Safety subsystem design method and system, test bench and vehicle
By conducting electrical safety verification and prevention design during the development stage of the drive motor, and using the power subsystem model and vehicle collision simulation analysis, the electrical safety problems caused by the failure of the drive motor during the vehicle model development process are solved, which reduces the development cost and verification cycle and improves safety.
Patent Information
- Application Number
- CN202510012943.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-01-03
- Publication Date
- 2025-05-13
AI Technical Summary
During the vehicle model development process, the electrical safety problems caused by the failure of the drive motor during the vehicle test resulted in high cost and tight cycles of later improvement design, which affected the safety development cost and cycle of the vehicle model.
By obtaining the powertrain installation data of the target vehicle, establishing a power subsystem model, performing vehicle collision simulation analysis of the target collision conditions, extracting power failure characteristics, determining safety areas, and generating safety subsystem design schemes to perform electrical safety verification and prevention design during the development stage of the drive motor.
It reduces the high-voltage electrical safety problems caused by the failure of the drive motor in the vehicle test in the later model development, reduces the development cost and verification cycle, and improves safety.
Smart Images
Figure CN119989643A_ABST
Abstract
Description
Technical Field
[0001] The present application relates to the field of vehicle technology, and in particular to a safety subsystem design method, system, test bench and vehicle. Background Art
[0002] As a significant feature that distinguishes new energy vehicles from traditional fuel vehicles, electrical safety has become a topic of widespread concern within and outside the industry. The drive motor is one of the core components of new energy vehicles. It is not only the main power source of the vehicle, but also a key part of the high-voltage electrical system. If the drive motor fails during a collision, such as the high-voltage coil is damaged and high-voltage electricity leaks, it may cause a serious risk of electrical fire, which not only threatens the life safety of the occupants, but may also cause huge property losses.
[0003] In the relevant technology, the circuit design is generally optimized, such as setting active short circuit and active discharge mechanisms, to quickly reduce the voltage of the high-voltage system in emergency situations such as collisions, thereby reducing potential electrical hazards. Although these measures can improve the electrical safety performance of new energy vehicles to a certain extent, they often rely on comprehensive testing at the vehicle level to verify their effectiveness. When the problem is discovered, the housing development of the drive motor is generally completed, resulting in many restrictions on dealing with such high-voltage electrical safety issues in the later stage, high costs for improving the design, and a tight cycle for improving and verifying the problem, which has a great impact on the safety development cost and cycle of the vehicle model. Summary of the invention
[0004] The present application provides a safety subsystem design method, system, test bench and vehicle to solve the electrical safety problem caused by drive motor failure in the whole vehicle test during the vehicle model development process.
[0005] The first aspect of the present application provides a safety subsystem design method, comprising the following steps: acquiring powertrain installation data of a target vehicle; establishing a power subsystem model of the target vehicle based on the powertrain installation data; performing a whole-vehicle collision simulation analysis of a target collision condition based on the power subsystem model, and extracting power failure characteristics from the simulation data of the whole-vehicle collision simulation analysis process; determining a target safety area in the whole-vehicle collision simulation analysis process based on the power failure characteristics, and generating a design plan for a target safety subsystem of the target vehicle based on the target safety area.
[0006] Optionally, the powertrain installation data includes an engine installation position, a drive motor installation position and a suspension installation position.
[0007] Optionally, the dynamic failure characteristic includes at least one of a failure mode, a failure peak force and a failure time.
[0008] Optionally, a whole vehicle collision simulation analysis of a target collision condition is performed based on the power subsystem model, including: obtaining a collision loading mode and a collision loading boundary of the whole vehicle collision simulation analysis; and performing a whole vehicle collision simulation analysis of the target collision condition on the power subsystem model under the collision loading mode and the collision loading boundary.
[0009] Optionally, before executing the whole vehicle collision simulation analysis of the target collision condition based on the power subsystem model, it also includes: obtaining collision data of different vehicle models under each whole vehicle frontal collision condition; extracting force characteristics in the collision data, and determining the target collision condition in each whole vehicle frontal collision condition according to the force characteristics.
[0010] Optionally, the frontal collision conditions of the whole vehicle include full frontal collision conditions, offset collision conditions, small offset collision conditions, frontal drilling and jamming conditions, and frontal pillar collision conditions.
[0011] A second aspect of the present application provides a security subsystem, which is designed using the security subsystem design method of the above embodiment.
[0012] A third aspect of the present application provides a powertrain system, including the safety subsystem of the above embodiment.
[0013] A fourth aspect of the present application provides a vehicle, comprising the powertrain system of the above embodiment.
[0014] A fifth aspect of the present application provides a test bench for a powertrain system, the test bench being used to perform a collision test on the powertrain system of the above-mentioned embodiment, wherein the test bench comprises: a barrier impact module and a bracket base; a plurality of mounting brackets, wherein the plurality of mounting brackets are arranged on the bracket base, the relative positions and spacings between the plurality of mounting brackets are adjustable, and the plurality of mounting brackets are used to place the powertrain system.
[0015] Therefore, this application includes the following beneficial effects:
[0016] The embodiments of the present application can perform electrical safety verification and preventive design during the drive motor development stage, flexibly adjust the design scheme to adapt to different collision conditions and safety requirements, and at the same time establish a power subsystem model of the target vehicle based on the powertrain installation data to perform vehicle collision simulation analysis of the target collision condition, which can reduce high-voltage electrical safety problems caused by drive motor failure in vehicle testing during later vehicle model development, and reduce development costs and verification cycles.
[0017] Additional aspects and advantages of the present application will be given in part in the description below, and in part will become apparent from the description below, or will be learned through the practice of the present application. BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The above and / or additional aspects and advantages of the present application will become apparent and easily understood from the following description of the embodiments in conjunction with the accompanying drawings, in which:
[0019] Figure 1 A flowchart of a security subsystem design method provided according to an embodiment of the present application;
[0020] Figure 2 This is an example diagram of a power subsystem model provided according to an embodiment of the present application;
[0021] Figure 3 A partial diagram of a collision simulation model provided according to an embodiment of the present application;
[0022] Figure 4 A schematic diagram of the force condition of the drive motor in a front working condition according to an embodiment of the present application;
[0023] Figure 5 A comparison chart of key indicators of different loading methods provided according to an embodiment of the present application;
[0024] Figure 6 A schematic diagram of a design scheme for a drive motor subsystem according to an embodiment of the present application;
[0025] Figure 7 A schematic diagram of a test bench for a powertrain system provided according to an embodiment of the present application;
[0026] Figure 8 The present invention is a flowchart corresponding to the method for the electric safety subsystem of a driving motor provided according to an embodiment of the present application. DETAILED DESCRIPTION
[0027] The embodiments of the present application are described in detail below, and examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present application, and should not be construed as limiting the present application.
[0028] The following describes the safety subsystem design method, safety subsystem, powertrain system, test bench and vehicle of the embodiment of the present application with reference to the accompanying drawings. In response to the problems mentioned in the above background technology, the present application provides a safety subsystem design method, which performs electrical safety verification and preventive design in the drive motor development stage, flexibly adjusts the design scheme to adapt to different collision conditions and safety requirements, and at the same time establishes a power subsystem model of the target vehicle based on the powertrain installation data to perform vehicle collision simulation analysis of the target collision condition, which can reduce the high-voltage electrical safety problems caused by the failure of the drive motor in the vehicle test during the later stage of vehicle model development, and reduce the development cost and verification cycle.
[0029] Specifically, Figure 1 A flowchart of a security subsystem design method provided in an embodiment of the present application.
[0030] like Figure 1 As shown, the safety subsystem design method includes the following steps:
[0031] In step S101 , the powertrain installation data of the target vehicle is obtained.
[0032] Among them, the powertrain installation data includes the engine installation position, the drive motor installation position and the suspension installation position.
[0033] In step S102, a power subsystem model of the target vehicle is established according to the powertrain installation data.
[0034] It is understandable that the embodiment of the present application obtains the powertrain installation data of the target vehicle, including information such as the engine installation position, the drive motor installation position, and the suspension installation position, which can be used to build an accurate power subsystem model, such as Figure 2 As shown in the figure, the model should accurately reflect the actual layout of the powertrain and its accessories in the whole vehicle, including the position and direction of all fixed points, so as to better understand and predict the behavioral characteristics of the powertrain under the whole vehicle collision condition.
[0035] In step S103, a full vehicle collision simulation analysis of a target collision condition is performed based on the power subsystem model, and power failure features in the simulation data of the full vehicle collision simulation analysis process are extracted.
[0036] The power failure characteristics include at least one of the failure mode, the failure peak force and the failure time. The embodiment of the present application can obtain the collision data of different vehicle models under various vehicle frontal collision conditions; extract the force characteristics in the collision data, and determine the target collision condition in each vehicle frontal collision condition according to the force characteristics.
[0037] Specifically, the embodiments of the present application can determine the collision conditions of the electrical safety design of the whole vehicle based on accident statistics, laws and regulations, and three-party evaluation procedures, which may include full frontal collision conditions FRB, offset collision conditions MPDB, small offset collision conditions SORB (25% overlap), front drill-stuck conditions URT, frontal pillar collision conditions FPB and other frontal collision conditions. In the actual implementation process, the embodiments of the present application can collect collision data of different vehicle models under various vehicle frontal collision conditions, including but not limited to collision speed, collision angle, obstacle type (such as rigid barriers, deformable barriers, etc.), vehicle deformation, in-vehicle dummy injury index, etc. Extract the key force parameters of the powertrain (especially the drive motor) during the collision process from the collision data, such as Figure 3As shown in the figure, a high-precision vehicle collision simulation model is established. Through the vehicle collision simulation technology, the force form, force size and characteristics of the drive motor (including the engine) of different models under various vehicle frontal collision conditions are compared and studied. Combined with the failure characteristics of the drive motor of different models in the frontal vehicle collision test, the target collision condition for the failure of the drive motor in the frontal condition is determined, such as Figure 4 As shown, in the embodiment of the present application, the working condition corresponding to the maximum value among F1, F2, F3, F4 and F5 can be selected as the target collision working condition.
[0038] Furthermore, a whole vehicle collision simulation analysis of a target collision condition is performed based on the power subsystem model, including: obtaining a collision loading mode and a collision loading boundary of the whole vehicle collision simulation analysis; and performing a whole vehicle collision simulation analysis of the target collision condition on the power subsystem model under the collision loading mode and the collision loading boundary.
[0039] In the embodiment of the present application, the collision loading boundary includes forced displacement, initial velocity, trolley weight, etc. Based on the power subsystem model, the failure mode (failure position), failure peak force and failure time of different loading methods and loading boundaries (forced displacement, initial velocity, trolley weight, etc.) are studied, as shown in Table 1. Among them, the X1 displacement ensures that the drive motor fails, and the V1 / V2 initial velocity acts to ensure that the drive motor shell fails, and V2>V1.
[0040] Table 1
[0041]
[0042] Furthermore, according to the obtained collision loading mode and loading boundary, the embodiment of the present application can set corresponding parameters in the simulation software, such as defining the collision speed, collision direction, collision object and the initial state of the vehicle, etc., to establish a high-precision vehicle collision simulation model to simulate the entire collision process, and after the simulation is completed, extract the required data from the simulation results, such as the failure position, failure peak force and failure time of the power subsystem during the collision.
[0043] like Figure 5 As shown, the embodiment of the present application determines the design of the drive motor subsystem that is decoupled from the whole vehicle through a comparative study of key evaluation indicators. Specifically, the comparative study of the simulation results of this embodiment shows that compared with the forced displacement loading and the initial speed (which can ensure the failure of the drive motor housing) loading method, the peak force of the initial speed loading method is closer to the whole vehicle simulation, and the fluctuation of the peak force and the failure time is smaller when loading with different initial speeds, and the fit with the whole vehicle collision condition is better, so the subsystem test can be carried out by initial speed loading. Combined with the failure characteristics of the drive motor in the whole vehicle collision test, the design of the high-voltage electrical safety subsystem of the drive motor frontal collision is determined, such as Figure 6 Through such simulation tests, preliminary verification can be carried out without actual collision tests, reducing high-voltage electrical safety issues caused by drive motor failure in the later vehicle development and vehicle testing, reducing development costs and verification cycles, and also improving safety.
[0044] In step S104, a target safety area in the whole vehicle collision simulation analysis process is determined according to the power failure characteristics, and a design scheme of a target safety subsystem of the target vehicle is generated according to the target safety area.
[0045] It can be understood that the embodiments of the present application can control the failure area (position) of the drive electric drive within the non-high-voltage electrical safety critical area, thereby solving the high-voltage electrical safety risk caused by the failure of the drive motor in the subsequent vehicle collision test, and can reduce the design changes of the drive motor caused by solving such problems, reduce repeated vehicle verification resources (test fees and test prototypes), and shorten the development cycle.
[0046] According to the safety subsystem design method proposed in the embodiment of the present application, electrical safety verification and preventive design are performed in the drive motor development stage, and the design scheme is flexibly adjusted to adapt to different collision conditions and safety requirements. At the same time, a power subsystem model of the target vehicle is established based on the powertrain installation data to perform vehicle collision simulation analysis of the target collision condition. This can reduce high-voltage electrical safety problems caused by drive motor failure in vehicle tests during later vehicle model development, and reduce development costs and verification cycles.
[0047] Secondly, an embodiment of the present application also provides a security subsystem, which is designed using the security subsystem design method of the above embodiment.
[0048] An embodiment of the present application also provides a powertrain system, including the safety subsystem of the above embodiment.
[0049] An embodiment of the present application also provides a vehicle, comprising the powertrain system of the above embodiment.
[0050] In addition, a test bench for a powertrain system according to an embodiment of the present application is described with reference to the accompanying drawings.
[0051] Figure 7 Schematic diagram of a test bench for a powertrain system according to an embodiment of the present application, wherein the test bench is used to perform a collision test on the powertrain system according to the above embodiment.
[0052] like Figure 7As shown, the test bench of the powertrain system includes: a barrier impact module and a bracket base; a plurality of mounting brackets arranged on the bracket base, wherein the plurality of mounting brackets include left / right suspension mounting brackets and rear suspension mounting brackets, the relative positions and spacings between the plurality of mounting brackets are adjustable, and the plurality of mounting brackets are used to place the powertrain system.
[0053] In the embodiment of the present application, the barrier impact module can also be used for other side column collision or other subsystem tests; the left, right and rear suspension mounting brackets have adjustable left and right, up and down spacing and positions, and the bench tooling is expandable. By adjusting the position of the mounting bracket, it can meet the installation of different drive motors (suspension).
[0054] In the actual implementation process, based on the test bench of the embodiment of the present application and using the existing traction system of the whole vehicle collision test to carry out the subsystem bench test, the failure of the whole vehicle collision test can be better presented, and the effectiveness of the safety subsystem solution is verified.
[0055] Combine the following Figure 8 The safety subsystem design method and test bench of the embodiment of the present application are described in detail, including the following steps:
[0056] Step 1: Based on accident statistics, regulations and third-party evaluation procedures, determine the collision conditions for the vehicle's electrical safety design, including full frontal collision (FRB), offset collision (MPDB), small offset collision (25% overlap rate SORB), frontal penetration (URT), frontal pole collision (FPB) and other frontal collision conditions;
[0057] Step 2: Compare and study the force forms, magnitudes and characteristics of the drive motors (including engines) of different models under various vehicle frontal collision conditions, and determine the most dangerous conditions for the failure of the drive motors in frontal collision tests of different models in combination with the failure characteristics of the drive motors of different models;
[0058] Step 3: Establish a power subsystem model of the target vehicle based on the powertrain installation data;
[0059] Step 4: Based on the subsystem design scheme model established in step 3 and combined with the failure characteristics of the drive motor in the vehicle collision test, determine the design scheme of the high-voltage electrical safety subsystem of the drive motor in frontal collision;
[0060] Step 5: Based on the subsystem design scheme determined in step 4 above, consider the versatility of the subsystem test device and the convenience of test implementation, and design the subsystem test fixture and test bench;
[0061] Step 6: Implementation of bench test of drive motor subsystem.
[0062] It should be noted that the safety subsystem design method and test bench involved in the embodiments of the present application are not limited to use in the field of high-voltage electrical safety of drive motors, but can also be used for the design and verification of other safety performance (such as oil leakage, etc.) of the power system.
[0063] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. In this specification, the schematic representations of the above terms are not necessarily directed to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or N embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine the different embodiments or examples described in this specification and the features of the different embodiments or examples, without contradiction.
[0064] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of the features. In the description of this application, "N" means at least two, such as two, three, etc., unless otherwise clearly and specifically defined.
[0065] Any process or method description in a flowchart or otherwise described herein may be understood to represent a module, fragment or portion of code comprising one or N executable instructions for implementing the steps of a custom logical function or process, and the scope of the preferred embodiments of the present application includes alternative implementations in which functions may not be performed in the order shown or discussed, including performing functions in a substantially simultaneous manner or in reverse order depending on the functions involved, which should be understood by technicians in the technical field to which the embodiments of the present application belong.
[0066] It should be understood that the various parts of the present application can be implemented in hardware, software, firmware or a combination thereof. In the above-mentioned embodiments, the steps or methods can be implemented in software or firmware stored in a memory and executed by a suitable instruction execution system. For example, if implemented in hardware, as in another embodiment, it can be implemented by any one of the following technologies known in the art or their combination: a discrete logic circuit having a logic gate circuit for implementing a logic function on a data signal, a dedicated integrated circuit having a suitable combination of logic gate circuits, a programmable gate array, a field programmable gate array, etc.
[0067] A person of ordinary skill in the art may understand that all or part of the steps carried by the method for implementing the above-mentioned embodiment may be completed by instructing related hardware through a program, and the above-mentioned program may be stored in a computer-readable storage medium, which, when executed, includes one of the steps of the method embodiment or a combination thereof.
[0068] Although the embodiments of the present application have been shown and described above, it can be understood that the above embodiments are exemplary and cannot be understood as limitations on the present application. Ordinary technicians in this field can change, modify, replace and modify the above embodiments within the scope of the present application.
Claims
1. A safety subsystem design method, characterized in that: The following steps are involved: Obtain the powertrain installation data of the target vehicle; Establishing a power subsystem model of the target vehicle according to the powertrain installation data; Performing a full-vehicle collision simulation analysis of a target collision condition based on the power subsystem model, and extracting power failure features from simulation data of the full-vehicle collision simulation analysis process; The target safety area in the whole vehicle collision simulation analysis process is determined according to the power failure characteristics, and the design scheme of the target safety subsystem of the target vehicle is generated according to the target safety area.
2. The safety subsystem design method according to claim 1, characterized in that: The powertrain installation data includes an engine installation position, a drive motor installation position, and a suspension installation position.
3. The safety subsystem design method according to claim 1, characterized in that: The dynamic failure characteristic includes at least one of a failure mode, a failure peak force, and a failure time.
4. The safety subsystem design method according to claim 1, characterized in that: The whole vehicle collision simulation analysis of the target collision condition is performed based on the power subsystem model, including: Obtaining a collision loading mode and a collision loading boundary for the whole vehicle collision simulation analysis; Under the collision loading mode and the collision loading boundary, a full vehicle collision simulation analysis of a target collision condition is performed on the power subsystem model.
5. The safety subsystem design method according to claim 1, characterized in that: Before performing the vehicle collision simulation analysis of the target collision condition based on the power subsystem model, the method further includes: Obtain collision data of different vehicle models under various vehicle frontal collision conditions; Extract force characteristics from the collision data, and determine target collision conditions in each vehicle frontal collision condition according to the force characteristics.
6. The safety subsystem design method according to claim 5, characterized in that: The frontal collision conditions of the whole vehicle include full frontal collision conditions, offset collision conditions, small offset collision conditions, frontal drilling and jamming conditions, and frontal pillar collision conditions.
7. A security subsystem, characterized in that: The safety subsystem is designed by using the safety subsystem design method described in any one of claims 1-6.
8. A powertrain system, characterized in that: Includes the security subsystem described in claim 7.
9. A vehicle, characterized in that: Includes the powertrain system as described in claim 8.
10. A test bench for a powertrain system, characterized in that: The test bench is used to perform a collision test on the powertrain system according to claim 8, wherein the test bench comprises: Barrier impact module and bracket base; A plurality of mounting brackets are arranged on the bracket base, the relative positions and spacings between the plurality of mounting brackets are adjustable, and the plurality of mounting brackets are used to place the powertrain system.