Electric drive collision simulation test system and test method

Abstract

The invention relates to the technical field of vehicle collision test, in particular to an electric drive collision simulation test system and method, and the system comprises an electric drive force subsystem, a collision simulation subsystem, and a control test subsystem. The electric drive subsystem comprises a thrust linear motor, a pulse energy storage device, a pulse discharge power supply device and a charging device; the collision simulation subsystem comprises an acceleration track, a test trolley and an anti-collision device; the control test subsystem comprises a measurement and control table and high-speed data acquisition equipment; the test trolley is driven by a thrust linear motor, precise change of thrust and acceleration is realized through precise control of voltage and current, and waveform control required by mapping test is realized; the efficiency is high, the required total energy is low, the thrust is continuously adjustable, the size is greatly reduced compared with that of a traditional test system, and the weight is reduced; various preset parameters and waveforms can be met, a motion curve can be freely adjusted, an acceleration curve can be freely set according to test requirements, and the acceleration curve is very smooth.

Description

Technical Field

[0001] The present invention relates to the technical field of vehicle collision testing, and in particular to an electric drive collision simulation testing system and a testing method. Background Art

[0002] In order to test whether the vehicle components meet the safety requirements of the above national standards when a collision occurs, in the relevant technology, the vehicle components to be tested are usually subjected to actual collision, and then the data generated by the vehicle components to be tested when the actual collision occurs is obtained, and the vehicle components are tested based on the data to see whether they meet the safety requirements. At present, the collision simulation test products on the domestic market are mainly hydraulic servo drive, pneumatic drive and hydraulic brake composite types, which will have a series of problems such as poor control accuracy, long response time, poor controllability of thrust size, large site requirements, high maintenance costs, etc. Therefore, the above problems need to be solved urgently. Summary of the invention

[0003] The purpose of the present invention is to overcome the shortcomings and deficiencies of the prior art. In view of the above-mentioned shortcomings of the prior art, the present invention provides an electric drive collision simulation test system and a test method. The electric drive collision simulation test system and the test method provided by the present invention can realize the electromagnetic force drive technology route, and have the characteristics of continuously adjustable load, precise control of arbitrary test waveform, small footprint, low maintenance cost and high intelligence level.

[0004] To achieve the above object, the present invention provides the following technical solutions:

[0005] A first aspect of the present invention provides an electric drive collision simulation test system, comprising: an electric drive force subsystem, a collision simulation subsystem and a control test subsystem;

[0006] The electric drive subsystem includes: a thrust linear motor, a pulse energy storage device, a pulse discharge power supply device and a charging device;

[0007] The collision simulation subsystem includes: an acceleration track, a test trolley and an anti-collision device;

[0008] The control and test subsystem includes: a test and control platform and high-speed data acquisition equipment.

[0009] Preferably, the charging device is connected to a pulse energy storage device, the pulse energy storage device is connected to a pulse discharge power supply, and the thrust linear motor is connected to a pulse discharge power supply device. The charging device is responsible for charging the pulse energy storage device, and the pulse discharge power supply device is responsible for providing power to the thrust linear motor.

[0010] Preferably, the test trolley is mounted on an acceleration track, the output end of the thrust linear motor is fixedly connected to the test trolley, the linear motor is arranged on the acceleration track, and the anti-collision device is arranged at one end of the acceleration track.

[0011] Preferably, the measurement and control platform is communicatively connected to a high-speed data acquisition device, and the high-speed data acquisition device is connected to the collision subsystem.

[0012] The pulse energy storage device includes a capacitor group, an inductor element and an energy storage medium. The capacitor group uses high-energy-density capacitors in the electromagnetic catapult system and can store a large amount of electrical energy in a short time. The inductor element is used to adjust the rate of change of the current. During the energy storage process, the inductor can limit the rapid rise of the current to avoid excessive impact on the power supply components. At the same time, during the discharge process, the inductor can also cooperate with the capacitor component to optimize the current waveform.

[0013] Preferably, the pulse discharge power supply device includes a power converter, a control unit and a trigger circuit. The power converter includes a rectifier and an inverter. The rectifier is used to convert the input alternating current into direct current to provide a stable direct current power supply for the subsequent energy storage and discharge process; the inverter converts the direct current into alternating current of a specific frequency and amplitude when necessary to meet the requirements of the electric drive ejection system for the electromagnetic force frequency parameters; the control unit obtains the status information of the energy storage device and the demand information of the electric drive system through a sensor, and then accurately controls the power converter according to a preset algorithm and control strategy; the trigger circuit is used to start the pulse discharge process. When a start ejection instruction is received, the trigger circuit will open the discharge path between the energy storage device and the electromagnetic catapult at a precise time, so that the electric energy in the energy storage device can be quickly released into the electric drive system.

[0014] Preferably, the high-speed data acquisition equipment includes an acceleration sensor, a high-speed camera, a strain gauge, a pressure sensor and a data acquisition system. The acceleration sensor is used to measure the acceleration change of vehicle parts at the moment of collision and during the collision. The acceleration sensor obtains acceleration data by detecting inertial force and accurately records the acceleration change curve over time. The acceleration sensor is installed on the armature or the load-bearing slider, or the key part of the tested component to comprehensively monitor the acceleration response of the seat during the collision and evaluate its component structural stability index and its protection ability for passengers.

[0015] Preferably, the high-speed camera is used to record image information of the collision process. It is installed on the side of the test slide rail and at key points inside the components to be tested to be arranged at multiple points to shoot the appearance and shape changes of the vehicle and components during extreme acceleration, extreme deceleration, and collision with obstacles. Common examples include shooting the working conditions of the driver's seat, seat belt, airbag, and power battery assembly components.

[0016] The strain gauge is used to measure the strain of parts during collision. When a part is subjected to external force, its shape will change slightly. The strain gauge will produce resistance changes as the part deforms. By measuring this resistance change and using the relationship between strain and resistance change, the strain of the part can be calculated. In the collision test of the automobile frame, the strain gauge can measure the degree of bending and twisting of the vehicle support and other components to be evaluated under the impact force of the collision; it is installed in the area where the part may undergo large deformation.

[0017] Preferably, the pressure sensor is used to measure the pressure changes generated during acceleration, deceleration and collision, and is installed inside the airbag module to monitor the airbag inflation pressure, and is installed near the seat belt retractor to measure the pressure changes when the seat belt is tightened;

[0018] The data acquisition system is a device that collects, processes and stores the data collected by the above-mentioned various sensors. It includes a data acquisition card, a signal conditioning module and computer software. The data acquisition card is responsible for connecting with the sensor and converting the analog signal into a digital signal; the signal conditioning module amplifies and filters the sensor signal to improve the signal quality; the computer software is used to set the acquisition parameters, display and analyze the collected data.

[0019] A second aspect of the present invention further provides a test method for an electric drive collision simulation test system, the test method comprising the following steps:

[0020] S1. Turn on the control console, which performs a system self-check. The system prompts whether charging is required. If charging is required, the control console issues a charging instruction, and the charging device charges the pulse energy storage device.

[0021] S2. The tested equipment is fixedly installed on the test bench;

[0022] S3. If the control console prompts that charging is not required, you can issue a command through the control console. If the control console prompts that charging is required, issue a command after charging is completed to move the test trolley to the starting position of the test;

[0023] S4. According to the test object and test standard, the corresponding test parameters are selected from the measurement and control platform. After the parameters are confirmed, the test command is issued, and the thrust linear motor responds and generates electromagnetic force to push the test trolley to accelerate instantly. After the test reaches the required acceleration curve, the thrust linear motor electromagnetic force is reversed to brake the test trolley to stop;

[0024] S5. The measurement and control console reads the system status data and data from high-speed data acquisition equipment, performs data fusion processing, and issues a test report for the test.

[0025] Compared with the known public technology, the technical solution provided by the present invention has the following advantages:

[0026] Beneficial effects:

[0027] 1. The test bench is driven by a thrust linear motor, and waveform control is achieved through precise control of voltage and current;

[0028] 2. High efficiency, low total energy required, continuously adjustable thrust, small size and light weight;

[0029] 3. It can meet various preset waveforms, freely adjust the motion curve (including braking), and set the acceleration curve arbitrarily according to the test requirements, and the acceleration curve is very smooth. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 It is a stereoscopic diagram of the electric drive collision simulation test system of the present invention.

[0031] Figure 2 This is a logic block diagram of the electric drive collision simulation test system test method of the present invention.

[0032] Figure 3 This is a curve diagram of the measured simulated collision trapezoidal wave acceleration in Example 2 of the present invention.

[0033] Figure 4 This is a velocity displacement curve diagram of the simulated trapezoidal wave test in Example 2 of the present invention.

[0034] Figure 5 This is a simulated triangle wave test acceleration diagram in Example 2 of the present invention.

[0035] Figure 6 This is a velocity displacement curve diagram in Example 2 of the present invention.

[0036] Figure 7 This is a simulated sinusoidal wave test acceleration diagram in Example 2 of the present invention.

[0037] Figure 8 This is a velocity displacement curve diagram in Example 2 of the present invention.

[0038] Legend: 1. Test trolley; 2. Acceleration track; 3. Thrust linear motor; 4. Anti-collision device; 5. Measurement and control platform; 6. Charging device; 7. Pulse energy storage device; 8. Pulse discharge power supply device. DETAILED DESCRIPTION

[0039] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0040] The present invention will be further described below in conjunction with the embodiments.

[0041] Embodiment 1:

[0042] like Figure 1 As shown, the present invention provides an electric drive collision simulation test system, including: an electric drive force subsystem, a collision simulation subsystem and a control test subsystem;

[0043] The electric drive subsystem includes: a thrust linear motor 3, a pulse energy storage device 7, a pulse discharge power supply device 8 and a charging device 6, wherein the charging device 6 is connected to the pulse energy storage device 7, the pulse energy storage device 7 is connected to the pulse discharge power supply device 8, the thrust linear motor 3 is connected to the pulse discharge power supply device 8, the charging device 6 is responsible for charging the pulse energy storage device 7, and the pulse discharge power supply device 8 is responsible for providing power to the thrust linear motor 3;

[0044] The collision simulation subsystem includes: an acceleration track 2, a test trolley 1 and an anti-collision device 4, wherein the test trolley 1 is mounted on the acceleration track 2, the output end of the thrust linear motor 3 is fixedly connected to the test trolley 1, the thrust linear motor 3 is arranged on the acceleration track 2, and the anti-collision device 4 is arranged at one end of the acceleration track 2;

[0045] The control test subsystem includes: a test and control platform 5 and a high-speed data acquisition device. The test and control platform 5 is in communication connection with the high-speed data acquisition device, and the high-speed data acquisition device is connected with the collision subsystem.

[0046] like Figure 2 As shown, the second aspect of the present invention also provides a test method for an electric drive collision simulation test system, comprising the following steps:

[0047] S1, turn on the control station 5, the control station 5 performs a system self-check, and the system prompts whether charging is required. If charging is required, the control station 5 issues a charging instruction, and the charging device 6 charges the pulse energy storage device 7;

[0048] S2. The test equipment is fixedly installed on the test bench 1;

[0049] S3. If the control station 5 indicates that charging is not required, a command can be issued through the control station 5. If the control station 5 indicates that charging is required, a command is issued after charging is completed to move the test trolley 1 to the test starting position;

[0050] S4. According to the test object and the test standard, the corresponding test parameters are selected from the measurement and control platform 5. After the parameters are confirmed, the test command is issued, and the thrust linear motor 3 responds and generates electromagnetic force to push the test trolley 1 to accelerate instantaneously. After the test reaches the required acceleration curve, the thrust linear motor 3 brakes in the reverse direction with electromagnetic force to brake the test trolley 1 to stop.

[0051] S5, the measurement and control station 5 reads the system status data and the data of the high-speed data acquisition equipment, performs data fusion processing, and issues a test report for the test.

[0052] Specifically, the key equipment and working principles of the pulse energy storage device, pulse discharge power supply device, and high-speed data acquisition equipment in the electric drive collision simulation test system are as follows:

[0053] 1. The pulse energy storage device includes a capacitor group, an inductor element and an energy storage medium;

[0054] Capacitor group: It is a key component of the pulse energy storage device. In the electromagnetic catapult system, high-energy-density capacitors such as multilayer ceramic capacitors (MLCC) or electrolytic capacitors are usually used. These capacitors can store a large amount of electrical energy in a short time. For example, for a large electromagnetic catapult system, multiple large-capacity electrolytic capacitors may be connected in parallel to form a capacitor group to meet the energy required for the launch.

[0055] Inductor component: used to adjust the rate of change of current. During the energy storage process, the inductor can limit the rapid rise of current to avoid excessive impact on components such as the power supply. At the same time, during the discharge process, the inductor can also cooperate with components such as capacitors to optimize the current waveform.

[0056] Energy storage media: In addition to capacitors, some new energy storage media are also being researched and applied, such as superconducting energy storage devices, which use the property of superconducting coils having almost no resistance in the superconducting state to store energy. However, superconducting energy storage currently faces technical difficulties such as low-temperature cooling, and the cost is also relatively high.

[0057] Working principle of pulse energy storage device: During the charging stage, the pulse energy storage device receives electric energy through an external power source (such as a generator or a power grid). When the external power source charges the capacitor bank, the charge gradually accumulates on the plates of the capacitor, and the electric field strength continues to increase. The electric energy is stored in the capacitor in the form of electric field energy, which is similar to filling a water tank with water. As the charging time increases, the energy stored in the capacitor increases. According to the energy storage formula of the capacitor (where is the energy storage, is the capacitance, and is the voltage across the capacitor), the energy storage can be increased by increasing the capacitance value and voltage;

[0058] During the discharge phase, when the electromagnetic catapult system needs energy, the capacitor in the energy storage device is connected to the electromagnetic coil of the catapult linear motor through the control circuit. At this time, the capacitor begins to discharge, and the stored electric field energy is quickly converted into electromagnetic energy, generating a strong magnetic field in the electromagnetic coil, driving the armature (or load-bearing slider) in the catapult to move, thereby realizing the ejection function.

[0059] 2. The pulse discharge power supply device comprises a power converter, a control unit and a trigger circuit;

[0060] Power converter: mainly includes rectifier and inverter. The rectifier is used to convert the input AC power (such as from a generator or a power grid) into DC power, providing a stable DC power supply for the subsequent energy storage and discharge process. The inverter converts DC power into AC power of a specific frequency and amplitude when necessary to meet the requirements of the electric drive ejection system for parameters such as electromagnetic force frequency. In the electric drive collision drive system customized according to the customer's predetermined technical requirements, the power converter can flexibly adjust the output AC power parameters of the power converter within the range not exceeding the maximum limit through the control system according to the weight and speed requirements of the ejection object.

[0061] Control unit: It is the core control component of the pulse discharge power supply device. It obtains the status information of the energy storage device (such as capacitor voltage, current, etc.) and the demand information of the electric drive system (such as ejection speed, acceleration, etc.) through sensors, and then accurately controls the power converter according to the preset algorithm and control strategy. During the motor drive process, the control unit can adjust the output voltage and current of the power converter in real time within the range of the maximum tolerance limit to ensure the stability and accuracy of the ejection process.

[0062] Trigger circuit: used to start the pulse discharge process. When receiving the ejection command, the trigger circuit will open the discharge path between the energy storage device and the electromagnetic catapult at a precise moment (milliseconds), so that the electrical energy in the energy storage device can be quickly released into the electromagnetic catapult. The accuracy and reliability of the trigger circuit are crucial to the performance of the electric drive ejection system. It needs to be able to complete the trigger action in a very short time and be able to withstand the impact of high voltage and large current.

[0063] The working principle of the pulse discharge power supply device: In the preparation stage, the power converter converts the external input AC power into DC power to charge the pulse energy storage device. During this process, the control unit will monitor the charging process to ensure that the voltage, current and other parameters of the energy storage device are stable within a safe and reasonable range.

[0064] When the ejection command is received, the trigger circuit is started, making the circuit between the pulse energy storage device and the electromagnetic drive controller conductive. At this time, under the command of the control unit, the power converter converts DC power into AC power that meets the requirements of the motor drive load and transmits it to the electromagnetic coil of the linear motor. This AC power generates an alternating magnetic field in the electromagnetic coil, which interacts with the armature (or load-bearing slider) in the ejection system slide rail to generate a strong electromagnetic force, which drives the objects on the entire ejection drive system to accelerate and achieve high-speed and high-thrust ejection. At the same time, the control unit will monitor and adjust the power output in real time to ensure the stability and efficiency of the ejection process.

[0065] Because the electric drive system uses powerful electromagnetic force to achieve acceleration, the drive system can achieve instantaneous reversal of the magnetic field through the control unit after reaching the required speed (completing the test), and use the kinetic energy of the high-speed moving armature (or load-bearing slider) to slow it down until it stops by using the principle of cutting the magnetic field to generate electricity. At the same time, the kinetic energy is converted into electrical energy, and the inverter recovers most of the electrical energy to charge the energy storage device, thereby achieving efficient energy utilization. The actual power consumption of each test is extremely small. In most cases, the power consumption of a test is less than 1 kWh.

[0066] 3. System of high-speed data acquisition equipment The data acquisition system is mainly completed by acceleration sensors, high-speed cameras, data acquisition and analysis systems, etc. In this solution, the installation of sensors for data acquisition is further improved to increase the reuse rate and reduce test consumption and equipment maintenance costs. The equipment mainly includes:

[0067] Acceleration sensor: Collection content and principle: It is mainly used to measure the acceleration changes of vehicle parts at the moment of collision and during the collision process (acceleration and deceleration). The acceleration sensor obtains acceleration data by detecting inertial force and accurately records the acceleration change curve over time.

[0068] Installation location: This system is designed to install the accelerometer on the armature (or load-bearing slider) or the key position of the tested component. For example, in the collision test of a car seat, the accelerometer may be installed on the headrest, seat back and seat bottom to comprehensively monitor the acceleration response of the seat during a collision and evaluate its ability to protect passengers. The accelerometer installed on the armature (or load-bearing slider) can be reused because of the two-way control of extreme acceleration and deceleration, and some components that require stable testing of the mechanism do not need to undergo destructive collision.

[0069] High-speed camera: Collection content and principle: High-speed camera is used to record image information of the collision process. It must be able to shoot at an extremely high frame rate, several thousand or even tens of thousands of frames per second, so that the movement state of components at the moment of collision, deformation process and interaction with other components can be clearly captured. When playing back these high-speed images, the state of components at each stage of the collision can be analyzed in detail. For example, in the airbag pop-up test, the high-speed camera can record the entire process of the airbag from triggering to full deployment, including its deployment speed, shape change and contact with the dummy in the car (used to simulate passengers).

[0070] Installation location: Usually, multiple points are arranged on the side of the test rail and key points inside the components to be tested to capture changes in the appearance and shape of vehicles and components during extreme acceleration, extreme deceleration, and collision with obstacles. Common examples include capturing the working conditions of components such as seats, seat belts, airbags, and power battery assemblies.

[0071] Strain gauge (customized according to customers' needs if necessary): Collection content and principle: Strain gauge is used to measure the strain of parts during collision. When parts are subjected to external force, their shapes will change slightly. The resistance of the strain gauge will change with the deformation of the parts. By measuring this resistance change and utilizing the relationship between strain and resistance change (according to the working principle of strain gauge, strain ε is proportional to the rate of change of resistance, i.e. ΔR / R = K·ε, where K is the sensitivity coefficient of strain gauge), the strain of parts can be calculated. In the collision test of automobile frames, strain gauges can measure the bending and twisting degree of the frame under the impact force of the collision.

[0072] Installation location: Generally installed in areas where parts may undergo significant deformation, such as the frame beam structure, engine bracket, new energy vehicle electromagnetic protection support frame, etc. When testing automotive suspension system components, strain gauges can be installed on suspension arms and other components to obtain the stress and deformation of suspension components during a collision.

[0073] Pressure sensor (customized if necessary): Collection content and principle: Pressure sensors are mainly used to measure pressure changes generated during acceleration, deceleration and collision. For example, pressure sensors play an important role in the testing of airbags and seat belt pretensioners. When a collision occurs, the air pressure changes during the inflation of the airbag can be measured by the pressure sensor. According to the ideal gas state equation pV=nRT (where p is pressure, V is volume, n is the amount of substance, R is the universal gas constant, and T is temperature), by measuring the changes in air pressure, we can understand parameters such as the inflation speed and inflation volume of the airbag. At the same time, when the seat belt pretensioner is triggered, the pressure sensor can also measure the changes in tension during the tightening of the seat belt, which is equivalent to measuring the pressure of the seat belt on the passenger.

[0074] Installation location: A pressure sensor is installed inside the airbag module to monitor the airbag inflation pressure. For seat belt pretensioners, the pressure sensor can be installed near the seat belt retractor to measure the pressure change when the seat belt is tightened.

[0075] Working principle of data acquisition system (DAQ): The data acquisition system is a device that collects, processes and stores the data collected by the above-mentioned various sensors. It amplifies and filters the analog signals from different types of sensors such as accelerometers, strain gauges, pressure sensors, etc., and then converts the analog signals into digital signals. These digital signals are transmitted to the computer through the data acquisition card, and are displayed, stored and analyzed in real time using special data acquisition software. The data acquisition system can set the sampling frequency to ensure that the rapidly changing data during the collision process can be accurately recorded.

[0076] Components: including data acquisition card, signal conditioning module and computer software. The data acquisition card is responsible for connecting with the sensor and converting the analog signal into a digital signal; the signal conditioning module amplifies and filters the sensor signal to improve the signal quality; the computer software is used to set the acquisition parameters, display and analyze the collected data.

[0077] The overall collision trolley system simulates the extreme acceleration, extreme deceleration and necessary collision environment that automobile parts may encounter according to the controller, and then analyzes the data collected by the data acquisition system to provide evaluation data on the structural stability, support strength, and tolerable collision speed intensity of the parts. It can also provide destructive damage to certain parts, the extreme acceleration that can be tolerated at the critical point of damage, reduction degree, extreme thrust, extreme collision pressure and other data to prove the ultimate reliability of specific parts.

[0078] In this embodiment, the above-mentioned test system can be widely used in new energy vehicle power battery system collision simulation test, vehicle seat belt assembly or restraint system dynamic test, vehicle seat / child seat and isolation device dynamic test, vehicle-mounted device pulley test, door assembly dynamic test, vehicle frontal collision pulley equivalent test, etc.

[0079] Before the test, the system is powered on and performs a self-check, displaying the system status and prompting the operator whether charging is required. When charging is required, a charging command is issued from the measurement and control console 5, and the charging device 6 draws power from the 380V power grid to charge the pulse energy storage device 7 with a set power. During the charging process of the pulse energy storage device 7, the operator fixes the test equipment on the test trolley 1. After the pulse energy storage device 7 is charged, the operator issues a command to move the test trolley 1 to the starting position of the test; if charging is not required, the operator can directly fix the test equipment on the test trolley 1 and issue a command to move the test trolley 1 to the starting position of the test.

[0080] During the test, the operator selects the corresponding test parameters from the human-machine interface of the measurement and control platform 5 according to the test object and test standard. After confirming the parameters, the test command is issued, and the thrust linear motor 3 responds and generates electromagnetic force to push the test trolley 1 to accelerate instantly. The magnitude of the electromagnetic force is controlled by controlling the amplitude and frequency of the alternating current, thereby achieving precise control of the motion acceleration curve of the test trolley 1. After the test reaches the required acceleration curve, the electromagnetic force of the thrust linear motor 3 is controlled to brake in the opposite direction, so that the test trolley can be accurately braked and stopped within a short distance.

[0081] After the test is completed, the measurement and control station 5 reads the system status data and data from high-speed data acquisition equipment, performs multi-source heterogeneous data fusion processing, and automatically issues a test report for the test.

[0082] Embodiment 2:

[0083] This example is the measured data of the system:

[0084] Using the electric drive collision simulation test system, collision simulation trapezoidal wave, simulated triangle wave and simulated sine wave tests were carried out.

[0085] Since the electromagnetic force of the electric drive subsystem is accurately controllable in real time, the acceleration curve can be set arbitrarily within the standard range. The measured acceleration can completely track the command acceleration curve through the precise control of the electromagnetic force (such as Figure 3 ).

[0086] Depend on Figure 4 It can be seen that at the end of the test, the maximum speed of the test trolley was 16m / s and the stroke was 1.1m. Through the reverse control of the electromagnetic force, the trolley can be braked within the 1.1m stroke. Combined with the test trolley's own length of 3m, the track length can be controlled within 6 meters, greatly reducing the test system's requirements for site space.

[0087] Depend on Figure 5 , Figure 6 It can be seen that the rise and fall time of the triangular wave are both 80ms, the maximum acceleration is 22g, and the velocity and displacement results are equivalent to those of the trapezoidal wave.

[0088] Depend on Figure 7 , Figure 8 It can be seen that the given acceleration curve has a positive half-wave and a negative half-wave, with an amplitude of 22g and a frequency of 60Hz. The measured acceleration curve can track the command acceleration curve well. The test bench moves back and forth at the starting position with acceleration and deceleration, and the actual displacement is small.

[0089] From the acceleration tests with three different waveforms, it can be seen that the electric drive collision simulation test system can achieve accurate tracking of the command acceleration curve through precise closed-loop control of the electromagnetic force, and can realize simulated collision tests of trapezoidal waves, triangle waves, sine waves and any combination of acceleration waveforms.

[0090] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features may be replaced by equivalents. Such modifications or replacements will not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. An electric drive collision simulation test system, characterized in that: include: Electric driving force subsystem, collision simulation subsystem and control test subsystem; The electric drive subsystem includes: a thrust linear motor, a pulse energy storage device, a pulse discharge power supply device and a charging device; The collision simulation subsystem includes: an acceleration track, a test trolley and an anti-collision device; The control and test subsystem includes: a test and control platform and high-speed data acquisition equipment.

2. The electric drive collision simulation test system according to claim 1, characterized in that: The charging device is connected to the pulse energy storage device, the pulse energy storage device is connected to the pulse discharge power supply, and the thrust linear motor is connected to the pulse discharge power supply device. The charging device is responsible for charging the pulse energy storage device, and the pulse discharge power supply device is responsible for providing power to the thrust linear motor.

3. The electric drive collision simulation test system according to claim 1, characterized in that: The test trolley is mounted on the acceleration track, the output end of the thrust linear motor is fixedly connected to the test trolley, the linear motor is arranged on the acceleration track, and the anti-collision device is arranged at one end of the acceleration track.

4. The electric drive collision simulation test system according to claim 1, characterized in that: The measurement and control platform is communicatively connected with a high-speed data acquisition device, and the high-speed data acquisition device is connected with a collision subsystem.

5. The electric drive collision simulation test system according to claim 1, characterized in that: The pulse energy storage device includes a capacitor group, an inductor element and an energy storage medium. The capacitor group uses high-energy-density capacitors in the electromagnetic catapult system and can store a large amount of electrical energy in a short time. The inductor element is used to adjust the rate of change of the current. During the energy storage process, the inductor can limit the rapid rise of the current to avoid excessive impact on the power supply components. At the same time, during the discharge process, the inductor can also cooperate with the capacitor component to optimize the current waveform.

6. The electric drive collision simulation test system according to claim 1, characterized in that: The pulse discharge power supply device includes a power converter, a control unit and a trigger circuit. The power converter includes a rectifier and an inverter. The rectifier is used to convert the input alternating current into direct current to provide a stable direct current power supply for the subsequent energy storage and discharge process; the inverter converts the direct current into alternating current with a specific frequency and amplitude when necessary to meet the requirements of the electric drive ejection system for the electromagnetic force frequency parameters; the control unit obtains the status information of the energy storage device and the demand information of the electric drive system through a sensor, and then accurately controls the power converter according to a preset algorithm and control strategy; the trigger circuit is used to start the pulse discharge process. When a start ejection instruction is received, the trigger circuit will open the discharge path between the energy storage device and the electromagnetic catapult at a precise time, so that the electric energy in the energy storage device can be quickly released into the electric drive system.

7. The electric drive collision simulation test system according to claim 1, characterized in that: The high-speed data acquisition equipment includes an acceleration sensor, a high-speed camera, a strain gauge, a pressure sensor and a data acquisition system. The acceleration sensor is used to measure the acceleration change of vehicle parts at the moment of collision and during the collision process. The acceleration sensor obtains acceleration data by detecting inertial force and accurately records the acceleration change curve over time. The acceleration sensor is installed on the armature or the load-bearing slider, or the key part of the tested component to comprehensively monitor the acceleration response of the seat during the collision process and evaluate its component structure stability index and its protection ability for passengers.

8. The electric drive collision simulation test system according to claim 7, characterized in that: The high-speed camera is used to record the image information of the collision process. It is installed on the side of the test slide rail and at key points inside the components to be tested to capture the appearance and shape changes of the vehicle and components during extreme acceleration, extreme deceleration, and collision with obstacles. Common examples include capturing the working conditions of the driver's seat, seat belt, airbag, and power battery assembly components. The strain gauge is used to measure the strain of parts during collision. When a part is subjected to external force, its shape will change slightly. The strain gauge will produce resistance changes as the part deforms. By measuring this resistance change and using the relationship between strain and resistance change, the strain of the part can be calculated. In the collision test of the automobile frame, the strain gauge can measure the bending and twisting degree of the vehicle support and other parts to be evaluated under the impact of the collision. It is installed in areas where components may experience significant deformation.

9. The electric drive collision simulation test system according to claim 7, characterized in that: The pressure sensor is used to measure the pressure changes generated during acceleration, deceleration and collision. It is installed inside the airbag module to monitor the airbag inflation pressure, and is installed near the seat belt retractor to measure the pressure changes when the seat belt is tightened; The data acquisition system is a device that collects, processes and stores the data collected by the above-mentioned various sensors. It includes a data acquisition card, a signal conditioning module and computer software. The data acquisition card is responsible for connecting with the sensor and converting the analog signal into a digital signal; the signal conditioning module amplifies and filters the sensor signal to improve the signal quality; the computer software is used to set the acquisition parameters, display and analyze the collected data.

10. A test method for an electric drive collision simulation test system, characterized in that: Based on the system according to any one of claims 1 to 9 above, the testing method comprises the following steps: S1. Turn on the control console, which performs a system self-check. The system prompts whether charging is required. If charging is required, the control console issues a charging instruction, and the charging device charges the pulse energy storage device. S2. The tested equipment is fixedly installed on the test bench; S3. If the control console prompts that charging is not required, you can issue a command through the control console. If the control console prompts that charging is required, issue a command after charging is completed to move the test trolley to the starting position of the test; S4. According to the test object and test standard, the corresponding test parameters are selected from the measurement and control platform. After the parameters are confirmed, the test command is issued, and the thrust linear motor responds and generates electromagnetic force to push the test trolley to accelerate instantly. After the test reaches the required acceleration curve, the thrust linear motor electromagnetic force is reversed to brake the test trolley to stop; S5. The measurement and control console reads the system status data and the data from the high-speed data acquisition equipment, performs data fusion processing, and issues a test report for the test.

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