Accelerated endurance load spectrum generation method for rack, computing equipment and medium
By identifying and optimizing the key damage mechanisms in the electric drive system, the accelerated durability load spectrum for benches is generated, which solves the problem of load spectrum acceleration and simplification difficulty in the prior art, and achieves more efficient durability testing.
Patent Information
- Application Number
- CN202510203847.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-02-24
- Publication Date
- 2025-06-24
AI Technical Summary
In the fatigue life and durability test of electric drive systems, it is difficult for the prior art to accelerate and simplify the original load spectrum while ensuring the consistent or close product damage effects, resulting in long test time and high cost.
By calculating the cumulative damage of each damage mechanism of the product during the life cycle, identifying the key damage mechanisms, and optimizing the original load spectrum with the goal of shortening the bench test time to generate the accelerated durability load spectrum for the bench.
On the basis of ensuring the consistency or proximity of product damage effects, the testing time is significantly shortened, the cost is reduced, and the efficiency and benefits of existing durable tests are improved.
Smart Images
Figure CN120194943A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the technical field of bench testing, and particularly to a method for generating an accelerated durability load spectrum for a bench, a computing device, and a medium. Background Art
[0002] In the fatigue life durability test of an electric drive system, mechanical fatigue durability, power-on temperature cycle endurance (PTCE), and high-temperature operation endurance (HTOE) are regarded as the three core challenges, collectively referred to as the "three mountains". Among the R & D costs, the durability test is the most expensive and time-consuming project in the manufacturing proofing and test verification stages, and its time cost is particularly crucial, directly affecting the market competitiveness of products.
[0003] Taking a vehicle as an example, the dynamic loading of the vehicle road spectrum (road test) is the main method for judging the durability performance of a product. This method uses a certain number of kilometers traveled as the test cycle and has the disadvantages of a long time cycle and high cost. Therefore, how to accelerate and simplify the original load spectrum on the premise of ensuring the same or similar damage effect of the product, so as to shorten the test time and reduce the cost, is an urgent problem to be solved at present. Summary of the Invention
[0004] Based on this, this application provides a method for generating an accelerated durability load spectrum for a bench, a computing device, and a medium, which can accelerate and simplify the overall original load spectrum on the premise of ensuring the same or similar damage effect of the product, so as to shorten the test time and reduce the cost.
[0005] In a first aspect, this application provides a method for generating an accelerated durability load spectrum for a bench. The method for generating an accelerated durability load spectrum for a bench includes: calculating the cumulative damage of each damage mechanism of the product in the product life cycle according to the original load spectrum; identifying the key damage mechanisms that cause serious damage to the product according to the magnitude of the cumulative damage; and taking the key damage mechanisms as the objects of key attention to optimize the original load spectrum with the goal of shortening the bench test time, so as to obtain an accelerated durability load spectrum for the bench.
[0006] In combination with the first aspect, in the first first feasible implementation manner of the first aspect, the step of optimizing the original load spectrum by taking the key damage mechanisms as the objects of key attention includes: setting the damage boundary of the key damage mechanisms according to the cumulative damage of the key damage mechanisms; determining all other non-key damage mechanisms other than the key damage mechanisms, and setting the damage boundary of the non-key damage mechanisms according to the range where the cumulative damage of all other non-key damage mechanisms is located; and using the damage boundary of the key damage mechanisms and the damage boundary of the non-key damage mechanisms as boundary conditions to optimize and solve the original load spectrum, so as to obtain an accelerated durability load spectrum for the bench.
[0007] Combined with the first implementable manner of the first aspect, in the second implementable manner of the first aspect, the step of setting the damage boundary of the key damage mechanism according to the cumulative damage of the key damage mechanism includes: when setting the damage boundary of the key damage mechanism according to the cumulative damage of the key damage mechanism, setting the damage boundary of the key damage mechanism to the damage level matching the original working condition; identifying the main damage mechanism and the secondary damage mechanism in the key damage mechanism, and expanding the damage boundary of the secondary damage mechanism so that the length of the region defined by the damage boundary of the main damage mechanism is greater than the length of the region defined by the damage boundary of the secondary damage mechanism.
[0008] Combined with the first implementable manner of the first aspect, in the third implementable manner of the first aspect, before the optimization solution, the method further includes: obtaining an acceleration strategy and identifying the acceleration strategy; in the case where the acceleration strategy is an overall acceleration strategy, narrowing the damage boundary of the non-critical damage mechanism to reduce the risk of product failure due to the non-critical damage mechanism.
[0009] Combined with the first implementable manner of the first aspect, in the fourth implementable manner of the first aspect, before the optimization solution, the method further includes: obtaining an acceleration strategy and identifying the acceleration strategy; in the case where the acceleration strategy is a key acceleration strategy, expanding the damage boundary of the non-critical damage mechanism to weaken the attention to the non-critical damage mechanism and strengthen the attention to the key damage mechanism.
[0010] Combined with the first implementable manner of the first aspect, in the fifth implementable manner of the first aspect, the step of using the damage boundary of the key damage mechanism and the damage boundary of the non-critical damage mechanism as boundary conditions to optimize the original load spectrum to obtain the accelerated durability load spectrum for the test bench includes: setting load steps under multiple working conditions according to multiple working conditions and the load characteristics of each working condition; using the load steps, the damage boundary of the key damage mechanism and the damage boundary of the non-critical damage mechanism as boundary conditions to optimize the original load spectrum to obtain the accelerated durability load spectrum for the test bench under multiple working conditions, so as to implement the test bench test under multiple working conditions and shorten the test bench test time and reduce costs.
[0011] In combination with the first aspect, in the sixth implementable manner of the first aspect, after optimizing and solving the original load spectrum with the damage boundaries of the critical damage mechanisms and the damage boundaries of the non-critical damage mechanisms as boundary conditions to obtain the accelerated durability load spectrum for the test bench, the method further includes: calculating the total damage of all damage mechanisms according to the accelerated durability load spectrum for the test bench; calculating the error between the total damage of all damage mechanisms under the original load spectrum and the total damage of all damage mechanisms under the accelerated durability load spectrum for the test bench to analyze the rationality of the accelerated durability load spectrum for the test bench; if it is unreasonable, adjusting the accelerated durability load spectrum for the test bench to reduce the error between the total damage of all damage mechanisms under the original load spectrum and the total damage of all damage mechanisms under the accelerated durability load spectrum for the test bench.
[0012] In a second aspect, the present application also provides a computing device, which includes: a calculation unit for calculating the cumulative damage of each damage mechanism of the product during the product life cycle according to the original load spectrum; an identification unit for identifying the critical damage mechanisms that cause serious damage to the product according to the magnitude of the cumulative damage; an optimization unit for optimizing the original load spectrum with the critical damage mechanisms as the key focus objects with the goal of shortening the test bench test time to obtain the accelerated durability load spectrum for the test bench.
[0013] In an implementable manner, the optimization unit is specifically configured to: set the damage boundary of the critical damage mechanism according to the cumulative damage of the critical damage mechanism; determine all other non-critical damage mechanisms other than the critical damage mechanism, and set the damage boundary of the non-critical damage mechanism according to the range where the cumulative damage of all other non-critical damage mechanisms is located; optimize and solve the original load spectrum with the damage boundary of the critical damage mechanism and the damage boundary of the non-critical damage mechanism as boundary conditions to obtain the accelerated durability load spectrum for the test bench.
[0014] In combination with the first implementable manner of the second aspect, in the second implementable manner of the second aspect, the above optimization unit is specifically configured to: when setting the damage boundary of the critical damage mechanism according to the cumulative damage of the critical damage mechanism, set the damage boundary of the critical damage mechanism to a damage level matching the original working condition; identify the main damage mechanism and the secondary damage mechanism in the critical damage mechanism, and expand the damage boundary of the secondary damage mechanism so that the length of the region defined by the damage boundary of the main damage mechanism is greater than the length of the region defined by the damage boundary of the secondary damage mechanism.
[0015] In combination with the first implementable manner of the second aspect, in the third implementable manner of the second aspect, the above optimization unit is further configured to: obtain an acceleration strategy and identify the acceleration strategy; in the case where the acceleration strategy is an overall acceleration strategy, narrow the damage boundary of the non-critical damage mechanism to reduce the risk of the product failing due to the non-critical damage mechanism.
[0016] Combined with the first implementable manner of the second aspect, in the fourth implementable manner of the second aspect, the above optimization unit is further configured to: obtain an acceleration strategy and identify the acceleration strategy; in the case where the acceleration strategy is a key acceleration strategy, expand the damage boundary of the non-critical damage mechanism to weaken the attention to the non-critical damage mechanism and strengthen the attention to the critical damage mechanism.
[0017] Combined with the first implementable manner of the second aspect, in the fifth implementable manner of the second aspect, the above optimization unit is specifically configured to: set load steps under multiple working conditions according to multiple working conditions and the load characteristics of each working condition; use the load steps, the damage boundary of the critical damage mechanism, and the damage boundary of the non-critical damage mechanism as boundary conditions to optimize and solve the original load spectrum, and obtain an accelerated durability load spectrum for the test bench under multiple working conditions, so as to implement the test bench test under multiple working conditions, and shorten the test bench test time and reduce costs.
[0018] Combined with the second aspect, in the sixth implementable manner of the second aspect, the computing device further includes an adjustment unit, and the adjustment unit is configured to: calculate the total damage of all damage mechanisms according to the accelerated durability load spectrum for the test bench; calculate the error between the total damage of all damage mechanisms under the original load spectrum and the total damage of all damage mechanisms under the accelerated durability load spectrum for the test bench, so as to analyze the rationality of the accelerated durability load spectrum for the test bench; if it is unreasonable, adjust the accelerated durability load spectrum for the test bench to reduce the error between the total damage of all damage mechanisms under the original load spectrum and the total damage of all damage mechanisms under the accelerated durability load spectrum for the test bench.
[0019] In a third aspect, the present application further provides a computing device, which includes a processor and a memory, and the processor and the memory are connected through a bus; the processor is configured to execute multiple instructions; the memory is configured to store multiple instructions, and the instructions are suitable for being loaded and executed by the processor to perform the method for generating an accelerated durability load spectrum for a test bench according to the first aspect or any one of the implementation manners of the first aspect.
[0020] In a fourth aspect, the present application further provides a computer-readable storage medium, and multiple instructions are stored in the computer-readable storage medium, and the instructions are suitable for being loaded and executed by the processor to perform the method for generating an accelerated durability load spectrum for a test bench according to the first aspect or any one of the implementation manners of the first aspect.
[0021] In summary, the present application provides a method for generating an accelerated durability load spectrum for a test bench, a computing device, and a medium. Among them, with the goal of shortening the test bench test time, the present application optimizes the original load spectrum by taking the key damage mechanisms of the product as the objects of key attention, weakening the attention to other non-key damage mechanisms, so that the cumulative damage of the key damage mechanisms is kept at the same or similar level as the original working conditions, while the cumulative damage of other non-key damage mechanisms is allowed to have a certain deviation. Therefore, when the optimized accelerated durability load spectrum for the test bench is applied to the test bench test, it can accurately simulate the durability performance of the product during actual operation, ensure that the damage effects of the product are the same or close, while accelerating and simplifying the original load spectrum of the product, shortening the test time and reducing costs, improving the disadvantages of the existing durability test being time-consuming and costly, and at the same time improving the efficiency, ability, and benefit of the test bench test. BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Figure 1 is a schematic flowchart of the method for generating an accelerated durability load spectrum in an embodiment of the present application;
[0023] Figure 2 is a schematic diagram of the load spectrum, S-N curve, and cumulative damage in an embodiment of the present application;
[0024] Figure 3 is a schematic diagram of the damage boundary of the damage mechanism in an embodiment of the present application;
[0025] Figure 4 is a schematic block diagram of a computing device in an embodiment of the present application;
[0026] Figure 5 is a structural block diagram of a computing device in an embodiment of the present application. DETAILED DESCRIPTION OF THE EMBODIMENTS
[0027] In order to make the objectives, technical solutions, and advantages of the present application clearer, the present application will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present application and are not used to limit the present application.
[0028] In order to accelerate the test process and reduce costs on the basis of ensuring consistent or similar product damage effects, this application proposes a method for generating an accelerated durability load spectrum for bench testing. This method first identifies the key damage mechanisms that cause serious product damage based on the cumulative damage of each damage mechanism under the original load spectrum, that is, one or more mechanisms with the largest cumulative damage. Multiple key damage mechanisms may include primary and secondary damage mechanisms (sorted by cumulative damage). Subsequently, these key damage mechanisms are taken as the core focus, and the original load spectrum is optimized, including adjusting parameters such as stress or strain amplitudes and cycle numbers, so as to generate an accelerated durability load spectrum suitable for bench testing. The accelerated durability load spectrum ensures that the cumulative damage of the key damage mechanisms of the product in the accelerated test is consistent or similar to the damage level under the original load spectrum, while allowing a large deviation in the cumulative damage of other non-key mechanisms compared with the original load spectrum. Thus, the accelerated durability load spectrum not only maintains the effectiveness of the test, but also significantly shortens the test time and reduces the test cost, making it very suitable for application in bench testing and improving the time-consuming and costly drawbacks of the existing technology.
[0029] The method for generating an accelerated durability load spectrum for bench testing provided by this application can be applied to computing devices, which can be computers, servers, vehicles (or in-vehicle terminals), and mobile terminal devices. In addition, the computing device can interact with other servers, computers, controllers, processors, ECUs, etc. and execute the method for generating an accelerated durability load spectrum for bench testing proposed by this application.
[0030] The product in this application refers to components or structures on an object that requires a durability test using a durability load spectrum. The aforementioned objects include vehicles, airplanes, ships, etc., and this application does not limit this.
[0031] Combined Figure 1 As shown, in order to better understand the method for generating an accelerated durability load spectrum for bench testing of this application, this application also provides an embodiment, taking the computing device as the execution entity, for detailed description:
[0032] 100: Calculate the cumulative damage of each damage mechanism of the product during the product life cycle according to the original load spectrum;
[0033] 200: Identify the key damage mechanisms that cause serious damage to the product according to the size of the cumulative damage;
[0034] 300: With the goal of shortening the bench test time, optimize the original load spectrum with the key damage mechanisms as the key focus to obtain an accelerated durability load spectrum for bench testing.
[0035] For step 100, obtain the original load spectrum and the S-N (stress-life) curves of each damage mechanism, and calculate the cumulative damage of each damage mechanism of the product during the entire life cycle according to the original load spectrum and the S-N curves of each damage mechanism of the product. Damage refers to the harm caused by the load to the material. The calculation of cumulative damage can specifically adopt the Miner linear damage accumulation rule. The specific calculation process is as follows:
[0036] According to the damage accumulation rule, when the product absorbs energy to reach the maximum value under the cyclic action of external forces, fatigue failure occurs. Combining with Figure 2 As shown, the left figure is the load spectrum, the middle figure is the S-N curve, and the right figure is the cumulative damage. If the stress levels generated by the product loading history are 01, 02,... oi, the fatigue lives corresponding to each stress level are N1, N2,... Ni, and the number of cycles corresponding to each stress level are nl, n2,... ni, then the cumulative damage of the part under the damage mechanism corresponding to the S-N curve is:
[0037]
[0038] Among them, D is the cumulative damage; i is the stress level grade of the variable amplitude load; n i is the number of cycles of the i-th level load, and N i is the fatigue life under the i-th level load. According to the damage accumulation rule, if the simulation result shows that the cumulative damage D > 1 at a certain place, it indicates that fatigue failure will occur at that place and optimization is required.
[0039] Before obtaining the S-N curve, the present application also identifies the damage mechanism of the component according to the entire topological structure of the system, and draws the S-N curve for the damage mechanism to describe the number of cycles or time required for each damage mechanism to reach a specific damage degree at different stress levels. Specifically, software such as KISSsoft or MASTA can be used to model the system, and configure the corresponding material properties, process properties, and damage mechanisms, so as to calculate the corresponding S-N curve according to the damage mechanism. It should be noted that the S-N curve shows how the life of the system or component changes under a given input torque. In other words, it tells us how long the system or component can continue to work without failing due to this specific damage mechanism as the input torque increases.
[0040] Before obtaining the original load spectrum, the present application can also collect product data and analyze the product data to obtain the true original load spectrum of the product. Taking a vehicle as an example, the foregoing process specifically includes collecting and analyzing the change of various loads of the vehicle over time during actual road driving. The loads include the vehicle's force conditions under different road surface types, different speeds, different accelerations, different steering angles, and different load weights.
[0041] For step 200, the present application ranks the damage degrees of each damage mechanism according to the magnitude of the cumulative damage of each damage mechanism. The greater the cumulative damage, the more serious the damage that can be caused. Furthermore, the key damage mechanisms that cause serious damage to the product structure or components are identified, as well as the main damage mechanisms and secondary damage mechanisms among the key damage mechanisms. The mechanisms include fatigue cracks, wear, corrosion, impact, etc.
[0042] In an implementable manner, the damage mechanism with the largest cumulative damage is taken as the key damage mechanism, while other damage mechanisms are taken as non-key damage mechanisms. In another implementable manner, multiple damage mechanisms ranked in the top N in the cumulative damage are taken as the key damage mechanisms, while other damage mechanisms are taken as non-key damage mechanisms. The key damage mechanisms include main damage mechanisms and secondary damage mechanisms.
[0043] For step 300, with the goal of shortening the test time, the present application adjusts the parameters (such as stress or strain amplitude, number of cycles, etc.) in the original load spectrum. During the adjustment process, the cumulative damage of the key damage mechanism under the accelerated durability load spectrum is maintained at the same or similar level as the cumulative damage under the original load spectrum, while a relatively large deviation is allowed for the cumulative damage of other non-key mechanisms.
[0044] In an implementable manner, the computing device can adjust the parameters of the original load spectrum according to the user's adjustment instruction, recalculate the cumulative damage of each damage mechanism under the adjusted load spectrum, and display the deviation of the cumulative damage of each damage mechanism under the load spectra before and after adjustment in order of the importance of each damage mechanism. According to the deviation of the key damage mechanism, the user is prompted to increase or decrease the parameters to keep the cumulative damage of the key damage mechanism consistent or similar to the original working condition.
[0045] In another implementable manner, the computing device can set the damage boundaries of each damage mechanism according to the cumulative damage of each damage mechanism, and use a solver to optimize and solve the original load spectrum based on the damage boundaries, so as to obtain the accelerated durability load spectrum for the test bench. Specifically, the steps of optimizing the original load spectrum with the key damage mechanism as the key object of attention include:
[0046] 310: Set the damage boundary of the key damage mechanism according to the cumulative damage of the key damage mechanism;
[0047] 320: Determine all other non-key damage mechanisms other than the key damage mechanism, and set the damage boundaries of the non-key damage mechanisms according to the range where the cumulative damage of all other non-key damage mechanisms is located;
[0048] 330: Optimize and solve the original load spectrum by using the damage boundaries of critical damage mechanisms and the damage boundaries of non-critical damage mechanisms as boundary conditions to obtain the accelerated durability load spectrum for the test bench.
[0049] Among them, step 310 sets the damage boundary of the critical damage mechanism according to the cumulative damage of the critical damage mechanism, which means restricting the damage level of the critical damage mechanism to be the same as or close to the damage level of the critical damage mechanism under the original working conditions. For example, Figure 3 , lay_shaft.B3 is the critical damage mechanism. Assume that the cumulative damage of lay_shaft.B3 under the original load spectrum is 1.13, and set its damage boundary as [1.12, 1.13]. The damage range is 0.1. The damage range is the length of the area defined by the damage boundary. It can be seen that its damage range is very small. Therefore, it can ensure that the cumulative damage of the critical damage mechanism is the same as or close to that under the original working conditions;
[0050] Step 320 sets the damage boundary of the non-critical damage mechanism according to the range where the cumulative damage of all other non-critical damage mechanisms is located, which means considering the overall situation of the cumulative damage of all non-critical damage mechanisms, rather than the cumulative damage of individual non-critical damage mechanisms. For example, Figure 3 , all other non-critical damage mechanisms are ALL other damagemechanisms. Assume that the maximum cumulative damage among all non-critical damage mechanisms is 0.8, and the range where the cumulative damage of all non-critical damage mechanisms is located is from 0 to 0.8. Then, set the damage boundary of the non-critical damage mechanism according to this range. For example, directly set the damage boundary of the non-critical damage mechanism as [0, 0.8], and the damage range is 0.8. Or shrink the range under Variant1 to get the damage boundary of the non-critical damage mechanism as [0, 0.75], and the damage range is 0.75. Or expand the range under Variant2 and set the damage boundary as [0, 0.85], and the damage range is 0.85. It can be seen that the damage range of the non-critical damage mechanism is relatively large. Therefore, it is allowed that the damage level of the non-critical damage mechanism can deviate greatly from the damage level under the original working conditions, so as to accelerate and simplify the original load spectrum and simplify the optimization and solution process, ensuring that the test time of the product under the accelerated durability load spectrum is shortened.
[0051] The process of step 330 using the optimization solver to optimize and solve the original load spectrum based on the damage boundary is actually a process of inversely deriving the load spectrum according to the damage boundary. The inverse derivation process is an optimization problem. In this application, by continuously adjusting the parameters of the load spectrum, an accelerated durability load spectrum that meets the damage boundary conditions is searched, so that the cumulative damage calculated based on the accelerated durability load spectrum meets the given damage boundary.
[0052] This process can use the optimization toolbox of MATLAB or write custom optimization algorithms. The optimization algorithms include genetic algorithms, particle swarm algorithms, etc., and this application places no restrictions on them. This application provides the specific usage process for MATLAB to determine the available solvers: First, it is necessary to understand the available solvers in the MATLAB optimization toolbox. The solver list can be obtained by referring to the MATLAB documentation or using the optimoptions function. Create an optimization options object: Use the optimoptions function to create an optimization options object, which is used to specify the solver and other parameters for the optimization problem. The first input parameter of the optimoptions function can be used to specify the solver to be used. Set option parameters: The optimoptions function allows setting various options, such as controlling whether to display detailed output information during the solution process. The options include but are not limited to displaying output information during the iteration process, only displaying output information of the final result, etc. Replace the solver: When creating the optimization options object, the solver can be replaced by passing the name of the new solver as an input parameter to the optimoptions function. For example, if the solver is to be replaced with interior-point, the corresponding code can be used to implement it. Select the appropriate solver: Select the appropriate solver according to the type of problem, such as linear programming, integer linear programming, non-linear constrained optimization, etc. MATLAB provides multiple solvers, and select according to the specific requirements of the problem. Coding implementation: Convert the problem into MATLAB code, define the objective function and constraint function, and set the solver options. Solve and analyze the results: Run the solver, obtain the optimization results, and analyze and verify the results. Adjust and optimize: Adjust the model parameters or solver options according to the result feedback, and perform multiple iterations to obtain a better solution.
[0053] In another implementable manner, for step 310, first set the damage boundary of the key damage mechanism to the damage level matching the original working condition, and then determine whether there are multiple key damage mechanisms. If there are multiple key damage mechanisms, identify the main damage mechanism and the secondary damage mechanism among them, keep the main damage mechanism at the original damage boundary, and appropriately expand the damage boundary of the secondary damage mechanism to further accelerate and simplify the original load spectrum and simplify the optimization solution process. If there are no multiple key damage mechanisms, no subsequent operations are performed. Specifically: The step of setting the damage boundary of the key damage mechanism according to the cumulative damage of the key damage mechanism includes: when setting the damage boundary of the key damage mechanism according to the cumulative damage of the key damage mechanism, set the damage boundary of the key damage mechanism to the damage level matching the original working condition; identify the main damage mechanism and the secondary damage mechanism in the key damage mechanism, and expand the damage boundary of the secondary damage mechanism so that the length of the region defined by the damage boundary of the main damage mechanism is greater than the length of the region defined by the damage boundary of the secondary damage mechanism.
[0054] For example, as Figure 3 shown, the key damage mechanisms include the main damage mechanism lay_shaft.B3 and the secondary damage mechanism input_shaft.B2. Assume that the cumulative damage of input_shaft.B2 under the original load spectrum is 0.85. To set its damage boundary to the damage level matching the original working condition, it can be set to [0.84, 0.85]. However, setting the damage ranges of both the main damage mechanism and the secondary damage mechanism to be relatively small is not conducive to the acceleration and simplification of the load spectrum and will also increase the difficulty of the optimization solution. In this regard, in this implementable manner, the damage boundary of the secondary damage mechanism is appropriately expanded. For example, under Variant1, the damage boundary of the secondary damage mechanism is expanded to [0.75, 0.85]. At this time, the damage range of the damage boundary of the main damage mechanism lay_shaft.B3 in the key damage mechanism is greater than the damage range of the damage boundary of the secondary damage range input_shaft.B2, ensuring that the cumulative damage of the main damage mechanism is consistent with that under the original working condition, and the cumulative damage of the secondary damage mechanism is close to that under the original working condition, thereby accelerating and simplifying the overall original load spectrum and simplifying the optimization solution process. It should be noted that the damage range of the damage boundary of the secondary damage mechanism is smaller than the damage range of the damage boundary of the non-key damage mechanism. Therefore, in the process of generating the durability load spectrum, the attention levels to the main damage mechanism, the secondary damage mechanism, and the non-key damage mechanism decrease in turn.
[0055] Before performing step 330, the present application also provides two acceleration strategies, including an overall acceleration strategy and a key acceleration strategy. Comparing the two, the overall acceleration strategy focuses more on the overall durability test and is applicable to the overall durability test. The overall acceleration strategy reduces the damage boundary / damage range of non-critical damage mechanisms and appropriately strengthens the attention to non-critical damage mechanisms. Therefore, while focusing on key damage mechanisms, it also takes into account various damage mechanisms and reduces the risk of product failure due to non-critical damage mechanisms. The key acceleration strategy focuses more on key damage mechanisms and is applicable to key durability tests, especially when a single component or structure is replaced. The key acceleration strategy further weakens the attention to non-critical damage mechanisms by expanding the damage boundary / damage range of non-critical damage mechanisms, indirectly strengthening the attention to key damage mechanisms. The key acceleration strategy further accelerates and simplifies the original load spectrum and simplifies the optimization solution process. Specifically:
[0056] In an implementable manner, before the optimization solution, it further includes: obtaining an acceleration strategy and identifying the acceleration strategy; in the case where the acceleration strategy is the overall acceleration strategy, reducing the damage boundary of non-critical damage mechanisms to reduce the risk of product failure due to non-critical damage mechanisms.
[0057] For example, the damage boundaries of each damage mechanism under the overall acceleration strategy are as Figure 3 shown in Variant1 of. ALL other damage mechanisms are non-critical damage mechanisms. Assuming that the maximum cumulative damage among them is 0.8, the damage boundary under normal circumstances should be set as [0, 0.8], and the damage range is 0.8. However, in order to reduce the possibility of product failure due to non-critical damage mechanisms, the damage boundary of non-critical damage mechanisms under Variant1 is reduced to [0, 0.75], and the damage range is 0.75.
[0058] In another implementable manner, before the optimization solution, it further includes: obtaining an acceleration strategy and identifying the acceleration strategy; in the case where the acceleration strategy is the key acceleration strategy, expanding the damage boundary of non-critical damage mechanisms to weaken the attention to non-critical damage mechanisms and strengthen the attention to key damage mechanisms. Further, in the case where there are multiple key damage mechanisms, the present application further expands the damage boundary of the secondary damage mechanism among the key damage mechanisms to weaken the attention to the secondary damage mechanism and strengthen the attention to the primary damage mechanism.
[0059] For example, the damage boundaries of each damage mechanism under the key acceleration strategy are as Figure 3As shown in Variant2, in order to further weaken the attention to non-critical damage mechanisms and strengthen the attention to critical damage mechanisms, the damage boundary of non-critical damage mechanisms under Variant2 is expanded to [0, 0.85], and the damage range is 0.85; in order to further weaken the attention to secondary damage mechanisms and strengthen the attention to primary damage mechanisms, the damage boundary of secondary damage mechanisms under Variant2 is expanded to [0, 0.9], and the damage range is 0.9. By expanding the damage boundaries of non-critical / secondary damage mechanisms, the original load spectrum is further accelerated and simplified, and the optimization solution process is also simplified.
[0060] It should be noted that in the foregoing embodiments, the optimization solution is only carried out according to the damage boundary without restricting the working conditions. Therefore, the accelerated working cycle of the generated accelerated durability load spectrum will only include one step, because this represents the possible shortest cycle time. That is to say, the accelerated durability load spectrum obtained through the foregoing optimization solution process belongs to a single working condition. However, in actual applications, the system or component may experience a variety of different load conditions, including coasting, acceleration, deceleration, etc. A wider range of torque and speed should be studied to improve the accuracy and reliability of the test. Therefore, it is necessary to define the boundaries of the number and nature of the load steps.
[0061] In response to this, the present application also proposes an accelerated durability load spectrum for a test bench under multiple working conditions. Specifically, the steps of optimizing and solving the original load spectrum by using the damage boundaries of critical damage mechanisms and non-critical damage mechanisms as boundary conditions to obtain the accelerated durability load spectrum for the test bench include: setting load steps under multiple working conditions according to multiple working conditions and the load characteristics of each working condition; using the load steps, the damage boundaries of critical damage mechanisms and the damage boundaries of non-critical damage mechanisms as boundary conditions to optimize and solve the original load spectrum, so as to obtain the accelerated durability load spectrum for the test bench under multiple working conditions, which is used to realize the test bench test under multiple working conditions and shorten the test bench test time and reduce costs.
[0062] Among them, when designing the accelerated working cycle under multiple working conditions, it is necessary to consider how many working conditions should be defined and the load characteristics of each working condition (such as torque range, load time, power, rotational speed, speed, etc.). Each working condition corresponds to a load step, so as to define multiple load steps. By reasonably defining the load steps, it can be ensured that the test is neither too simple to lose representativeness nor too complex to be implemented.
[0063] For example, referring to Table 1, the load steps under multiple working conditions can be as shown in the table:
[0064]
[0065] Table 1 Load steps under multiple working conditions
[0066] Further, taking the overall acceleration strategy and the key acceleration strategy as examples, the accelerated durability load spectrum under the overall acceleration strategy after multi-condition evolution is shown in Table 2, while the accelerated durability load spectrum under the key acceleration strategy after multi-condition evolution is shown in Table 3:
[0067]
[0068]
[0069] Table 2 (left) and Table 3 (right)
[0070] It can be seen from Table 2 and Table 3 that the total test time of the accelerated durability load spectrum under the key acceleration strategy is less than that of the accelerated durability load spectrum under the overall acceleration strategy, which further proves that the key acceleration strategy can further accelerate and simplify the load spectrum compared with the overall acceleration strategy.
[0071] It should also be noted that there may still be errors between the accelerated durability load spectrum obtained in the foregoing embodiments and the actual situation. To reduce the errors, the present application also analyzes and evaluates the generated accelerated durability load spectrum to select a most suitable accelerated durability load spectrum from the accelerated durability load spectra generated under multiple strategies, or performs reverse iteration on the accelerated durability load spectrum to further optimize the accelerated durability load spectrum. Specifically:
[0072] In an implementable manner, after optimizing and solving the original load spectrum with the damage boundaries of the key damage mechanisms and the non-key damage mechanisms as boundary conditions to obtain the accelerated durability load spectrum for the test bench, the method further includes: calculating the total damage of all damage mechanisms according to the accelerated durability load spectrum for the test bench; calculating the error between the total damage of all damage mechanisms under the original load spectrum and the total damage under the accelerated durability load spectrum for the test bench to analyze the rationality of the accelerated durability load spectrum for the test bench; if it is unreasonable, adjusting the accelerated durability load spectrum for the test bench to reduce the error between the total damage of all damage mechanisms under the original load spectrum and the total damage under the accelerated durability load spectrum for the test bench.
[0073] Among them, the present application compares the cumulative damage of each damage mechanism in the original load spectrum and the accelerated durability load spectrum under the current strategy to obtain the error of the cumulative damage, and then takes the key damage mechanism as the object of key concern for error analysis. For example, if the error of the key damage mechanism is greater than the preset value, it is determined that the accelerated durability load spectrum generated under the current strategy is unreasonable; otherwise, it is determined that the accelerated durability load spectrum generated under the current strategy is reasonable. If the accelerated durability load spectra generated under all strategies are unreasonable, the accelerated durability load spectrum can be inversely iterated according to the error to modify the accelerated durability load spectrum so that the error between the modified accelerated durability load spectrum and the original load spectrum becomes smaller, thereby obtaining a reasonable accelerated durability load spectrum.
[0074] In another implementable manner, after optimizing and solving the original load spectrum using the damage boundaries of the key damage mechanism and the non-key damage mechanism as boundary conditions to obtain the accelerated durability load spectrum for the test bench, it further includes: calculating the cumulative damage of each damage mechanism according to the accelerated durability load spectrum for the test bench; calculating the error between the cumulative damage of each damage mechanism under the original load spectrum and the cumulative damage under the accelerated durability load spectrum for the test bench to analyze the rationality of the accelerated durability load spectrum for the test bench; if it is unreasonable, adjusting the accelerated durability load spectrum for the test bench to reduce the error between the cumulative damage of each damage mechanism under the original load spectrum and the cumulative damage under the accelerated durability load spectrum for the test bench.
[0075] Among them, different from the previous implementable manner, the damage sum of all damage mechanisms is compared in this implementation manner, and this implementation manner pays more attention to the overall rationality, while the previous implementable manner pays more attention to the rationality of the key damage mechanism. According to actual needs, different inverse iteration methods can be selected. For example, the previous inverse iteration method can be used under the key acceleration strategy, and the latter inverse iteration method can be used under the overall acceleration strategy. Moreover, the aforementioned inverse iteration process can be repeatedly executed until it is determined that the latest accelerated durability load spectrum is reasonable, and then the inverse iteration is stopped.
[0076] When calculating the cumulative damage of each damage mechanism and the damage sum of all damage mechanisms, software of the same type such as KISSsoft can be used to calculate the accelerated durability load spectrum.
[0077] Before performing reverse iteration, the present application also generated a time cumulative distribution diagram and a corresponding damage cumulative distribution diagram based on the original load spectrum. These two types of diagrams constitute important criteria for evaluating the rationality of the accelerated durability load spectrum, and are used for horizontal comparison of loads and damages under different overall parameters or electric drive systems. Specifically, the time cumulative distribution diagram intuitively shows the load distribution of multiple working conditions of the product over time, which helps to determine whether the multi-working condition setting of the accelerated durability load spectrum is reasonable. The damage cumulative distribution diagram shows the damage distribution of different damage mechanisms over time, which helps to determine whether the cumulative damage level of the accelerated durability load spectrum is reasonable.
[0078] The present application also provides a computing device. Embodiments of the present application can divide the functions of the device according to the above method examples. For example, each function module can be divided corresponding to each function, or two or more functions can be integrated into one module. The above integrated module can be implemented in the form of hardware or in the form of a software function module. It should be noted that the division of modules in the embodiments of the present application is illustrative, and is only a logical function division. There can be other division methods in actual implementation. Specifically, the computing device includes: a calculation unit 410 for calculating the cumulative damage of each damage mechanism of the product during the product life cycle according to the original load spectrum; an identification unit 420 for identifying the key damage mechanisms that cause serious damage to the product according to the magnitude of the cumulative damage; an optimization unit 430 for taking shortening the bench test time as the goal, taking the key damage mechanisms as the objects of key attention to optimize the original load spectrum, and obtaining the accelerated durability load spectrum for the bench.
[0079] In an implementable manner, the optimization unit 430 is specifically configured to: set the damage boundary of the key damage mechanism according to the cumulative damage of the key damage mechanism; determine all other non-key damage mechanisms other than the key damage mechanism, and set the damage boundary of the non-key damage mechanism according to the range where the cumulative damage of all other non-key damage mechanisms is located; use the damage boundary of the key damage mechanism and the damage boundary of the non-key damage mechanism as boundary conditions to optimize and solve the original load spectrum, and obtain the accelerated durability load spectrum for the bench.
[0080] In an implementable manner, the above optimization unit 430 is specifically configured to: when setting the damage boundary of the key damage mechanism according to the cumulative damage of the key damage mechanism, set the damage boundary of the key damage mechanism to a damage level matching the original working condition; identify the main damage mechanism and the secondary damage mechanism in the key damage mechanism, and expand the damage boundary of the secondary damage mechanism so that the length of the region defined by the damage boundary of the main damage mechanism is greater than the length of the region defined by the damage boundary of the secondary damage mechanism.
[0081] In one implementable manner, the above-mentioned optimization unit 430 is further configured to: obtain an acceleration strategy and identify the acceleration strategy; in the case that the acceleration strategy is an overall acceleration strategy, narrow the damage boundary of non-critical damage mechanisms to reduce the risk of product failure due to non-critical damage mechanisms.
[0082] In one implementable manner, the above-mentioned optimization unit 430 is further configured to: obtain an acceleration strategy and identify the acceleration strategy; in the case that the acceleration strategy is a key acceleration strategy, expand the damage boundary of non-critical damage mechanisms to weaken the attention to non-critical damage mechanisms and strengthen the attention to key damage mechanisms.
[0083] In one implementable manner, the above-mentioned optimization unit 430 is specifically configured to: set load steps under multiple working conditions according to multiple working conditions and the load characteristics of each working condition; use the load steps, the damage boundary of key damage mechanisms, and the damage boundary of non-critical damage mechanisms as boundary conditions to optimize and solve the original load spectrum, so as to obtain an accelerated durability load spectrum for the test bench under multiple working conditions, so as to implement the test bench test under multiple working conditions and shorten the test bench test time and reduce costs.
[0084] In one implementable manner, the computing device further includes an adjustment unit, and the adjustment unit is configured to: calculate the total damage of all damage mechanisms according to the accelerated durability load spectrum for the test bench; calculate the error between the total damage of all damage mechanisms under the original load spectrum and the total damage under the accelerated durability load spectrum for the test bench, so as to analyze the rationality of the accelerated durability load spectrum for the test bench; if it is unreasonable, adjust the accelerated durability load spectrum for the test bench to reduce the error between the total damage of all damage mechanisms under the original load spectrum and the total damage under the accelerated durability load spectrum for the test bench.
[0085] The present application also provides a computing device, which may include: a processor 510 and a memory 520. The above-mentioned processor 510 and memory 520 are connected through a bus 530. The processor 510 is configured to execute multiple instructions; the memory is configured to store multiple instructions, and the instructions are adapted to be loaded and executed by the processor to generate a bench test accelerated durability load spectrum method as in the above embodiments. Among them, the processor may be an Electronic Control Unit (ECU), a central processing unit (CPU), a general-purpose processor, a coprocessor, a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic devices, transistor logic devices, hardware components or any combination thereof. The processor may also be a combination for implementing computing functions, such as a combination including one or more microprocessors, a combination of 5SP and a microprocessor, and so on. In this embodiment, the processor may adopt a single-chip microcomputer, and various control functions can be realized by programming the single-chip microcomputer. The processor has the advantages of powerful computing ability and fast processing speed. Specifically, the processor 510 is configured to execute the functions of the computing unit 410, and is used to calculate the cumulative damage of each damage mechanism of the product in the product life cycle according to the original load spectrum; the processor 510 is also configured to execute the functions of the identification unit 420, and is used to identify the key damage mechanism that causes serious damage to the product according to the magnitude of the cumulative damage; the processor 510 is also configured to execute the functions of the optimization unit 430, and is used to optimize the original load spectrum with the goal of shortening the bench test time, taking the key damage mechanism as the key object of concern, and obtaining a bench test accelerated durability load spectrum.
[0086] In an implementable manner, the processor 510 is specifically configured to: set the damage boundary of the key damage mechanism according to the cumulative damage of the key damage mechanism; determine all other non-key damage mechanisms other than the key damage mechanism, and set the damage boundary of the non-key damage mechanism according to the range where the cumulative damage of all other non-key damage mechanisms is located; use the damage boundary of the key damage mechanism and the damage boundary of the non-key damage mechanism as boundary conditions to optimize and solve the original load spectrum, and obtain a bench test accelerated durability load spectrum.
[0087] In one implementable manner, the processor 510 is specifically configured to: when setting the damage boundary of the critical damage mechanism according to the cumulative damage of the critical damage mechanism, set the damage boundary of the critical damage mechanism to a damage level matching the original working condition; identify the main damage mechanism and the secondary damage mechanism in the critical damage mechanism, and expand the damage boundary of the secondary damage mechanism so that the length of the region defined by the damage boundary of the main damage mechanism is greater than the length of the region defined by the damage boundary of the secondary damage mechanism.
[0088] In one implementable manner, the processor 510 is further configured to: obtain an acceleration strategy and identify the acceleration strategy; in the case where the acceleration strategy is an overall acceleration strategy, narrow the damage boundary of the non-critical damage mechanism to reduce the risk of product failure due to the non-critical damage mechanism.
[0089] In one implementable manner, the processor 510 is further configured to: obtain an acceleration strategy and identify the acceleration strategy; in the case where the acceleration strategy is a key acceleration strategy, expand the damage boundary of the non-critical damage mechanism to weaken the attention to the non-critical damage mechanism and strengthen the attention to the critical damage mechanism.
[0090] In one implementable manner, the processor 510 is specifically configured to: set load steps under multiple working conditions according to multiple working conditions and the load characteristics of each working condition; use the load steps, the damage boundary of the critical damage mechanism, and the damage boundary of the non-critical damage mechanism as boundary conditions to optimize and solve the original load spectrum, and obtain an accelerated durability load spectrum for the test bench under multiple working conditions to implement the test bench test under multiple working conditions, and shorten the test bench test time and reduce costs.
[0091] In one implementable manner, the processor 510 is further configured to perform the function of an adjustment unit, and the adjustment unit is configured to: calculate the total damage of all damage mechanisms according to the accelerated durability load spectrum for the test bench; calculate the error between the total damage of all damage mechanisms under the original load spectrum and the total damage of all damage mechanisms under the accelerated durability load spectrum for the test bench to analyze the rationality of the accelerated durability load spectrum for the test bench; if it is unreasonable, adjust the accelerated durability load spectrum for the test bench to reduce the error between the total damage of all damage mechanisms under the original load spectrum and the total damage of all damage mechanisms under the accelerated durability load spectrum for the test bench.
[0092] In one embodiment, the present application further provides a computer-readable storage medium, in which multiple instructions are stored, and the instructions are suitable for being loaded and executed by a processor to perform the methods in any of the foregoing embodiments. A processor for executing multiple instructions; a memory for storing multiple instructions, and the instructions are loaded and executed by the processor to perform the method for generating an accelerated durability load spectrum for the test bench as described in the above embodiment.
[0093] The technical features of the above embodiments can be combined arbitrarily. For the sake of concise description, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, it should be considered as the scope described in this specification.
[0094] The above embodiments only represent several implementation manners of the present application. The description is relatively specific and detailed, but it should not be understood as a limitation to the scope of the invention patent. It should be noted that for those of ordinary skill in the art, without departing from the concept of the present application, several modifications and improvements can still be made, and these all belong to the protection scope of the present application. Therefore, the protection scope of the patent of the present application shall be subject to the appended claims.
Claims
1. A method for generating an accelerated durability load spectrum for a test bench, characterized in that: include: Calculate the cumulative damage of each damage mechanism of the product during the product life cycle based on the original load spectrum; Identify the key damage mechanisms that cause serious damage to the product based on the magnitude of the cumulative damage; With the goal of shortening the bench test time, the key damage mechanism is taken as the focus to optimize the original load spectrum and obtain the accelerated durability load spectrum for the bench.
2. The method according to claim 1, characterized in that The step of optimizing the original load spectrum by focusing on the key damage mechanism comprises: Setting a damage boundary of a key damage mechanism according to the cumulative damage of the key damage mechanism; Determine all other non-critical damage mechanisms other than the critical damage mechanism, and set the damage boundary of the non-critical damage mechanism according to the range of the cumulative damage of all other non-critical damage mechanisms; The damage boundary of the critical damage mechanism and the damage boundary of the non-critical damage mechanism are used as boundary conditions to optimize and solve the original load spectrum, and obtain the accelerated durability load spectrum for the test bench.
3. The method according to claim 2, characterized in that The step of setting the damage boundary of the key damage mechanism according to the accumulated damage of the key damage mechanism comprises: When setting the damage boundary of the key damage mechanism according to the accumulated damage of the key damage mechanism, setting the damage boundary of the key damage mechanism to a damage level matching the original working condition; A primary damage mechanism and a secondary damage mechanism among the key damage mechanisms are identified, and the damage boundary of the secondary damage mechanism is expanded so that the length of the area defined by the damage boundary of the primary damage mechanism is greater than the length of the area defined by the damage boundary of the secondary damage mechanism.
4. The method according to claim 2, characterized in that: Before optimizing the solution, it also includes: Obtaining an acceleration strategy and identifying the acceleration strategy; When the acceleration strategy is an overall acceleration strategy, the damage boundary of the non-critical damage mechanism is reduced to reduce the risk of product failure due to the non-critical damage mechanism.
5. The method according to claim 2, characterized in that: Before optimizing the solution, it also includes: Obtaining an acceleration strategy and identifying the acceleration strategy; When the acceleration strategy is a focused acceleration strategy, the damage boundary of the non-critical damage mechanism is expanded to weaken the focus on the non-critical damage mechanism and strengthen the focus on the critical damage mechanism.
6. The method according to claim 2, characterized in that The step of optimizing and solving the original load spectrum by taking the damage boundary of the key damage mechanism and the damage boundary of the non-key damage mechanism as boundary conditions to obtain the accelerated durability load spectrum for the test bench comprises: Set load steps under multiple working conditions according to multiple working conditions and load characteristics of each working condition; The load steps, the damage boundary of the critical damage mechanism and the damage boundary of the non-critical damage mechanism are used as boundary conditions to optimize and solve the original load spectrum, and an accelerated durability load spectrum for the bench under multiple working conditions is obtained to realize bench testing under multiple working conditions, shorten the bench testing time and reduce costs.
7. The method according to claim 1, characterized in that After optimizing and solving the original load spectrum by taking the damage boundary of the key damage mechanism and the damage boundary of the non-key damage mechanism as boundary conditions to obtain the accelerated durability load spectrum for the test bench, the method further includes: Calculating the sum of damages of all damage mechanisms according to the accelerated endurance load spectrum used on the test bench; Calculate the error between the sum of the damage of all damage mechanisms under the original load spectrum and the sum of the damage under the accelerated durability load spectrum for the bench to analyze the rationality of the accelerated durability load spectrum for the bench; If it is unreasonable, the accelerated durability load spectrum for the test bench is adjusted to reduce the error between the sum of damages of all damage mechanisms under the original load spectrum and the sum of damages under the accelerated durability load spectrum for the test bench.
8. A computing device, characterized in that The computing device comprises: A calculation unit, used to calculate the cumulative damage of each damage mechanism of the product during the product life cycle according to the original load spectrum; An identification unit, used to identify the key damage mechanism that causes serious damage to the product based on the magnitude of the accumulated damage; The optimization unit is used to optimize the original load spectrum with the key damage mechanism as the focus with the goal of shortening the bench test time, so as to obtain the accelerated durability load spectrum for the bench.
9. A computing device, characterized in that The computing device comprises a processor and a memory, wherein the memory stores a program or an instruction, and when the program or the instruction is executed by the processor, the method according to any one of claims 1 to 7 is implemented.
10. A computer-readable storage medium, characterized in that: The computer-readable storage medium includes the program or the instructions, and when the program or the instructions are executed on a device, the device is caused to perform the method according to any one of claims 1 to 7.