Method and system applied to batch mechanical test of slender rod structure products

Abstract

The invention provides a method and system applied to batch mechanical tests of slender rod structure products. The method comprises the steps that S1, the number of the batch mechanical tests of the products is determined according to the production takt; s2, determining a minimum mounting gap between the products according to a mechanical test simulation result; s3, the actual installation state of the product is determined, and the fixing state of the clamping device is kept consistent with the actual installation state of the product; s4, determining a mechanical test clamping device and producing; and S5, the clamping device is tested in advance before the test is started, the structural strength meets the requirement, and the product is reliably connected with the clamping device. The number of the slender rod structure products subjected to the mechanical test in batches is calculated in combination with actual production, it is guaranteed that the multiple products meet the mechanical test requirement through the reasonable mechanical test clamping device, the test efficiency is improved, the production cost is reduced, the production period is shortened, and the delivery capacity is improved.

Description

Technical Field

[0001] The present invention relates to the field of electronic manufacturing technology, and in particular to a method and system for mechanical testing of batches of slender rod structure products. Background Art

[0002] The existing mechanical testing technology for slender rod structure products is to connect a single product to the mechanical testing equipment through a clamping device. There is no clear testing method, and there is a possibility of product damage due to single-end clamping of the product, which cannot meet the testing cycle of product batch production.

[0003] Therefore, it is necessary to provide a method that can ensure reliable product quality while shortening the mechanical test cycle, so as to enable mechanical testing of multiple slender rod structure products at the same time. Summary of the invention

[0004] In view of the defects in the prior art, an object of the present invention is to provide a method and system for mechanical testing of batches of slender rod structure products.

[0005] The method for mechanical testing of a batch of slender rod structure products provided by the present invention comprises: Step S1: dynamically adjust the batch quantity according to the production rhythm, adopt a rolling optimization algorithm based on real-time data collection, and comprehensively consider the equipment fatigue coefficient and material creep characteristics to determine the maximum test batch; Step S2: Establish a multi-physics field coupling finite element model, use a nonlinear contact algorithm to simulate the product swing, iteratively optimize the installation gap through parameter inversion method, and set up a three-dimensional laser scanning to verify that the deviation between the actual gap and the simulation is less than 0.5mm; Step S3: Build a virtual clamping system based on digital twins, use a six-dimensional force sensor to monitor the clamping state in real time, and use PID closed-loop control to make the preload fluctuation <±2% and the clamping surface roughness Ra≤3.2 m and the contact area ≥ 85%; Step S4: Develop a modular adaptive fixture system, including a piezoelectric ceramic-driven dynamic damper with a frequency response range of 5 Hz-500 Hz; a variable stiffness arm with a stiffness adjustment ratio of ≥10:1, and a topology optimized design; Step S5: Establish a clamping quality inspection system based on machine vision, identify connection defects through convolutional neural networks, use acoustic emission technology to monitor structural damage in real time, and set up a dual redundant safety interlocking mechanism.

[0006] Preferably, in step S1, the batch quantity is dynamically adjusted according to the production rhythm, and the formula is: Z=A÷(T÷t), where t is the single mechanical test time, T is the mechanical test production cycle, and A is the total product volume; The dynamic correction coefficient η is introduced, ranging from 0.8 to 1.2, and the calculation formula is optimized as follows: Z = η × [A ÷ (T / (t + t))], where t is the equipment cooling time and t=0.1t× , N is the cumulative number of tests; set the infrared thermal imager to monitor the temperature rise of the equipment in real time. When T>15℃, η value correction is automatically triggered.

[0007] Preferably, in step S3, the fixing state of the clamping device is kept consistent with the actual installation state of the product, including the strength of the clamping device, the preload force of the connection interface and the edge condition of the product fixation, wherein the resonance point of the clamping device is consistent with the actual state, and the tension force and angle of the soft connection part are consistent with the actual state; The specific implementation includes: using swept frequency vibration testing to ensure that the deviation between the first three natural frequencies of the clamping device and the product installation base is <±3%; setting a preload gradient loading system with a loading rate of ≤50N / s, and monitoring the interface stress distribution through a fiber grating sensor array with a spatial resolution of 1cm; establishing an edge condition digital twin database to store ≥100 sets of typical working condition parameter combinations.

[0008] Preferably, in step S3, the actual installation state of the slender rod structure product is: one end is fixed by a clamp and rigidly connected to the structural member, and the other end is fixed by a clamp and tightened and fixed by three steel wire ropes distributed at 120°, and the angle between the steel wire rope and the product is 90°. The above conditions need to be considered in the design of the clamping device, and the tensioning force of the steel wire rope and the material of the clamping device are consistent with the actual state; Building a virtual clamping system based on digital twins includes: developing a bionic clamp with self-sensing function, built-in MEMS accelerometer and strain gauge, using magnetorheological intelligent rope for wire rope tension, adjusting the response time <50ms, setting up a binocular vision system to measure the angle deviation in real time with an accuracy of ±0.1°, and automatically compensating for the thermal expansion coefficient of the material when the temperature fluctuates >±5℃.

[0009] Preferably, in step S4, the fixing methods of the two ends of the product are inconsistent, one end is rigidly connected, and the other end is non-rigidly connected, and the products are 180° symmetrically distributed; in the product testing phase, the electrical environment of the environment in which the equipment is located is tested, and if the actual environment does not meet the preset requirements, an electrical environment that meets the preset requirements is created by connecting an isolation transformer to the front end of the product; The electrical environment simulation is as follows: a three-degree-of-freedom hydraulic excitation table is set at the non-rigid end, with a displacement accuracy of ±0.01mm; an electromagnetic shielding room is constructed, with a shielding effectiveness of ≥80dB@10MHz-1GHz; the isolation transformer adopts a double shielding structure, and the leakage flux <1 T; Set up a power quality analyzer, THD<3%; Set up a ground resistance monitoring device, resistance<0.1Ω.

[0010] The system for mechanical testing of a batch of slender rod structure products provided by the present invention comprises: Module M1: Dynamically adjust the batch quantity according to the production rhythm, adopt a rolling optimization algorithm based on real-time data collection, and comprehensively consider the equipment fatigue coefficient and material creep characteristics to determine the maximum test batch; Module M2: Establish a multi-physics field coupling finite element model, use a nonlinear contact algorithm to simulate the product swing, iteratively optimize the installation gap through parameter inversion method, and set up a three-dimensional laser scan to verify that the deviation between the actual gap and the simulation is less than 0.5mm; Module M3: Build a virtual clamping system based on digital twins, use a six-dimensional force sensor to monitor the clamping state in real time, and use PID closed-loop control to make the preload fluctuation <±2% and the clamping surface roughness Ra≤3.2 m and the contact area ≥ 85%; Module M4: Development of a modular adaptive fixture system, including a piezoelectric ceramic-driven dynamic damper with a frequency response range of 5Hz-500Hz; a variable stiffness arm with a stiffness adjustment ratio of ≥10:1, and a topologically optimized design; Module M5: Establish a clamping quality inspection system based on machine vision, identify connection defects through convolutional neural networks, use acoustic emission technology to monitor structural damage in real time, and set up a dual redundant safety interlock mechanism.

[0011] Preferably, in the module M1, the batch quantity is dynamically adjusted according to the production rhythm, and the formula is: Z=A÷(T÷t), where t is the single mechanical test time, T is the mechanical test production cycle, and A is the total product volume; The dynamic correction coefficient η is introduced, ranging from 0.8 to 1.2, and the calculation formula is optimized as follows: Z = η × [A ÷ (T / (t + t))], where t is the equipment cooling time and t=0.1t× , N is the cumulative number of tests; set the infrared thermal imager to monitor the temperature rise of the equipment in real time. When T>15℃, η value correction is automatically triggered.

[0012] Preferably, in the module M3, the fixing state of the clamping device is kept consistent with the actual installation state of the product, including the strength of the clamping device, the preload force of the connection interface and the edge condition of the product fixation, wherein the resonance point of the clamping device is consistent with the actual state, and the tension force and angle of the soft connection part are consistent with the actual state; The specific implementation includes: using swept frequency vibration testing to ensure that the deviation between the first three natural frequencies of the clamping device and the product installation base is <±3%; setting a preload gradient loading system with a loading rate of ≤50N / s, and monitoring the interface stress distribution through a fiber grating sensor array with a spatial resolution of 1cm; establishing an edge condition digital twin database to store ≥100 sets of typical working condition parameter combinations.

[0013] Preferably, in the module M3, the actual installation state of the slender rod structure product is: one end is fixed by a clamp and rigidly connected to the structural member, and the other end is fixed by a clamp and tightened and fixed with three steel wire ropes distributed at 120°, and the angle between the steel wire rope and the product is 90°. The above conditions need to be considered in the design of the clamping device, and the tensioning force of the steel wire rope and the material of the clamping device should be consistent with the actual state; Building a virtual clamping system based on digital twins includes: developing a bionic clamp with self-sensing function, built-in MEMS accelerometer and strain gauge, using magnetorheological intelligent rope for wire rope tension, adjusting the response time <50ms, setting up a binocular vision system to measure the angle deviation in real time with an accuracy of ±0.1°, and automatically compensating for the thermal expansion coefficient of the material when the temperature fluctuates >±5℃.

[0014] Preferably, in the module M4, the fixing methods at both ends of the product are inconsistent, one end is rigidly connected, and the other end is non-rigidly connected, and the products are 180° symmetrically distributed; in the product testing phase, the electrical environment of the environment in which the equipment is located is tested. If the actual environment does not meet the preset requirements, an electrical environment that meets the preset requirements is created by connecting an isolation transformer to the front end of the product; The electrical environment simulation is as follows: a three-degree-of-freedom hydraulic excitation table is set at the non-rigid end, with a displacement accuracy of ±0.01mm; an electromagnetic shielding room is constructed, with a shielding effectiveness of ≥80dB@10MHz-1GHz; the isolation transformer adopts a double shielding structure, and the leakage flux <1 T; Set up a power quality analyzer, THD<3%; Set up a ground resistance monitoring device, resistance<0.1Ω.

[0015] Compared with the prior art, the present invention has the following beneficial effects: (1) The present invention starts from the perspective of the full-cycle production of slender rod structure products, integrates various links of product production, calculates the number of mechanical tests for batches of slender rod structure products, determines the structure of the clamping device by clarifying three key factors: product installation clearance, fixing requirements, and the load capacity of the test equipment, and obtains a method for batch mechanical tests, which helps to ensure product quality, improve mechanical test efficiency, optimize production processes, reduce production costs, and shorten production cycles; (2) The present invention solves the problem of low efficiency in mechanical testing of products with slender rod structures by optimizing the production process and designing a clamping device, which helps to achieve batch mechanical testing of more products with special-shaped structures. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Other features, objects and advantages of the present invention will become more apparent from the detailed description of non-limiting embodiments made with reference to the following drawings: Figure 1 The present invention mainly embodies a flow chart of determining the number of mechanical tests for a batch of slender rod structure products according to the production rhythm in step S1. DETAILED DESCRIPTION

[0017] The present invention is described in detail below in conjunction with specific embodiments. The following embodiments will help those skilled in the art to further understand the present invention, but are not intended to limit the present invention in any form. It should be noted that, for those of ordinary skill in the art, several changes and improvements can also be made without departing from the concept of the present invention. These all belong to the protection scope of the present invention.

[0018] Example 1 like Figure 1 As shown, the present invention provides a method for mechanical testing of a batch of slender rod structure products, comprising the following steps: Step S1, determining the number of mechanical tests for product batches according to the production rhythm; Step S2, determining the minimum installation gap between products according to the mechanical test simulation results; Step S3, determining the actual installation state of the product, and whether the fixing state of the clamping device is consistent with the actual installation state of the product; Step S4, determining and producing a mechanical test clamping device; Step S5, before the test begins, the clamping device is pre-tested to ensure that the structural strength meets the requirements and the product is reliably connected to the clamping device.

[0019] The present invention is aimed at the current status of mechanical testing of slender rod structure products. Slender rod structure products are generally cylindrical with a length of 1600~2400mm and a diameter of 30~60mm. With the goal of realizing mechanical testing of multiple slender rod structure products at the same time, a method for mechanical testing of batches of slender rod structure products is provided. The present invention combines production practice, accurately determines the number of product batches, and reasonably designs a clamping device, which can realize a method for mechanical testing of batches of slender rod structure products and can be widely used.

[0020] In step S1, the calculation method for determining the number of batch mechanical test products is: single mechanical test time t, mechanical test production cycle T, total product volume A, batch quantity Z = A ÷ (T ÷ t). Single mechanical test time t is determined by the mechanical test conditions and the difficulty of fixing the product and the clamping device; the mechanical test production cycle T is related to the total product volume A. Limited by the production cycle of the entire product, it is necessary to consider the maximum value of the batch quantity Z, balance T and A, and at the same time, T and A should reversely constrain the rolling quantity and production cycle of the previous product assembly process; the maximum value of the batch quantity Z is related to the size of the installation surface of the mechanical test equipment and the installation distance around the equipment.

[0021] The present invention takes the following data as an example: the mechanical test production cycle is T=4h, the total number of products is 16, the single mechanical test time (including product installation, test and testing time) is t=0.5h, and it takes 8h to complete the test of 16 products, which does not meet the mechanical test production cycle requirements. The batch mechanical test method is adopted, combined with the actual production situation, and the batch quantity Z=2 is determined. Combined with the full cycle production of the product, in order to meet the production peak demand, the batch mechanical test quantity is determined to be 4.

[0022] In step S2, a geometric model consistent with the shape of the slender rod structure product is established in the drawing software, and details that do not affect the mechanical behavior are removed to reduce the calculation amount of subsequent simulations; the elastic modulus, Poisson's ratio, density and other properties are defined according to the actual material of the product; the unit type is selected, and the grid is encrypted in the stress concentration area; the actual mechanical test conditions of the product are used as constraints, loads are applied, and the model is simulated on the SolidWorks Simulation simulation tool to determine that the shaking amplitude of the product end is about 36 mm, so the minimum installation gap between the two products is determined to be 72 mm.

[0023] 1. Refined Model Simulation Process 1. Geometric modeling and feature simplification Use SolidWorks parametric modeling to build a 1:1 three-dimensional solid model (modeling accuracy ±0.1mm); Remove non-load-bearing features such as threaded holes with a diameter of <3mm and fillets with a chamfer radius of <1mm (based on the Saint-Venant principle); Retain key connection structures: flange contact surface (roughness Ra=3.2μm), clamp installation groove (width tolerance ±0.05mm).

[0024] 2. Definition of material constitutive model Enter the material properties: Elastic modulus E = 210 GPa (typical value for alloy steel); Poisson's ratio ν = 0.3 (empirical value for metal materials); Density ρ = 7850 kg / m³; Yield strength σ_s=355 MPa (refer to GB / T 3077 standard); A bilinear strengthening model is established: tangent modulus E_t=0.01E.

[0025] 3. Intelligent grid division strategy The main body adopts hexahedral elements (element size 10mm); The stress concentration areas (such as the clamp contact surface) are encrypted with tetrahedral secondary elements; Encryption standard: start adaptive refinement when curvature change > 15°; The formula for calculating the number of grids is: N = k·(L / d)^3, k=1.2 is the density factor, L is the rod length 2000mm, and d is the unit size; The calculated total number of grids N≈1.2×(2000 / 10)^3=9600000 units.

[0026] 4. Boundary conditions and load settings Constraints: Fixed end: constrain X / Y / Z displacement and rotation (UX=UY=UZ=ROTX=ROTY=ROTZ=0); Active end: constrain radial displacement (UX=UY=0), allow axial rotation (ROTZ free); Load application: Transverse vibration load: F(t)=F_0·sin(2πft) (F_0=500N, f=25Hz); Axial preload: P = 2000N (simulated by bolt connection).

[0027] 5. Solution and post-processing Newton-Raphson iteration method (convergence tolerance 0.1%) Key output parameters: Maximum equivalent stress σ_max = 287 MPa < σ_s (safety factor n = 355 / 287 ≈ 1.24); End displacement time history curve: peak-to-peak value S_pp=36mm (corresponding amplitude A=18mm); The first-order natural frequency f_1=32.5Hz (1.3 times the excitation frequency of 25Hz).

[0028] 2. Implementation details of mechanical test process 1. Experimental preparation stage Test bench configuration: Three-axis vibration table (maximum thrust 20kN, frequency range 5-2000Hz) Clamping device: Rigid end: 42CrMo alloy steel clamp (hardness HRC50-55) Flexible end: 304 stainless steel wire rope (diameter 8mm, breaking strength ≥1570MPa) Environmental Control: Temperature: 23±2℃ (PID temperature control system) Humidity: 45±5%RH (dehumidifier unit) 2. Dynamic loading implementation Load spectrum design (refer to MIL-STD-810G standard): | Operating Conditions | Frequency (Hz) | Acceleration (g) | Duration (min) | | Sweep | 5-500 | 1.5 | 15 | | Fixed frequency | 25 | 3.0 | 30 | | Random | 20-2000 | 0.04g² / Hz | 60 | Dynamic clearance calculation formula: D= , =1.5 is the dynamic amplification factor; Substituting S_static=36mm, we get D=108mm. Taking the safety factor of 1.5, we determine the final gap to be 72mm.

[0029] 3. Data Acquisition System Sensor arrangement: | Measurement parameters | Sensor type | Sampling frequency | Layout location | | Acceleration | PCB 356A01 (±500g) | 10kHz | 50mm from the end | | Strain | HBM LY41 (±5000με) | 2kHz | Middle of the rod | | Displacement | Keyence LK-H050 (±50mm) | 1kHz | Active end | Synchronous trigger error <1μs (using IEEE 1588 precise clock protocol) 4. Test verification process Preliminary test (50% load): Check that the slippage of the clamping device is less than 0.1 mm (verified by laser rangefinder) Monitored resonance frequency deviation <±2% (compared with simulation) Formal test: Use step loading: 50% → 80% → 100% → 120% load Each load level lasts for 10 minutes and records the data Failure criteria (test terminated if any condition is met): Residual deformation>0.2%L (L=rod length) Crack length>5mm (industrial endoscope detection) Frequency characteristic change>10% 3. Comparison and verification of key parameters | Parameters| Simulation Value| Test Value| Error| | End displacement (mm) | 36.0 | 37.2 | +3.3% | | First-order frequency (Hz) | 32.5 | 31.8 | -2.2% | | Maximum stress (MPa) | 287 | 301 | +4.9% | | Installation clearance (mm) | 72 | 75 (actual measurement requirement) | +4.2% | Technical effect: Through refined modeling (error <5%) and dynamic gap calculation, the batch test efficiency is improved by 40% (originally single-piece testing was required), while avoiding product interference (measured minimum gap 75mm> theoretical value 72mm).

[0030] In step S3, the actual installation state of the slender rod structure product is that one end is fixed with a clamp and rigidly connected to the structural member, and the other end is fixed with a clamp and tightened with three steel ropes distributed at 120°. The angle between the steel rope and the product is 90°. The above conditions must be considered in the design of the clamping device, and the tensioning force of the steel rope and the material of the clamping device must be consistent with the actual state.

[0031] In step S4, the fixing methods at both ends of the product are inconsistent, one end is rigidly connected and the other end is non-rigidly connected, and the shaking amplitude is 36mm. Therefore, when designing the clamping device, the products are distributed 180° symmetrically, and the minimum installation gap of the product is reduced from 72mm to 40mm; since the product length is 1600~2400mm, the space around the test equipment can meet the needs of laying the product flat; at the same time, the product has relatively high requirements on the electrical environment of the equipment during the test phase. When the requirements are not met, an isolation transformer is connected to the front end of the product to create a relatively pure electrical environment.

[0032] In step S5, before the product and the clamping device are installed, the clamping device should be pre-tested to ensure the reliability of the clamping device. At the same time, the clamping device is designed with binding points for fixing the wire harness to protect the wire harness.

[0033] The present invention provides a method for designing a clamping device in combination with a method for calculating the number of mechanical tests on a batch of slender rod structure products in actual production, thereby realizing mechanical tests on a batch of slender rod structure products.

[0034] Example 2 The present invention also provides a system for mechanical testing of batches of slender rod structure products. The system for mechanical testing of batches of slender rod structure products can be realized by executing the process steps of the method for mechanical testing of batches of slender rod structure products, that is, those skilled in the art can understand the method for mechanical testing of batches of slender rod structure products as a preferred implementation of the system for mechanical testing of batches of slender rod structure products.

[0035] The system for mechanical testing of batches of slender rod structure products provided by the present invention comprises: module M1: dynamically adjusting the batch quantity according to the production rhythm, adopting a rolling optimization algorithm based on real-time data acquisition, and comprehensively considering the equipment fatigue coefficient and material creep characteristics to determine the maximum test batch; module M2: establishing a multi-physical field coupling finite element model, adopting a nonlinear contact algorithm to simulate the product swing amplitude, iteratively optimizing the installation gap through the parameter inversion method, and setting a three-dimensional laser scanning to verify that the actual gap and the simulation deviation are <0.5mm; module M3: constructing a virtual clamping system based on digital twins, adopting a six-dimensional force sensor to monitor the clamping state in real time, and using PID closed-loop control to make the preload fluctuation <±2%, and the clamping surface roughness Ra≤3.2 m and the contact area ≥85%; Module M4: Develop a modular adaptive fixture system, including a piezoelectric ceramic-driven dynamic damper with a frequency response range of 5Hz-500Hz; variable stiffness arm, stiffness adjustment ratio ≥10:1, and adopt topological optimization design; Module M5: Establish a clamping quality inspection system based on machine vision, identify connection defects through convolutional neural networks, use acoustic emission technology to monitor structural damage in real time, and set up a dual redundant safety interlocking mechanism.

[0036] In the module M1, the batch quantity is dynamically adjusted according to the production rhythm, and the formula is: Z = A ÷ (T ÷ t), where t is the single mechanical test time, T is the mechanical test production cycle, and A is the total product volume; The dynamic correction coefficient η is introduced, ranging from 0.8 to 1.2, and the calculation formula is optimized as follows: Z = η × [A ÷ (T / (t + t))], where t is the equipment cooling time and t=0.1t× , N is the cumulative number of tests; set the infrared thermal imager to monitor the temperature rise of the equipment in real time. When T>15℃, η value correction is automatically triggered.

[0037] In the module M2, the multi-physics field coupling finite element modeling process is: 1. Model framework construction: Structural Field: Using Explicit Dynamics Equations

[0038] Contact Field: Defining Contact Pairs

[0039] Thermal Field: Coupled Temperature Field

[0040] In the formula, is the density, is the Cauchy stress tensor, k is the thermal conductivity, The power generated by frictional heat.

[0041] 2. Material constitutive model Nonlinear elastoplastic model:

[0042] Temperature dependent properties (when coupled with thermal fields):

[0043] The nonlinear swing simulation implementation process is: 1. Solving kinetic equations Display time integral:

[0044] Time step control:

[0045] Load application method: Inertial load: Apply base acceleration

[0046] Forced Vibration: Direct Nodal Force Loading

[0047] Convergence Control Residual control criteria:

[0048] Adaptive time step adjustment: When the number of iterations > 5,

[0049] The parameter inversion iterative optimization process is: Optimization problem definition, objective function:

[0050] is the installation gap involved variable, λ=0.1: Tikhonov regularization coefficient.

[0051] Sensitivity analysis, derivative of adjoint variables:

[0052] The accompanying variable λ satisfies: .

[0053] In the module M3, the fixing state of the clamping device is kept consistent with the actual installation state of the product, including the strength of the clamping device, the preload force of the connection interface and the edge conditions of the product fixation, wherein the resonance point of the clamping device is consistent with the actual state, and the tension force and angle of the soft connection part are consistent with the actual state; The specific implementation includes: using swept frequency vibration testing to ensure that the deviation between the first three natural frequencies of the clamping device and the product installation base is <±3%; setting a preload gradient loading system with a loading rate of ≤50N / s, and monitoring the interface stress distribution through a fiber grating sensor array with a spatial resolution of 1cm; establishing an edge condition digital twin database to store ≥100 sets of typical working condition parameter combinations.

[0054] In the module M3, the actual installation state of the slender rod structure product is: one end is fixed with a clamp and rigidly connected to the structural member, and the other end is fixed with a clamp and tightened with three steel wire ropes distributed at 120°. The angle between the steel wire rope and the product is 90°. The above conditions need to be considered in the design of the clamping device, and the tension of the steel wire rope and the material of the clamping device should be consistent with the actual state; Building a virtual clamping system based on digital twins includes: developing a bionic clamp with self-sensing function, built-in MEMS accelerometer and strain gauge, using magnetorheological intelligent rope for wire rope tension, adjusting the response time <50ms, setting up a binocular vision system to measure the angle deviation in real time with an accuracy of ±0.1°, and automatically compensating for the thermal expansion coefficient of the material when the temperature fluctuates >±5℃.

[0055] In the module M4, the fixing methods at both ends of the product are inconsistent, one end is rigidly connected, and the other end is non-rigidly connected, and the products are 180° symmetrically distributed; in the product testing phase, the electrical environment of the equipment is tested. If the actual environment does not meet the preset requirements, an electrical environment that meets the preset requirements is created by connecting an isolation transformer to the front end of the product; The electrical environment simulation is as follows: a three-degree-of-freedom hydraulic excitation table is set at the non-rigid end, with a displacement accuracy of ±0.01mm; an electromagnetic shielding room is constructed, with a shielding effectiveness of ≥80dB@10MHz-1GHz; the isolation transformer adopts a double shielding structure, and the leakage flux <1 T; Set up a power quality analyzer, THD<3%; Set up a ground resistance monitoring device, resistance<0.1Ω.

[0056] Those skilled in the art know that, in addition to implementing the system, device and its various modules provided by the present invention in a purely computer-readable program code, it is entirely possible to implement the same program in the form of logic gates, switches, application-specific integrated circuits, programmable logic controllers and embedded microcontrollers by logically programming the method steps. Therefore, the system, device and its various modules provided by the present invention can be considered as a hardware component, and the modules included therein for implementing various programs can also be considered as structures within the hardware component; the modules for implementing various functions can also be considered as both software programs for implementing the method and structures within the hardware component.

[0057] The above describes the specific embodiments of the present invention. It should be understood that the present invention is not limited to the above specific embodiments, and those skilled in the art can make various changes or modifications within the scope of the claims, which does not affect the essence of the present invention. In the absence of conflict, the embodiments of the present application and the features in the embodiments can be combined with each other arbitrarily.

Claims

1. A method for mechanical testing of batches of slender rod structure products, characterized in that: include: Step S1: dynamically adjust the batch quantity according to the production rhythm, adopt a rolling optimization algorithm based on real-time data collection, and comprehensively consider the equipment fatigue coefficient and material creep characteristics to determine the maximum test batch; Step S2: Establish a multi-physics field coupling finite element model, use a nonlinear contact algorithm to simulate the product swing, iteratively optimize the installation gap through parameter inversion method, and set up a three-dimensional laser scanning to verify that the deviation between the actual gap and the simulation is less than 0.5mm; Step S3: Build a virtual clamping system based on digital twins, use a six-dimensional force sensor to monitor the clamping state in real time, and use PID closed-loop control to make the preload fluctuation <±2% and the clamping surface roughness Ra≤3.2 m and the contact area ≥ 85%; Step S4: Develop a modular adaptive fixture system, including a piezoelectric ceramic-driven dynamic damper with a frequency response range of 5 Hz-500 Hz; a variable stiffness arm with a stiffness adjustment ratio of ≥10:1, and a topology optimized design; Step S5: Establish a clamping quality inspection system based on machine vision, identify connection defects through convolutional neural networks, use acoustic emission technology to monitor structural damage in real time, and set up a dual redundant safety interlocking mechanism.

2. The method for mechanical testing of a batch of slender rod structure products according to claim 1 is characterized in that: In the step S1, the batch quantity is dynamically adjusted according to the production rhythm, and the formula is: Z=A÷(T÷t), where t is the single mechanical test time, T is the mechanical test production cycle, and A is the total product volume; The dynamic correction coefficient η is introduced, ranging from 0.8 to 1.2, and the calculation formula is optimized as follows: Z = η × [A ÷ (T / (t + t))], where t is the equipment cooling time and t=0.1t× , N is the cumulative number of tests; set the infrared thermal imager to monitor the temperature rise of the equipment in real time. When T>15℃, η value correction is automatically triggered.

3. The method for mechanical testing of a batch of slender rod structure products according to claim 1, characterized in that: In step S3, the fixing state of the clamping device is kept consistent with the actual installation state of the product, including the strength of the clamping device, the preload force of the connection interface and the edge condition of the product fixation, wherein the resonance point of the clamping device is consistent with the actual state, and the tension force and angle of the soft connection part are consistent with the actual state; The specific implementation includes: using swept frequency vibration testing to ensure that the deviation between the first three natural frequencies of the clamping device and the product installation base is <±3%; setting a preload gradient loading system with a loading rate of ≤50N / s, and monitoring the interface stress distribution through a fiber grating sensor array with a spatial resolution of 1cm; establishing an edge condition digital twin database to store ≥100 sets of typical working condition parameter combinations.

4. The method for mechanical testing of a batch of slender rod structure products according to claim 1, characterized in that: In step S3, the actual installation state of the slender rod structure product is: one end is fixed by a clamp and rigidly connected to the structural member, and the other end is fixed by a clamp and tightened and fixed with three steel wire ropes distributed at 120°, the angle between the steel wire rope and the product is 90°, and the tension of the steel wire rope and the material of the clamping device are consistent with the actual state; Building a virtual clamping system based on digital twins includes: developing a bionic clamp with self-sensing function, built-in MEMS accelerometer and strain gauge, using magnetorheological intelligent rope for wire rope tension, adjusting the response time <50ms, setting up a binocular vision system to measure the angle deviation in real time with an accuracy of ±0.1°, and automatically compensating for the thermal expansion coefficient of the material when the temperature fluctuates >±5℃.

5. The method for mechanical testing of a batch of slender rod structure products according to claim 1, characterized in that: In step S4, the fixing methods of the two ends of the product are inconsistent, one end is rigidly connected, and the other end is non-rigidly connected, and the products are 180° symmetrically distributed; in the product testing phase, the electrical environment of the environment in which the equipment is located is tested. If the actual environment does not meet the preset requirements, an electrical environment that meets the preset requirements is created by connecting an isolation transformer to the front end of the product; The electrical environment simulation is as follows: a three-degree-of-freedom hydraulic excitation table is set at the non-rigid end, with a displacement accuracy of ±0.01mm; an electromagnetic shielding room is constructed, with a shielding effectiveness of ≥80dB@10MHz-1GHz; the isolation transformer adopts a double shielding structure, and the leakage flux <1 T; Set the power quality analyzer, THD < 3%; Set up a ground resistance monitoring device with a resistance value of <0.1Ω.

6. A system for mechanical testing of batches of slender rod structure products, characterized in that: include: Module M1: Dynamically adjust the batch quantity according to the production rhythm, adopt a rolling optimization algorithm based on real-time data collection, and comprehensively consider the equipment fatigue coefficient and material creep characteristics to determine the maximum test batch; Module M2: Establish a multi-physics field coupling finite element model, use a nonlinear contact algorithm to simulate the product swing, iteratively optimize the installation gap through parameter inversion method, and set up a three-dimensional laser scan to verify that the deviation between the actual gap and the simulation is less than 0.5mm; Module M3: Build a virtual clamping system based on digital twins, use a six-dimensional force sensor to monitor the clamping state in real time, and use PID closed-loop control to make the preload fluctuation <±2% and the clamping surface roughness Ra≤3.2 m and the contact area ≥ 85%; Module M4: Development of a modular adaptive fixture system, including a piezoelectric ceramic-driven dynamic damper with a frequency response range of 5Hz-500Hz; a variable stiffness arm with a stiffness adjustment ratio of ≥10:1, and a topologically optimized design; Module M5: Establish a clamping quality inspection system based on machine vision, identify connection defects through convolutional neural networks, use acoustic emission technology to monitor structural damage in real time, and set up a dual redundant safety interlock mechanism.

7. The system for mechanical testing of batches of slender rod structure products according to claim 6, characterized in that: In the module M1, the batch quantity is dynamically adjusted according to the production rhythm, and the formula is: Z = A ÷ (T ÷ t), where t is the single mechanical test time, T is the mechanical test production cycle, and A is the total product volume; The dynamic correction coefficient η is introduced, ranging from 0.8 to 1.2, and the calculation formula is optimized as follows: Z = η × [A ÷ (T / (t + t))], where t is the equipment cooling time and t=0.1t× , N is the cumulative number of tests; set the infrared thermal imager to monitor the temperature rise of the equipment in real time. When T>15℃, η value correction is automatically triggered.

8. The system for batch mechanical testing of slender rod structure products according to claim 6, characterized in that: In the module M3, the fixing state of the clamping device is kept consistent with the actual installation state of the product, including the strength of the clamping device, the preload force of the connection interface and the edge conditions of the product fixation, wherein the resonance point of the clamping device is consistent with the actual state, and the tension force and angle of the soft connection part are consistent with the actual state; The specific implementation includes: using swept frequency vibration testing to ensure that the deviation between the first three natural frequencies of the clamping device and the product installation base is <±3%; setting a preload gradient loading system with a loading rate of ≤50N / s, and monitoring the interface stress distribution through a fiber grating sensor array with a spatial resolution of 1cm; establishing an edge condition digital twin database to store ≥100 sets of typical working condition parameter combinations.

9. The system for batch mechanical testing of slender rod structure products according to claim 6, characterized in that: In the module M3, the actual installation state of the slender rod structure product is: one end is fixed with a clamp and rigidly connected to the structural member, and the other end is fixed with a clamp and tightened with three steel wire ropes distributed at 120°, the angle between the steel wire rope and the product is 90°, and the tension of the steel wire rope and the material of the clamping device are consistent with the actual state; Building a virtual clamping system based on digital twins includes: developing a bionic clamp with self-sensing function, built-in MEMS accelerometer and strain gauge, using magnetorheological intelligent rope for wire rope tension, adjusting the response time <50ms, setting up a binocular vision system to measure the angle deviation in real time with an accuracy of ±0.1°, and automatically compensating for the thermal expansion coefficient of the material when the temperature fluctuates >±5℃.

10. The system for batch mechanical testing of slender rod structure products according to claim 6, characterized in that: In the module M4, the fixing methods at both ends of the product are inconsistent, one end is rigidly connected, and the other end is non-rigidly connected, and the products are 180° symmetrically distributed; in the product testing phase, the electrical environment of the equipment is tested. If the actual environment does not meet the preset requirements, an electrical environment that meets the preset requirements is created by connecting an isolation transformer to the front end of the product; The electrical environment simulation is as follows: a three-degree-of-freedom hydraulic excitation table is set at the non-rigid end, with a displacement accuracy of ±0.01mm; an electromagnetic shielding room is constructed, with a shielding effectiveness of ≥80dB@10MHz-1GHz; the isolation transformer adopts a double shielding structure, and the leakage flux <1 T; Set the power quality analyzer, THD < 3%; Set up a ground resistance monitoring device with a resistance value of <0.1Ω.

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