OF REFERENCE NUMERALS

[0042] 1, base; 2, loading system; 21, column; 22, beam; 23, servo actuator; 3, rigid piece; 4, flexible holder; 5, test piece. DETAILED DESCRIPTION

[0043] The preferred embodiments of the present application will be described below with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are only used to explain the technical principles of the present application, and are not intended to limit the protection scope of the present application.

[0044] It should be noted that in the description of the present application, the terms indicating the direction or positional relationship of "up", "down", "left", "right", "inner", "outer" and the like are based on the direction or positional relationship shown in the drawings, which is only for the convenience of description, and does not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present application. In addition, the terms "first", "second" are only for the purpose of description, and cannot be understood as indicating or implying relative importance.

[0045] In addition, it should be noted that in the description of the present application, unless otherwise specified and limited, the terms "mounting", "setting", "connecting" should be understood broadly, for example, it can be fixed connection, or detachable connection, or integrally connected; it can be directly connected, or indirectly connected through an intermediate medium, or the internal communication of two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0046] Because the size of the integrated die casting is huge, dozens of parts are integrated together, which is equivalent to an assembly itself, and the entire die casting belongs to the concerned area, and the clamping point can only be fixed on the structure of the die casting, so it cannot be away from the concerned area. If the traditional tooling is used for fixation, the position of the clamping point will be too "rigid", which does not match the stress of the parts on the real vehicle, causing false high stress during the test process, resulting in test failure.

[0047] In order to solve the above technical problems, as shown in Figures 1-4 The present embodiment discloses a test equipment, which comprises a plurality of clamping toolings, a loading system 2 and a base 1.

[0048] The clamping toolings and the loading system 2 are arranged on the base 1, the clamping toolings are used for clamping the test piece 5, the specific number of the clamping toolings is determined according to the positions needed to be clamped by the test piece 5, and the arrangement positions of the clamping toolings on the base 1 are also determined according to the positions needed to be clamped by the test piece 5. It should be noted that the position needed to be clamped is outside the loading point to avoid affecting the subsequent test load. The clamping tooling comprises a rigid piece 3 and a flexible clamping piece 4, wherein the flexible clamping piece 4 is connected with the rigid piece 3 through a connecting piece, specifically through a bolt connection. The flexible clamping piece 4 is in contact with the test piece 5, and the constraint of the flexible clamping piece 4 to the test piece 5 is the same as the constraint of the whole vehicle to the test piece 5. The constraint of the whole vehicle to the test piece 5 means that when the test piece is installed on the real vehicle, the components connected with the test piece on the real vehicle constrain the displacement and force of the test piece; the constraint of the plurality of clamping toolings to the displacement and force of the test piece is the same as the constraint of the components connected with the test piece on the real vehicle to the displacement and force of the test piece. The number of the flexible clamping pieces 4 is two, and the flexible clamping pieces 4 are arranged on both sides of the position where the test piece 5 is clamped, and the two flexible clamping pieces 4 are fixed on the rigid piece 3 through bolts. The material of the flexible clamping piece 4 is rubber, silica gel, nylon or composite material, and the elastic modulus of the material is required, because the elastic modulus is required to be high, finally the composite rubber may be selected to control the elastic modulus within the design requirement range.

[0049] It should be noted that, although the two flexible clamping members 4 share one rigid member 3 in the embodiment, this is not a limitation of the present application. In other embodiments, one flexible clamping member 4 can be equipped with one rigid member 3 without departing from the principles of the present application. Therefore, all of these will fall within the scope of the present application.

[0050] The flexible clamping member 4 is in contact with the test piece 5, and the clamping point is a flexible contact, without the phenomenon of excessive rigidity. The constraint of the flexible clamping member 4 on the test piece 5 is the same as the constraint of the whole vehicle on the test piece 5, which can ensure that the stress state around the concerned area during loading is the same as that of the whole vehicle, and both are flexible constraints, thereby ensuring that the stress and strain during the test are consistent with those of the real vehicle test, thereby ensuring the accuracy of the results. The presence of the rigid member 3 can ensure that the test piece 5 is effectively constrained during the test, avoiding the test piece 5 from being pushed off during loading, which would result in the test being unable to proceed.

[0051] The loading system 2 is used to load the test piece 5 with a load for bench testing. The loading system 2 includes a gantry support and a servo actuator 23. The gantry support includes at least two upright columns 21 and a cross beam 22 arranged on the upright columns 21. Specifically, the upright column 21 includes multiple sections arranged vertically, and the multiple sections of the upright column 21 are connected by bolts. The number of upright columns 21 is two, and the bottom end of the upright column 21 is fixed on the base 1. The two ends of the cross beam 22 are fixed on the upright columns 21, which can be fixed by bolts. The servo actuator 23 is slidably arranged on the cross beam 22 and can be locked on the cross beam 22, specifically by bolts. The position of the servo actuator 23 is adjusted according to the loading point of the load, and then the servo actuator 23 loads the test piece 5 with a load. Preferably, the servo actuator 23 is an electro-hydraulic servo actuator; in other embodiments, the servo actuator 23 can also be a hydraulic actuator.

[0052] As shown in Figure 5 the manufacturing method of the test equipment includes the following steps:

[0053] S01, determining the elastic modulus E of the flexible clamping member 4 by simulation n so that the constraint of the flexible clamping member 4 on the test piece 5 is the same as the constraint of the whole vehicle on the test piece 5; the elastic modulus E of the flexible clamping member is determined by CAE simulation n .

[0054] S02, selecting a material with an elastic modulus of E n to prepare the flexible clamping member 4; specifically, rubber with an elastic modulus of E n is used to prepare the flexible clamping member 4;

[0055] S03. Prepare rigid component 3 and connect flexible clamping component 4 and rigid component 3 to form clamping fixture;

[0056] S04. Fix the rigid component 3 onto the base 1;

[0057] S05. Build a gantry support on the base 1. Specifically, first build the column 21, and then install the crossbeam 22.

[0058] S06. Servo actuator 23 is mounted on the gantry support.

[0059] Through simulation calculations, the elastic modulus of the flexible clamping component 4 in the simulation model was adjusted to match the stress-strain cloud of the design target. Figure One In this way, the elastic modulus of the flexible clamping component 4 can be calculated. Using this elastic modulus to select materials, the constraint of the flexible clamping component 4 on the test piece 5 can be the same as the constraint of the whole vehicle on the test piece 5, thereby ensuring the accuracy of the test results.

[0060] The order of the above steps is not limited. In other embodiments, steps S05 and S06 can be performed first, followed by steps S01-04; or steps S05-06 and S01-04 can be performed simultaneously.

[0061] like Figure 6 As shown, "the elastic modulus E of the flexible clamping component 4 is determined by simulation". n The specific steps include the following:

[0062] S1. Simulate the stress state of the test piece 5 on the vehicle structure and output the stress-strain cloud map of the test piece 5 on the vehicle structure, using this as the target value; specifically, through CAE simulation, simulate the stress state of the test piece 5 on the vehicle structure and output the stress-strain cloud map of the test piece 5 on the vehicle structure. The stress-strain cloud map specifically includes a deformation cloud map and a stress cloud map; in other embodiments, the stress-strain cloud map may also include one or more of the following: a deformation cloud map and a stress cloud map, a stress cloud map and a strain cloud map, a stress / strain energy cloud map and a strain cloud map, and a stress / strain energy cloud map and a deformation cloud map.

[0063] S2. Set the initial elastic modulus of the flexible clamping component 4 to E0 in the simulation model; specifically, through CAE simulation, set the initial elastic modulus of the flexible clamping component 4 to E0 in the simulation model.

[0064] S3, simulate the installation of the test piece 5 on the test bench, simulate the external load applied by the loading system 2, and output the stress-strain cloud diagram of the test piece 5 on the test bench as the simulation result. Specifically, through CAE simulation, the installation of the test piece 5 on the test bench is simulated, the external load applied by the loading system 2 is simulated, and the stress-strain cloud diagram of the test piece 5 on the test bench is output as the simulation result.

[0065] S4, compare the simulation result with the target value, if the two do not match, proceed to step S5; if the two match, proceed to step S6; matching means that the deformation cloud diagram of the simulation result and the deformation cloud Figure One diagram of the target value match. Figure One

[0066] S5, adjust the elastic modulus of the flexible clamp 4 to E i , and proceed to step S3.

[0067] S6, the elastic modulus E n is set to the current elastic modulus of the flexible clamp 4 in the simulation model.

[0068] The test equipment is completed through the above steps, and then the test bench test is performed.

[0069] As Figure 7 shown, the detailed manufacturing process of the test equipment is as follows:

[0070] S11, simulate the stress state of the test piece 5 on the whole vehicle structure, and output the stress-strain cloud diagram of the test piece 5 on the whole vehicle structure as the target value.

[0071] S12, set the initial elastic modulus of the flexible clamp 4 in the simulation model to E0.

[0072] S13, simulate the installation of the test piece 5 on the test bench, simulate the external load applied by the loading system 2, and output the stress-strain cloud diagram of the test piece 5 on the test bench as the simulation result.

[0073] S14, compare the simulation result with the target value, if the two do not match, proceed to step S15; if the two match, proceed to step S16.

[0074] S15, adjust the elastic modulus of the flexible clamp 4 to E i , and proceed to step S13.

[0075] S16, the elastic modulus E n is set to the current elastic modulus of the flexible clamp 4 in the simulation model.

[0076] S17, select the elastic modulus E n ​The material of the flexible holder 4 is selected from rubber with an elastic modulus of E n The material of the flexible holder 4 is selected from rubber with an elastic modulus of E

[0077] S18, preparing the rigid part 3 and connecting the flexible holder 4 and the rigid part 3 to form a clamping tool;

[0078] S19, fixing the rigid part 3 on the base 1;

[0079] S20, erecting a gantry on the base 1, specifically erecting a column 21 first and then installing a cross beam 22;

[0080] S21, loading a servo actuator 23 on the gantry.

[0081] The technical solutions of the present application have been described in combination with the preferred embodiments shown in the drawings, but it is easy for those skilled in the art to understand that the protection scope of the present application is obviously not limited to these specific embodiments. Those skilled in the art can make equivalent changes or replacements to the related technical features without departing from the principles of the present application, and the technical solutions after these changes or replacements will all fall within the protection scope of the present application.

Claims

1. A method for manufacturing an experimental device, characterized in that, The testing equipment includes: multiple clamping fixtures for clamping the test piece (5), the clamping fixtures including a rigid part (3) and a flexible clamping part (4), the flexible clamping part (4) being disposed on the rigid part (3), the flexible clamping part (4) contacting the test piece (5) and the contact point being flexibly connected, the constraint of the flexible clamping part (4) on the test piece (5) being the same as the constraint of the whole vehicle on the test piece (5); and a loading system (2) for loading a load on the test piece (5) for bench testing. The test equipment also includes a base (1), and the loading system (2) and rigid component (3) are both mounted on the base (1); The loading system (2) includes a gantry support and a servo actuator (23). The manufacturing method includes the following steps: The elastic modulus E of the flexible clamping member (4) was determined by simulation. n So that the constraint of the flexible clamp (4) on the test piece (5) is the same as the constraint of the whole vehicle on the test piece (5); Choose the elastic modulus as E n The flexible clamping member (4) is prepared from the material. Prepare the rigid member (3) and connect the flexible clamping member (4) and the rigid member (3) to form the clamping fixture, such that the flexible clamping member (4) is configured to contact the test piece (5) and the contact point is flexibly connected; The rigid member (3) is fixed to the base (1); The gantry support is erected on the base (1); The servo actuator (23) is mounted on the gantry support. Among them, "the elastic modulus E of the flexible clamping component (4) is determined by simulation". n The steps include: S1. Simulate the stress state of the test piece (5) on the vehicle structure and output the stress-strain cloud diagram of the test piece (5) on the vehicle structure as the target value; S2. In the simulation model, the initial elastic modulus of the flexible clamping component (4) is set to E0; S3. Simulate the test piece (5) being mounted on the test bench, simulate the loading system (2) applying external loads, and output the stress-strain cloud diagram of the test piece (5) on the test bench as the simulation result; S4. Compare the simulation results with the target value. If they do not match, adjust the elastic modulus of the flexible clamping member (4) to E. i Then proceed to step S3. If the two match, the elastic modulus E n The current elastic modulus of the flexible clamping component (4) in the simulation model.

2. The method for manufacturing the experimental equipment according to claim 1, characterized in that, The stress-strain cloud map includes one or more of the following: deformation cloud map and stress cloud map, stress cloud map and strain cloud map, stress / strain energy cloud map and strain cloud map, and stress / strain energy cloud map and deformation cloud map.

3. The method for manufacturing the experimental equipment according to claim 1, characterized in that, The gantry bracket is mounted on the base (1), and the servo actuator (23) is movably mounted on the gantry bracket. The servo actuator (23) is used to apply loads to the test piece (5).

4. The method for manufacturing the experimental equipment according to claim 3, characterized in that, The gantry support includes at least two columns (21) and a crossbeam (22) disposed on the columns (21). The servo actuator (23) is slidably disposed on the crossbeam (22) and can be locked on the crossbeam (22).

5. The method for manufacturing the experimental equipment according to claim 3, characterized in that, The servo actuator (23) is an electro-hydraulic servo actuator.

6. The method for manufacturing the experimental equipment according to claim 1, characterized in that, The flexible clamping member (4) is made of rubber, silicone, nylon or composite material.

7. The method for manufacturing the experimental equipment according to claim 1, characterized in that, The flexible clamping member (4) and the rigid member (3) are connected by a connector.

8. A testing device, characterized in that, The test equipment is manufactured using the method for manufacturing test equipment according to any one of claims 1-7.

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