Method and system for managing service life of frame die casting

Abstract

The invention discloses a service life management method and system for a frame die casting, and relates to the technical field of service life management, the final service life of the frame die casting is determined based on the second theoretical service life and the first theoretical service life of the frame die casting, and the accuracy of the final service life of the frame die casting is ensured. Therefore, a plurality of damaged features are determined according to the damaged image of the frame die casting, and the remaining service life of the frame die casting is predicted based on the plurality of damaged features and the final service life of the frame die casting; the service life management of the frame die casting is triggered according to the remaining service life of the frame die casting, the service life management of the frame die casting is carried out on the damaged frame die casting, the remaining service life of the frame die casting is fully considered, it is guaranteed that the frame die casting pointedly repairs all damaged features, and the service life of the frame die casting is effectively improved. And the effectiveness of service life management of the frame die casting is ensured.

Description

Technical Field

[0001] The present invention relates to the technical field of service life management, and in particular to a service life management method and system for a vehicle frame die casting. Background Art

[0002] With the development of science and technology, the frame die-casting of new energy vehicles is one of the components of new energy vehicles. The frame die-casting is generally made of aluminum through high-pressure die-casting. In the existing technology, the frame die-casting forms data during the die-casting process, and the service life of the frame die-casting is predicted based on the die-casting data, which realizes a single-dimensional prediction and cannot guarantee the accuracy of the final service life of the frame die-casting, further affecting the effectiveness of the service life management of the frame die-casting. Summary of the Invention

[0003] The purpose of the present invention is to overcome the deficiencies of the prior art, and the present invention provides a method and system for managing the service life of a vehicle frame die casting.

[0004] An embodiment of the present invention provides a method for managing the service life of a vehicle frame die casting, comprising:

[0005] Determining die-casting data of the frame die-casting according to the model of the frame die-casting and a die-casting database, and determining a first theoretical service life according to the die-casting data of the frame die-casting;

[0006] The second theoretical service life is determined according to the use position and corresponding three-dimensional shape of the frame die-casting;

[0007] determining a final service life of the frame die casting based on the second theoretical service life and the first theoretical service life of the frame die casting;

[0008] After a new energy vehicle is involved in a vehicle collision, multiple damage features are determined based on a damage image of a frame die-casting, and the remaining service life of the frame die-casting is predicted based on the multiple damage features and the ultimate service life of the frame die-casting;

[0009] The service life management of the frame die casting is triggered according to the remaining service life of the frame die casting. In the service life management of the frame die casting, repair events of multiple damaged features are determined according to the remaining service life of the frame die casting, multiple damaged features and a repair mapping relationship.

[0010] An embodiment of the present invention provides a service life management system for a vehicle frame die-casting. The service life management system for a vehicle frame die-casting is applied to the above-mentioned service life management method for a vehicle frame die-casting. The service life management system for a vehicle frame die-casting includes:

[0011] A first theoretical service life module is used to determine die-casting data of the frame die-casting according to the model of the frame die-casting and the die-casting database, and to determine a first theoretical service life according to the die-casting data of the frame die-casting;

[0012] A second theoretical service life module is used to determine the second theoretical service life according to the use position and corresponding three-dimensional shape of the frame die-casting;

[0013] a final service life module, used for determining a final service life of the frame die casting based on a second theoretical service life and a first theoretical service life of the frame die casting;

[0014] a remaining useful life module for determining a plurality of damage features based on a damaged image of a frame die-casting after a new energy vehicle collision, and predicting the remaining useful life of the frame die-casting based on the plurality of damage features and the ultimate useful life of the frame die-casting;

[0015] The repair event module is used to trigger the service life management of the frame die-casting according to the remaining service life of the frame die-casting. In the service life management of the frame die-casting, the repair events of multiple damaged features are determined according to the remaining service life of the frame die-casting, multiple damaged features and the repair mapping relationship.

[0016] Compared with the prior art, the present invention has the following beneficial effects:

[0017] In an embodiment of the present invention, through the method in the embodiment of the present invention, the die-casting molding data of the frame die-casting is determined according to the model of the frame die-casting and the die-casting database, and the first theoretical service life is determined according to the die-casting molding data of the frame die-casting; the second theoretical service life is determined according to the use position and the corresponding three-dimensional form of the frame die-casting; and the final service life of the frame die-casting is determined based on the second theoretical service life and the first theoretical service life of the frame die-casting, which is compatible with the overall consideration of the second theoretical service life and the first theoretical service life of the frame die-casting, and ensures the accuracy of the final service life of the frame die-casting.

[0018] Therefore, after a new energy vehicle is involved in a vehicle collision, multiple damaged features are determined based on the damaged image of the frame die-casting, and the remaining service life of the frame die-casting is predicted based on the multiple damaged features and the final service life of the frame die-casting; the service life management of the frame die-casting is triggered according to the remaining service life of the frame die-casting, and in the service life management of the frame die-casting, repair events of the multiple damaged features are determined based on the remaining service life of the frame die-casting, the multiple damaged features and the repair mapping relationship, and the service life management of the frame die-casting is performed on the damaged frame die-casting, and the remaining service life of the frame die-casting is fully considered, thereby ensuring the targeted repair of each damaged feature of the frame die-casting and the effectiveness of the service life management of the frame die-casting, so as to realize the cycle management of the service life of the frame die-casting. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 1 is a flow chart of a method for managing the service life of a vehicle frame die casting according to an embodiment of the present invention;

[0020] Figure 2 1 is a flow chart of step S11 in the service life management method of a vehicle frame die casting in an embodiment of the present invention;

[0021] Figure 3 1 is a flow chart of step S12 in the service life management method of a vehicle frame die casting according to an embodiment of the present invention;

[0022] Figure 4 1 is a flow chart of step S13 in the service life management method of a vehicle frame die casting in an embodiment of the present invention;

[0023] Figure 5 1 is a flow chart of step S14 in the service life management method of a vehicle frame die casting according to an embodiment of the present invention;

[0024] Figure 6 1 is a flow chart of step S15 in the service life management method of a vehicle frame die casting according to an embodiment of the present invention;

[0025] Figure 7 Schematic diagram of the structure of the service life management system of the vehicle frame die casting in an embodiment of the present invention. DETAILED DESCRIPTION

[0026] The technical solutions in the embodiments of the present invention will be described clearly and completely below with reference to the accompanying drawings in the embodiments of the present invention.

[0027] See also Figures 1 to 7 , a service life management method for a vehicle frame die casting, comprising:

[0028] Step S11: determining die-casting data of the vehicle frame die-casting according to the model of the vehicle frame die-casting and a die-casting database, and determining a first theoretical service life according to the die-casting data of the vehicle frame die-casting;

[0029] Step S12: determining a second theoretical service life according to the use position and corresponding three-dimensional shape of the frame die-casting;

[0030] Step S13: determining a final service life of the vehicle frame die casting based on the second theoretical service life and the first theoretical service life of the vehicle frame die casting;

[0031] Step S14: after the new energy vehicle is involved in a vehicle collision, determining a plurality of damage features according to the damage image of the frame die-casting, and predicting the remaining service life of the frame die-casting based on the plurality of damage features and the ultimate service life of the frame die-casting;

[0032] Step S15: triggering service life management of the frame die-casting according to the remaining service life of the frame die-casting, wherein in the service life management of the frame die-casting, repair events of the multiple damaged features are determined according to the remaining service life of the frame die-casting, the multiple damaged features, and the repair mapping relationship;

[0033] refer to Figure 2 In step S11, the die-casting data of the frame die-casting is determined according to the model of the frame die-casting and the die-casting database, and the first theoretical service life is determined according to the die-casting data of the frame die-casting;

[0034] In the specific implementation process of the present invention, the specific steps are:

[0035] S111: During the die-casting process of the vehicle frame die-casting, the corresponding model is marked on the vehicle frame die-casting, and the die-casting molding data of the vehicle frame die-casting during the die-casting process is completely stored in a die-casting database; the die-casting database records all data of the vehicle frame die-casting;

[0036] S112: After the die-casting of the vehicle frame die-casting is completed, the die-casting database is triggered based on the frame die-casting, and the die-casting molding data of the frame die-casting is determined. At the same time, the mechanical data of the frame die-casting is determined based on the mechanical test of the frame die-casting;

[0037] S113: Determine a first theoretical service life according to the die-casting molding data, mechanical data and the first life mapping relationship of the frame die-casting component, where the first theoretical service life represents the service life of the frame die-casting component in a comprehensive dimension of die-casting dimension and mechanical dimension.

[0038] In an embodiment of the present application, during the die-casting process of the vehicle frame die-casting, the corresponding model is marked on the vehicle frame die-casting, and the die-casting molding data of the vehicle frame die-casting during the die-casting process is completely stored in a die-casting database; the die-casting database records all data of the vehicle frame die-casting;

[0039] At this time, ensure that each frame die-casting is uniquely identified to facilitate subsequent data traceability and management; during the die-casting process, before or after the molten metal is injected into the mold (depending on the specific circumstances of the process and equipment), use laser marking, engraving or other appropriate methods to mark the frame die-casting with a unique model identification. This identification includes the model code, production date, batch number and other information of the frame die-casting; the position of the mark should be selected without affecting the structural strength and appearance of the frame die-casting. At the same time, the mark should be clear, durable, and not easily worn or tampered with.

[0040] Record all key data of the frame die-casting parts during the die-casting process for subsequent analysis and optimization of the manufacturing process; install sensors and data acquisition systems on the die-casting machine to monitor and record key parameters such as temperature, pressure, time, speed, etc. during the die-casting process in real time. These data should be associated with the model identification of the frame die-casting parts and stored in the die-casting database; at this time, the die-casting database is a system specifically used to store data related to the frame die-casting parts. It should have functions such as data entry, query, and analysis; each record in the database should contain information such as the model identification of the frame die-casting parts, die-casting molding data, test data, and service life prediction.

[0041] Alternatively, assume that a die-cast part for a new energy vehicle frame, model XYZ-001, is being produced. During the die-casting process, a laser marking of XYZ-001-20230401-001 is performed on the die-cast part, where XYZ-001 is the model code, 20230401 is the production date, and 001 is the first die-cast part in the batch. During the die-casting process, the following data is monitored and recorded in real time: die-casting temperature: 680°C; injection pressure: 50 MPa; cooling time: 60 seconds; mold opening speed: 0. 1m / s. These data are associated with the identifier XYZ-001-20230401-001 and stored in the die-casting database. In this way, the manufacturing data of the frame die-casting can be queried and analyzed at any time for subsequent quality traceability, service life prediction and other operations. Through this example, we can see the importance of step S111: it ensures that each frame die-casting is uniquely identified and all key data in its manufacturing process are accurately recorded, which provides a solid foundation for subsequent service life management.

[0042] Furthermore, after the die-casting of the frame die-casting is completed, the traceability of the die-casting database is triggered based on the frame die-casting, and the die-casting molding data of the frame die-casting is determined. At the same time, the mechanical data of the frame die-casting is determined based on the mechanical test of the frame die-casting, and the mechanical data of the frame die-casting is introduced.

[0043] At this time, ensure that all relevant data of the specific frame die-casting during the die-casting process can be obtained accurately and quickly; at the same time, when the frame die-casting is completed, the traceability function of the die-casting database is triggered by scanning the model identification on the frame die-casting (such as barcode, QR code or laser marking, etc.), or by entering the model code and other relevant information of the frame die-casting; the database system will quickly retrieve and display all die-casting molding data related to the frame die-casting based on the input information; ensure that the model identification on the frame die-casting is clear and accurate, and the database system can quickly respond to traceability requests; at the same time, the data in the database should be checked and verified to ensure its accuracy and completeness.

[0044] Obtain key data of the frame die-casting parts during the die-casting process for subsequent analysis and evaluation; at this time, after triggering the traceability function, the database system will display all die-casting molding data related to the frame die-casting parts, including but not limited to die-casting temperature, pressure, time, speed, etc. These data are the basis for subsequent mechanical testing, service life prediction and other analyses.

[0045] Evaluate the mechanical properties of frame die-castings to understand their load-bearing capacity and durability in actual use; at the same time, perform mechanical tests on frame die-castings, such as tensile tests, compression tests, bending tests, impact tests, etc. These tests simulate the stress conditions of frame die-castings in actual use, thereby evaluating their mechanical properties; after the test is completed, record and organize the test data, including yield strength, tensile strength, hardness, toughness and other indicators; mechanical testing should be carried out in accordance with relevant standards and specifications to ensure the accuracy and reliability of the test results; at the same time, attention should be paid to safety during the test to avoid accidents.

[0046] Optionally, assume that a frame die-casting with model number XYZ-002 is being traced and mechanically tested; scan the QR code on the frame die-casting (the QR code contains the model information of the frame die-casting) to trigger the traceability function of the die-casting database; the database system quickly retrieves and displays all die-casting molding data related to the frame die-casting, such as die-casting temperature 690°C, injection pressure 55MPa, cooling time 65 seconds, etc.; carefully check the data displayed by the database system to confirm its accuracy and completeness, and these data will be used for subsequent analysis and evaluation; Mechanical testing: tensile test and impact test were performed on the frame die-casting; the tensile test results showed that the yield strength of the frame die-casting was 300MPa and the tensile strength was 350MPa; the impact test results showed that the impact toughness of the frame die-casting was 15J / cm 2 These mechanical data will be used to evaluate the load-bearing capacity and durability of the frame die-casting in actual use. Through this example, we can see the importance of step S112: it ensures that all relevant data of the specific frame die-casting in the die-casting process can be accurately and quickly obtained, and its mechanical properties are evaluated through mechanical testing, which provides key information support for subsequent service life prediction and management.

[0047] Therefore, the first theoretical service life is determined based on the die-casting molding data, mechanical data and the first life mapping relationship of the frame die-casting. The first theoretical service life presents the service life of the frame die-casting in the comprehensive dimension of die-casting dimension and mechanical dimension, and is compatible with the overall consideration of the die-casting molding data, mechanical data and the first life mapping relationship of the frame die-casting, thereby ensuring the accuracy of the first theoretical service life.

[0048] At this point, ensure that all necessary data has been collected and organized for subsequent analysis and calculations; at the same time, obtain the die-casting molding data of the frame die-casting parts (such as die-casting temperature, pressure, time, etc.) from the die-casting database, as well as the mechanical data of the frame die-casting parts obtained through mechanical testing (such as yield strength, tensile strength, impact toughness, etc.); ensure that this data is accurate, complete and verified.

[0049] The first life mapping relationship between die-casting molding data, mechanical data and the service life of frame die-casting parts is established, and the first life mapping relationship is introduced. At this time, this is obtained through a large amount of experimental data, statistical analysis, machine learning and other methods; the first life mapping relationship is a complex mathematical model, which takes into account the influence of multiple factors (such as die-casting process parameters, material properties, use environment, etc.) on the service life of frame die-casting parts. This mapping relationship should be fully verified and calibrated to ensure its accuracy and reliability.

[0050] Based on the collected data and the first life mapping relationship, the first theoretical service life of the frame die-casting is calculated; at this time, the die-casting molding data and mechanical data of the frame die-casting are input into the first life mapping relationship for calculation. This process is automated and also requires manual intervention and adjustment; the calculated first theoretical service life should be an estimated value, which indicates the time or period that the frame die-casting is expected to be used under specific conditions (such as normal working environment, standard usage conditions, etc.).

[0051] Alternatively, assume that the first theoretical service life of a die-cast frame part, model XYZ-003, is being determined; die-casting molding data: die-casting temperature 700°C, injection pressure 60 MPa, cooling time 70 seconds; mechanical data: yield strength 320 MPa, tensile strength 370 MPa, impact toughness 18 J / cm 2 Through extensive experimental data and statistical analysis, a first life mapping relationship model has been established. This model takes into account multiple factors such as die-casting temperature, pressure, time, as well as yield strength, tensile strength, impact toughness, and presents the complex relationship between these factors and the service life of vehicle frame die-casting parts.

[0052] The collected data is input into the first life mapping relationship model for calculation. After calculation, it is concluded that the first theoretical service life of the XYZ-003 frame die-casting is 10 years, or it can withstand 1 million cycles of loading under normal working environment and standard use conditions. Through this example, we can see the importance of step S113: it uses the collected data and the first life mapping relationship to provide the frame die-casting with a first theoretical service life in a comprehensive dimension based on the die-casting dimension and the mechanical dimension. This theoretical service life is the basis for subsequent service life management, maintenance plan formulation and other work.

[0053] Specifically, a first theoretical service life matching table is collected, and the first theoretical service life is shown in Table 1:

[0054] Table 1 Theoretical service life

[0055]

[0056] Consider a frame die-casting with a die-casting temperature of 695°C, an injection pressure of 58 MPa, a yield strength of 315 MPa, and a tensile strength of 355 MPa. In the matching table, find the row closest to the frame die-casting data. Read the first theoretical service life value corresponding to that row. In this example, the frame die-casting data is closest to the second row (690-700°C, 55-60 MPa, 310-320 MPa, 350-360 MPa), so its first theoretical service life is 10 years.

[0057] refer to Figure 3 In step S12, a second theoretical service life is determined according to the use position and the corresponding three-dimensional shape of the frame die-casting;

[0058] In the specific implementation process of the present invention, the specific steps are:

[0059] S121: In a new energy vehicle equipped with the frame die-casting, determining a usage position of the frame die-casting according to a distribution map of the new energy vehicle and a usage mark of the frame die-casting, and determining an impact resistance coefficient of the frame die-casting according to a mapping relationship between the usage position of the frame die-casting and the impact resistance coefficient;

[0060] S122: determining a theoretical shape of the frame die-casting based on the tracing of the model of the frame die-casting, performing a circular photograph of the frame die-casting, generating an actual shape of the frame die-casting, and determining a three-dimensional shape of the frame die-casting based on a synthesis of the actual shape of the frame die-casting and the theoretical shape;

[0061] S123: Determine a second theoretical service life based on the three-dimensional shape, impact resistance coefficient, and second life mapping relationship of the frame die-casting, where the second theoretical service life represents the service life of the frame die-casting in a comprehensive dimension of shape and impact resistance;

[0062] In an embodiment of the present application, in a new energy vehicle equipped with the frame die-casting, the usage position of the frame die-casting is determined according to the distribution map of the new energy vehicle and the usage mark of the frame die-casting, and the impact resistance coefficient of the frame die-casting is determined according to the mapping relationship between the usage position of the frame die-casting and the impact resistance coefficient, which is compatible with the overall consideration of the mapping relationship between the usage position of the frame die-casting and the impact resistance coefficient, and ensures the accuracy of the impact resistance coefficient of the frame die-casting.

[0063] At this time, the specific location of the frame die-casting in the new energy vehicle is determined for subsequent analysis; at this time, the distribution map of the new energy vehicle contains the various components of the vehicle and their location information; by consulting the distribution map and combining the use markings of the frame die-casting (such as labels, numbers or location indicators), the exact location of the frame die-casting in the vehicle is determined; ensure the accuracy and update of the distribution map, and the clear visibility and easy identification of the use markings of the frame die-casting.

[0064] The impact resistance coefficient of the frame die-casting is determined based on the mapping relationship between the use position of the frame die-casting and the impact resistance coefficient, and the ability of the frame die-casting to withstand impact loads in a specific position is evaluated; at this time, the impact resistance coefficient mapping relationship is a pre-established database or model, which provides the corresponding impact resistance coefficient according to the use position of the frame die-casting (or related parameters, such as location type, surrounding environment, etc.); once the use position of the frame die-casting is determined, its impact resistance coefficient is obtained by querying the mapping relationship; the impact resistance coefficient mapping relationship should be established based on sufficient experimental data, simulation analysis or expert experience to ensure its accuracy and reliability; at the same time, attention should be paid to the scope of application and restrictions of the mapping relationship.

[0065] Alternatively, assume that the impact resistance coefficient of the frame die-casting of a new energy vehicle named "EcoDrive-X1" is being evaluated; first, the distribution map of "EcoDrive-X1" is consulted, which lists the various components of the vehicle and their locations in detail; in the distribution map, the frame die-casting marked "FD-001" is found, which is located at the front end of the bottom of the vehicle, close to the collision buffer zone.

[0066] Next, the pre-established impact resistance coefficient mapping relationship was queried; this mapping relationship takes into account factors such as the use location of the frame die-casting, the surrounding environment (such as whether there are other structural parts to provide protection), and the potential impact load type; based on the use location of the "FD-001" frame die-casting (the front end of the bottom of the vehicle, close to the collision buffer zone), the mapping relationship provides a corresponding impact resistance coefficient of 1.8, which means that under standard impact test conditions, the "FD-001" frame die-casting can withstand an impact load equivalent to 1.8 times its own weight without being damaged; through this example, we can see the importance of step S121: it helps determine the specific location of the frame die-casting in the new energy vehicle and evaluates its impact resistance in this location. This information is of great significance for subsequent frame die-casting service life assessment, safety analysis, and maintenance plan formulation.

[0067] Furthermore, the theoretical form of the frame die-casting is determined based on the tracing of the model of the frame die-casting, the frame die-casting is photographed in a circular manner, and the actual form of the frame die-casting is generated. The three-dimensional form of the frame die-casting is determined based on the synthesis of the actual form and the theoretical form of the frame die-casting, which is compatible with the overall consideration of the synthesis of the actual form and the theoretical form of the frame die-casting, ensuring the accuracy of the three-dimensional form of the frame die-casting.

[0068] At this time, the theoretical form is determined based on the model of the frame die-casting, and the theoretical three-dimensional form of the frame die-casting during design or manufacturing is obtained; at the same time, the model of the frame die-casting is associated with its design drawings, CAD models or manufacturing specifications; by tracing the model of the frame die-casting, its theoretical form is found in the relevant design database or manufacturing files, which is a three-dimensional model that describes the geometric shape, size, material and other information of the frame die-casting.

[0069] Capture the actual three-dimensional form of the frame die-casting, including its surface details and any manufacturing defects; at this time, use a circular shooting device or technology to shoot the frame die-casting from multiple angles; circular shooting involves rotating one or more cameras around the frame die-casting to capture images of all its surfaces, which are then used to generate a three-dimensional model or point cloud data of the frame die-casting; when shooting, ensure that the lighting is sufficient and uniform to avoid shadows and reflections that affect the image quality; at the same time, ensure the accuracy of the camera position and angle to ensure the accuracy of the generated three-dimensional model or point cloud data.

[0070] The three-dimensional form of the frame die-casting is determined based on the synthesis of the actual form and the theoretical form, and the actual form of the frame die-casting is compared and synthesized with the theoretical form to generate a three-dimensional form that combines information from both. At this time, three-dimensional modeling software or image processing tools are used to align and compare the three-dimensional model or point cloud data obtained by actual photography with the theoretical form, which involves adjusting position, rotation and scaling parameters to align the actual form with the theoretical form in space. Once aligned, the two are merged into a three-dimensional form that not only contains the design intent of the frame die-casting but also reflects its actual manufacturing status.

[0071] Specifically, suppose a quality inspection is being performed on the die-cast frame of a new energy vehicle called "EcoFlex-3000." First, the model of the die-cast frame, "XYZ-1234," is traced, and the corresponding CAD model is found in the design database. This model describes the geometry, dimensions, and material composition of the die-cast frame in detail. Using a circular camera, the die-cast frame is photographed from multiple angles. During the photography process, the uniformity of the light and the accuracy of the camera are ensured. After the photography is completed, a series of two-dimensional images of the die-cast frame are obtained.

[0072] The captured images are imported into the 3D modeling software, and the registration and comparison tools in the software are used to align the actual form with the theoretical form. During the comparison process, some minor manufacturing defects such as surface scratches and dimensional deviations are found. In order to generate the final three-dimensional form, these defects are smoothed and resized. Finally, a three-dimensional form model that combines the design intent and actual manufacturing status of the frame die-casting is obtained. Through this example, we can see the importance of step S122: it helps to obtain the theoretical and actual forms of the frame die-casting, and generates a comprehensive three-dimensional form model by synthesizing the two, which is of great significance for subsequent quality inspection, defect analysis and design improvement.

[0073] Therefore, the second theoretical service life is determined based on the three-dimensional morphology, impact resistance coefficient and second life mapping relationship of the frame die-casting. The second theoretical service life presents the service life of the frame die-casting in the comprehensive dimension of morphological dimension and impact resistance dimension, and is compatible with the overall consideration of the three-dimensional morphology, impact resistance coefficient and second life mapping relationship of the frame die-casting, ensuring the accuracy of the second theoretical service life.

[0074] At this time, detailed morphological information and impact resistance data of the frame die-casting are collected to provide a basis for subsequent life assessment; at this time, the three-dimensional morphology is a three-dimensional morphological model of the frame die-casting obtained through three-dimensional scanning, modeling or design database, which contains detailed information such as the geometry, size, surface features, etc. of the frame die-casting; the impact resistance coefficient is determined through the previous steps (such as S121), which indicates the bearing capacity of the frame die-casting under specific impact conditions; ensure the accuracy and completeness of the three-dimensional morphology, as well as the reliability and applicability of the impact resistance coefficient.

[0075] Determine the second life mapping relationship and establish a model or relationship that associates the three-dimensional shape and impact resistance coefficient of the frame die-casting with its service life; at this time, collect a large amount of usage data of the frame die-casting, including its three-dimensional shape, impact resistance coefficient and actual service life; use statistical methods, machine learning algorithms or physical simulation and other technologies to establish a second life mapping relationship based on the collected data. This relationship is a mathematical formula, lookup table or complex model used to predict the service life of the frame die-casting based on its three-dimensional shape and impact resistance coefficient; ensure the accuracy and diversity of the data, as well as the scientific nature and effectiveness of the modeling method.

[0076] Based on the three-dimensional shape and impact resistance coefficient of the frame die-casting, as well as the second life mapping relationship, its expected service life is calculated; at this time, the three-dimensional shape and impact resistance coefficient of the frame die-casting are used as input parameters; these parameters are input into the second life mapping relationship for calculation; the second theoretical service life of the frame die-casting is obtained, which is a value or range representing time; the accuracy of the input parameters and the applicability of the mapping relationship, as well as the accuracy and efficiency of the calculation process, are ensured.

[0077] Specifically, assume that the second theoretical service life of the die-cast frame of a new energy vehicle called "EcoSpeed-5000" is being evaluated. A three-dimensional morphological model of the die-cast frame is obtained through 3D scanning, which describes the geometry and dimensions of the die-cast frame in detail. Through the previous steps, the impact coefficient of the die-cast frame is determined to be 1.6, indicating that it can withstand an impact load equivalent to 1.6 times its own weight.

[0078] The usage data of a variety of similar frame die-castings were collected, including their three-dimensional shape, impact resistance coefficient and actual service life; a second life mapping relationship model was established based on this data using a machine learning algorithm; the model can predict the service life of the frame die-casting based on its three-dimensional shape and impact resistance coefficient; the obtained three-dimensional shape and impact resistance coefficient are input into the second life mapping relationship model; after calculation, the model outputs a second theoretical service life of the frame die-casting of 12 years (under normal use and maintenance conditions); through this example, we can see the importance of step S123: it combines the three-dimensional shape and impact resistance coefficient of the frame die-casting, and calculates its expected service life through the second life mapping relationship model, which is an important reference information for automobile manufacturers to help them understand the performance and durability of frame die-castings, so as to formulate more reasonable maintenance and replacement plans.

[0079] In one embodiment of the present application, a pre-established second theoretical service life matching table is collected. The second theoretical service life matching table gives the second theoretical service life according to the three-dimensional form (form grade), impact resistance coefficient and second life mapping relationship (here simplified as life interval) of the frame die casting. The second theoretical service life matching table is shown in Table 2:

[0080] Table 2 The second theoretical service life matching table

[0081] Morphological level Impact resistance coefficient Second theoretical service life (years) A 1.0-1.4 8-10 A 1.5-1.9 10-12 B 1.0-1.4 6-8 B 1.5-1.9 8-10 C 1.0-1.4 4-6 C 1.5-1.9 6-8

[0082] In this example, shape grade A represents the best shape, B represents the medium shape, and C represents the poor shape. The impact resistance coefficient is determined based on the actual test value of the frame die casting.

[0083] Through three-dimensional scanning and morphological analysis, it is determined that the three-dimensional morphological grade of the frame die-casting is A; through the previous steps (such as S121), it is determined that the impact resistance coefficient of the frame die-casting is 1.6; in the second theoretical service life matching table, the row with a morphological grade of A and an impact resistance coefficient of 1.5-1.9 is found; according to the second theoretical service life matching table, the second theoretical service life of the frame die-casting is 10-12 years.

[0084] refer to Figure 4 In step S13, the final service life of the vehicle frame die casting is determined based on the second theoretical service life and the first theoretical service life of the vehicle frame die casting;

[0085] In the specific implementation process of the present invention, the specific steps are:

[0086] S131: collecting the second theoretical service life and the first theoretical service life of the frame die-casting, matching the second theoretical service life and the first theoretical service life of the frame die-casting, and determining a corresponding matching coefficient;

[0087] S132: If the matching coefficient is higher than a preset matching coefficient threshold, determining a service life range according to the second theoretical service life and the first theoretical service life;

[0088] S133: Determine a final service life of the frame die-casting according to the service life range, the three-dimensional shape of the frame die-casting, and the safe use strength of the frame die-casting, and the final service life is within the service life range.

[0089] In an embodiment of the present application, the second theoretical service life and the first theoretical service life of the frame die-casting are collected, the second theoretical service life and the first theoretical service life of the frame die-casting are matched, and the corresponding matching coefficient is determined, and the matching coefficient is introduced.

[0090] At this point, the first theoretical service life and the second theoretical service life of the frame die-casting are collected, and the matching coefficient between them is calculated. This step is the basis for subsequent analysis and decision-making, ensuring a comprehensive and accurate understanding of the service life of the frame die-casting.

[0091] The second theoretical service life and the first theoretical service life of the frame die-casting are collected and compared to evaluate the consistency or difference between them; the first theoretical service life and the second theoretical service life are numerically compared by simple proportional calculation, chart comparison or more complex statistical analysis methods; the degree of match between the two theoretical service lives is quantified; the matching coefficient can be a simple proportional value (such as the second theoretical service life divided by the first theoretical service life) or a comprehensive indicator derived from a more complex algorithm; the specific calculation method of the matching coefficient depends on the evaluation needs and objectives.

[0092] Specifically, suppose the service life of a new frame die-casting is being evaluated. By consulting the design documents and material performance data, it is learned that the first theoretical service life of the frame die-casting is 10 years, which is a traditional evaluation result based on its material, manufacturing process and design specifications. By applying advanced simulation software and experimental testing methods, and comprehensively considering multiple dimensions such as the shape, impact resistance and use environment of the frame die-casting, the second theoretical service life is 12 years, which is a more comprehensive and accurate result. The first theoretical service life (10 years) is compared with the second theoretical service life (12 years). Through simple proportional calculation, It was found that the second theoretical service life was 20% longer than the first theoretical service life. In this example, the matching coefficient was defined as the ratio of the second theoretical service life to the first theoretical service life, which is 1.2 (12 years / 10 years). This matching coefficient shows that the service life based on a more comprehensive evaluation method is longer than that obtained by the traditional method. Through this example, we can see the importance of step S131: it helps to collect and compare the theoretical service lives of the frame die-casting parts obtained by two different methods, and quantifies the consistency or difference between them through the matching coefficient, which provides valuable information for subsequent analysis and decision-making.

[0093] Furthermore, if the matching coefficient is higher than a preset matching coefficient threshold, the service life range is determined based on the second theoretical service life and the first theoretical service life, which is compatible with the overall consideration of the second theoretical service life and the first theoretical service life and ensures the accuracy of the service life range.

[0094] At this point, the service life range of the frame die-casting is determined based on the comparison results of the matching coefficient and the preset matching coefficient threshold. This step is a bridge connecting theoretical evaluation and practical application, ensuring that a safe and economical expected service life can be set for the frame die-casting.

[0095] Determine whether the matching coefficient meets or exceeds a preset standard, which is based on industry experience, safety considerations or economic factors; at this time, compare the calculated matching coefficient with a preset matching coefficient threshold; the preset matching coefficient threshold is a fixed value, a range or a dynamically adjusted value.

[0096] When the matching coefficient is higher than the preset threshold, a reasonable service life range is set for the frame die-casting in combination with the first theoretical service life and the second theoretical service life; at the same time, a service life range is determined based on the level of the matching coefficient, the specific values of the first theoretical service life and the second theoretical service life, and other influencing factors (such as the use environment, maintenance conditions, etc.). This range is an interval that represents the number of years that the frame die-casting is expected to work safely and effectively.

[0097] Specifically, assume that the service life of the new frame die-casting mentioned above is still being evaluated; in the previous step, the matching coefficient has been calculated to be 1.2 (the second theoretical service life of 12 years divided by the first theoretical service life of 10 years); the preset matching coefficient threshold is set to 1.1, which is based on industry experience and safety considerations; the matching coefficient 1.2 is compared with the preset matching coefficient threshold 1.1, and it is found that the matching coefficient is higher than the preset threshold; since the matching coefficient is higher than the preset threshold, it is believed that the second theoretical service life (12 years) is closer to the actual service life of the frame die-casting; at the same time, considering that the first theoretical service life (10 years) is traditional The results of the evaluation method have a certain reference value; therefore, combined with the comparison results of the two theoretical service lives and the preset matching coefficient threshold, a service life range is set for the frame die-casting: 10 to 12 years. This range takes into account both the results obtained by advanced evaluation methods and the reference value of traditional methods. Through this example, we can see the importance of step S132: it helps to set a reasonable service life range for the frame die-casting based on the comparison results of the matching coefficient and the preset matching coefficient threshold. This range is not only based on a comprehensive evaluation method, but also takes into account industry experience and safety factors, providing a valuable reference for the practical application of frame die-castings.

[0098] Therefore, the final service life of the frame die-casting is determined based on the service life range, the three-dimensional form of the frame die-casting and the safe use strength of the frame die-casting. The final service life is within the service life range, which is compatible with the overall consideration of the service life range, the three-dimensional form of the frame die-casting and the safe use strength of the frame die-casting, ensuring the accuracy of the final service life of the frame die-casting. At the same time, it is compatible with the overall consideration of the second theoretical service life and the first theoretical service life of the frame die-casting.

[0099] At this point, the service life range, the three-dimensional shape of the frame die-casting, and the safe use strength are comprehensively considered to determine a final service life that is both in line with the actual situation and ensures safety. This step is the key to ensuring that the frame die-casting can perform at its best in actual applications.

[0100] Understand the range of years over which the frame die-castings are expected to operate safely and effectively; review the service life range determined in the previous step, considering the upper and lower limits of the range, as well as the intermediate values; also, understand the impact of the physical structure of the frame die-castings on their service life; through methods such as 3D scanning, morphological analysis, or expert evaluation, determine whether the three-dimensional shape of the frame die-castings is conducive to extending service life or whether there are potential defects that may lead to early failure.

[0101] Ensure that the frame die-castings can meet the safety performance requirements within the expected service life; evaluate their safety performance under different usage intensities based on factors such as the design specifications, material properties, and usage environment of the frame die-castings, which involves methods such as strength testing, fatigue analysis, or safety assessment; based on the above analysis, set a final service life for the frame die-castings that is both in line with actual conditions and ensures safety; at this time, select a suitable value within the service life range as the final service life, which should take into account factors such as the three-dimensional shape of the frame die-castings, safe use intensity, and maintenance conditions; the final service life should be within the service life range, but it is not necessarily the middle value or average value of the range, but the result of weighing and selecting according to the specific situation.

[0102] Specifically, assume that the service life of the previously mentioned new frame die-casting is still being evaluated and has been determined to be in the range of 10 to 12 years. It is known that the frame die-casting can be expected to operate safely and effectively for between 10 and 12 years. Through 3D scanning and morphological analysis, it is found that the three-dimensional design of the frame die-casting is reasonable, which is conducive to stress dispersion and extended service life. There are no obvious potential defects that may cause early failure.

[0103] Based on the design specifications and material properties, strength tests and fatigue analyses were conducted. The results showed that the frame die-castings could maintain stable performance under the safety intensity and had sufficient margin to cope with unexpected situations. Based on the above analysis, it was decided to select 11 years as the ultimate service life of the frame die-castings. This value is within the service life range and takes into account the three-dimensional shape and safety intensity of the frame die-castings. It is believed that 11 years is an expected service life that is both in line with the actual situation and ensures safety, and can provide a valuable reference for the actual application of frame die-castings. Through this example, we can see the importance of step S133: it helps to comprehensively consider multiple factors and set a ultimate service life for the frame die-castings that is both in line with the actual situation and ensures safety. This ultimate service life can provide important guidance for the design, manufacture and use of frame die-castings, ensuring that they can perform at their best in actual applications.

[0104] In one embodiment of the present application, each factor is matched with the corresponding service life range to determine the final service life; the service life matching table of the frame die casting is shown in Table 3:

[0105] Table 3 Frame die casting service life matching table

[0106] Service life range (years) Stereomorphological assessment Safety use strength assessment Final service life (years) 10-12 excellent high 12 10-12 good high 11 10-12 middle high 10.5 10-12 excellent middle 11.5 10-12 good middle 10.75 10-12 middle middle 10

[0107] Assuming that the service life of the frame die-casting ranges from 10 to 12 years, the three-dimensional morphology is evaluated as "good", and the safety strength is evaluated as "high"; according to the matching table, the corresponding final service life is found to be 11 years.

[0108] refer to Figure 5 In step S14, after the new energy vehicle is involved in a vehicle collision, a plurality of damage features are determined based on the damage image of the frame die-casting, and the remaining service life of the frame die-casting is predicted based on the plurality of damage features and the final service life of the frame die-casting;

[0109] In the specific implementation process of the present invention, the specific steps are:

[0110] S141: A new energy vehicle is driving on the road and collides with another vehicle. The die-casting of the vehicle frame is impacted and damaged. A circular image of the die-casting is taken, and images of the damaged die-casting are captured.

[0111] S142: determining a damaged area based on the damaged image of the vehicle frame die-casting and the three-dimensional shape of the vehicle frame die-casting, determining a plurality of damaged features based on the identification of each damaged area, and marking the damage levels and spatial positions of the plurality of damaged features;

[0112] S143: Determine a primary change in service life based on the damage levels of the plurality of damaged features and the ultimate service life of the frame die casting, predict a life reduction based on the primary change in service life and the spatial positions of the plurality of damaged features, and predict a remaining service life of the frame die casting based on the ultimate service life and the life reduction of the frame die casting.

[0113] In an embodiment of the present application, a new energy vehicle is traveling on a road and collides with another vehicle. At this time, the frame die-casting is impacted and damaged. A circular image of the frame die-casting is taken, and a damaged image of the frame die-casting is collected, thereby introducing a damaged image of the frame die-casting.

[0114] At this point, after a new energy vehicle is involved in a traffic accident, the frame die-casting is damaged, and circular photography is performed to collect damaged images; the following is a detailed description of each step: At this point, when the new energy vehicle is driving normally on the road, it collides with other vehicles due to various reasons (such as driver operating errors, poor road conditions, violations by other vehicles, etc.); the accident involves different degrees of collision force, resulting in different degrees of impact and damage to the frame die-casting; the collision is frontal, side or rear, depending on the situation of the accident.

[0115] During a collision, the frame die-casting, as a key structural component of the vehicle, bears the main impact force; therefore, the frame die-casting will be damaged by deformation, cracks, fractures, etc. At this time, the extent of the damage depends on factors such as the severity of the collision, the material properties of the frame die-casting, the manufacturing process, and the design structure. In some cases, the frame die-casting is only slightly damaged, while in other cases, it is completely destroyed.

[0116] In order to fully record the damage to the frame die-casting, circular photography is required, which means photographing the frame die-casting from multiple angles and positions to ensure that all damage details are captured; at this time, the circular photography uses a professional camera or smartphone and requires auxiliary equipment such as a tripod and flash; when shooting, ensure sufficient lighting to clearly show the damaged area; the choice of shooting angle and position should be adjusted according to the shape and damage of the frame die-casting.

[0117] The damaged images captured should be saved to a designated storage device for subsequent analysis and processing. These images will be used to assess the extent of damage to the frame die-castings, determine repair plans, and predict the remaining service life of the frame die-castings. At this time, the damaged images should be saved in a high-resolution format so that they can still maintain clarity when magnified. At the same time, the naming and storage structure of the image files should be orderly to facilitate quick search and use.

[0118] Specifically, suppose a new energy vehicle collides with another vehicle sideways on a highway; after the accident, technicians rush to the scene and follow the S141 steps: the technicians observe that the left side of the new energy vehicle collides severely with the right side of the other vehicle, with debris and liquid scattered at the scene; after a preliminary inspection, the technicians find that the die-casting of the frame has been severely impacted in the collision, and the frame part near the left door has obvious deformation and cracks; at the same time, the technicians use a professional camera to take a circular shot of the damaged die-casting of the frame; they take pictures of the damaged area from multiple angles and positions, including the front, side, top and bottom, etc.; each shooting angle ensures sufficient lighting to clearly show the damage details; technicians save the damaged images they capture to a designated storage device; they name and classify the images according to chronological order and shooting angle for subsequent analysis and processing. These images will be used to assess the extent of damage to the frame die-castings, develop repair plans, and predict the remaining service life of the frame die-castings; through the above steps and examples, the importance of S141 in handling new energy vehicle accidents is clearly understood; circular shooting and collection of damaged images provide key information for subsequent analysis and processing, helping to ensure that the frame die-castings are correctly evaluated and repaired.

[0119] Furthermore, the damaged area is determined based on the damaged image of the frame die-casting and the three-dimensional morphology of the frame die-casting, and multiple damaged features are determined based on the identification of each damaged area, and the damage levels and spatial positions of the multiple damaged features are marked, which is compatible with the overall consideration of the damaged image of the frame die-casting and the three-dimensional morphology of the frame die-casting, ensuring the accuracy of the damaged area.

[0120] At this point, the specific damaged area is determined based on the collected image of the damaged frame die-casting and the three-dimensional form of the frame die-casting (such as design drawings, three-dimensional models or actual observations). This step requires technicians to have an in-depth understanding of the structure of the frame die-casting and to be able to accurately identify the relationship between the damaged area in the image and the overall structure of the frame die-casting. This involves operations such as image magnification, comparison, and annotation.

[0121] After determining the damaged area, further identify multiple damaged features within the area. These features include cracks, deformations, dents, fractures, scratches, etc. When identifying damaged features, it is necessary to carefully observe every detail in the image and distinguish the shapes and manifestations of different features. Professional image analysis software or tools are needed to assist in identification.

[0122] Each identified damaged feature is assessed for damage level. The damage level is determined based on factors such as the severity and scope of the feature and its impact on the overall structure of the die-cast frame. Damage levels are categorized as mild, moderate, and severe. The assessment is conducted in accordance with relevant industry standards and empirical data to ensure the accuracy and consistency of the assessment results.

[0123] Determining the specific spatial location of each damaged feature on the frame die-cast part involves annotating the image and recording the location information of each feature. At the same time, when marking the spatial location, tools such as coordinate systems, grid lines, and scales are used to assist in positioning. This ensures that the location information of each feature is accurate for subsequent analysis and processing.

[0124] Specifically, assume that a technician is conducting a damage assessment on the frame die-casting of a new energy vehicle and follows step S142: the technician first observes the collected damage image and finds obvious impact marks on the left front area of the frame die-casting; combining the three-dimensional shape of the frame die-casting and the design drawings, they determine that the specific damaged area is the left front longitudinal beam and part of the cross beam connected to it; after determining the damaged area, the technician carefully observes the details in the image and identifies multiple damage features, including cracks on the left front longitudinal beam, dents and deformation of the cross beam, and breakage of some connecting parts.

[0125] Each identified damaged feature was assessed for damage level; cracks were assessed as moderate damage because they significantly affected the strength of the frame die-casting; dents and deformations were assessed as mild damage because they had relatively little impact on the overall structure; and the fracture of the connector was assessed as severe damage because it reduced the overall stability of the frame die-casting. Technicians used image annotation tools to annotate each damaged feature on the damaged image and recorded their specific location information. For example, the crack was located in the upper middle part of the left front longitudinal beam, the dents and deformations were located at the left front end of the crossbeam, and the fracture of the connector was located at the connection between the crossbeam and the longitudinal beam. Through the above steps and examples, the importance of S142 in the damage assessment of frame die-castings is clearly understood. Determining the damaged area, identifying the damaged features, and marking the damage level and spatial location provide key information for subsequent analysis and processing, helping to ensure that the frame die-castings are correctly assessed and repaired.

[0126] Therefore, based on the damage levels of multiple damaged features and the ultimate service life of the frame die-casting, the primary change in service life is determined, and the life reduction is predicted based on the primary change in service life and the spatial positions of multiple damaged features. The remaining service life of the frame die-casting is predicted based on the ultimate service life and the life reduction of the frame die-casting, which is compatible with the overall consideration of the damage levels of multiple damaged features and the ultimate service life of the frame die-casting, ensuring the accuracy of the primary change in service life.

[0127] At this point, a preliminary service life change is determined based on the damage levels of multiple damaged features of the frame die-casting and the degree of influence of these features on the overall structure of the frame. This change reflects the direct impact of the damaged features on the service life of the frame die-casting. At this point, it is necessary to comprehensively consider the severity, location, number of each damaged feature and the interaction between them. It is also necessary to refer to factors such as the material properties, manufacturing process, and historical maintenance records of the frame die-casting. The higher the damage level, the greater the impact on the service life. Therefore, the determination of the preliminary change requires a certain amount of experience, judgment, and professional knowledge.

[0128] After determining the primary change in service life, the reduction in service life of the frame die-casting is further predicted based on the spatial locations of multiple damaged features. This reduction takes into account the distribution of damaged features on the frame, the mutual influence between adjacent features, and the stability of the overall frame structure. At this time, when predicting the life reduction, it is necessary to use professional life prediction models or algorithms. These models are based on a large amount of experimental data, simulation analysis, and empirical formulas, and can comprehensively consider the impact of multiple factors on the frame life. The consideration of spatial location is particularly important because damaged features in different locations have different effects on the overall stability of the frame.

[0129] The remaining service life of the frame die-casting is calculated based on the final service life of the frame die-casting (i.e., the expected service life when undamaged) and the predicted life reduction. This remaining service life reflects the actual usable time or mileage of the frame after damage. At this time, when calculating the remaining service life, it is necessary to subtract the predicted life reduction from the final service life. At the same time, the potential risks and maintenance requirements of the frame die-casting during subsequent use also need to be considered. For example, if the damaged characteristics make the frame more prone to failure under certain conditions, then the remaining service life needs to be further adjusted.

[0130] Specifically, assuming that technicians are predicting the remaining service life of the frame die-casting of a new energy vehicle, the technicians first preliminarily estimate the change in service life based on the damage level of the identified damage features (such as cracks, dents, fractures, etc.) and the degree of impact of these features on the overall structure of the frame; for example, cracks are assessed as moderate damage, resulting in a decrease in frame strength of approximately 10%; dents and fractures are assessed as severe damage, resulting in a decrease in the overall stability of the frame of approximately 20%; taking all these factors into consideration, the technicians preliminarily estimate that the service life of the frame die-casting will be reduced by approximately 25%.

[0131] After determining the primary amount of change, the technicians further considered the spatial location of the damaged features. They found that cracks were located in key load-bearing parts of the frame, while dents and fractures were located in adjacent areas. The interaction between these features made the frame more susceptible to failure under certain conditions. Therefore, the technicians used a professional life prediction model, combined with the location, number and severity of the damaged features, to predict that the life of the frame die-casting would be reduced by approximately 30%.

[0132] Based on the ultimate service life of the frame die-casting (assuming it is 10 years) and the predicted life reduction (30%), the technicians calculated the remaining service life of the frame die-casting. They concluded that after the damage, the remaining service life of the frame die-casting is approximately 7 years (i.e., 10 years * 70%). At the same time, they also recommended that vehicle owners strengthen inspection and maintenance during subsequent use to ensure the safety and stability of the frame die-casting. Through the above steps and examples, the importance of S143 in predicting the remaining service life of frame die-castings is clearly understood. Determining the primary change in service life, the predicted life reduction, and the remaining service life provides key information for subsequent decision-making and maintenance, helping to ensure the safety and reliability of the vehicle.

[0133] In one embodiment of the present application, a damage feature matching table is developed based on the damage features of the vehicle frame die casting. The damage feature matching table lists the damage features, damage levels, and corresponding life variation coefficients. Then, combined with the final service life of the vehicle frame die casting, the damage feature matching table is used to determine the primary variation in service life, and further predict the life reduction and remaining service life. The life variation coefficient matching table is shown in Table 4:

[0134] Table 4 Damaged feature matching table

[0135] Damaged features Damage level Life span variation coefficient crack Mild 0.05 crack Moderate 0.15 crack severe 0.30 Depression Mild 0.03 Depression Moderate 0.10 Depression severe 0.20 fracture Any level 0.50

[0136] Assuming the ultimate service life of the frame die casting is 10 years, calculate the impact of each damage feature on the life based on the matching table of damage features. For example, if there is one moderate crack and two minor dents on the frame, then: Primary change = (1 0.15 + 2 0.03) * 10 years = 1.5 years + 0.6 years = 2.1 years.

[0137] After determining the primary change, the impact of the damaged features' spatial location on life needs to be considered. This involves a more complex analysis, but for simplicity, we assume that the impact of spatial location on life is adjusted by an additional factor. For example, if the damaged features are concentrated in key areas of the frame, the life reduction is assumed to be 20% higher than the primary change. Life reduction = 2.1 years * 1.20 = 2.52 years. Finally, the remaining service life is calculated based on the final service life of the frame die casting and the predicted life reduction: Remaining service life = Final service life - Life reduction = 10 years - 2.52 years = 7.48 years.

[0138] refer to Figure 6 In step S15, the service life management of the frame die-casting is triggered according to the remaining service life of the frame die-casting. In the service life management of the frame die-casting, repair events of the multiple damaged features are determined according to the remaining service life of the frame die-casting, the multiple damaged features, and the repair mapping relationship;

[0139] In the specific implementation process of the present invention, the specific steps are:

[0140] S151: comparing the remaining service life of the frame die-casting with a preset remaining service life threshold; if the remaining service life of the frame die-casting is higher than the preset remaining service life threshold, triggering service life management of the frame die-casting;

[0141] S152: In the service life management of the vehicle frame die casting, a preset repair mapping relationship is collected, and a corresponding repair level is determined according to the remaining service life of the vehicle frame die casting and the preset repair mapping relationship;

[0142] S153: Determine repair events for the multiple damaged features based on the repair level, the damage levels and spatial positions of the multiple damaged features.

[0143] In an embodiment of the present application, the remaining service life of the frame die-casting is compared with a preset remaining service life threshold. If the remaining service life of the frame die-casting is higher than the preset remaining service life threshold, the service life management of the frame die-casting is triggered.

[0144] At this point, it is necessary to obtain the remaining useful life of the frame die-casting from the previous analysis (such as step S143). This value is a time range (such as years) or mileage, indicating how long the frame die-casting is expected to be used without further damage; the preset remaining useful life threshold is a preset standard used to determine whether the frame die-casting needs to enter the service life management program. This threshold is determined based on the manufacturer's recommendations, industry standards, safety considerations or economic factors; it is a fixed time value (such as 5 years) or mileage, and also a range.

[0145] The remaining service life of the frame die-casting is compared with the preset remaining service life threshold; if the remaining service life is higher than the threshold, it means that the frame die-casting has sufficient remaining service life and does not need to enter the strict service life management procedure for the time being; if the remaining service life is lower than or equal to the threshold, the service life management procedure of the frame die-casting is triggered.

[0146] Specifically, suppose there is a frame die-casting. After the previous analysis (such as step S143), it is concluded that the remaining service life is 6 years; at the same time, according to the manufacturer's recommendations and industry standards, a preset remaining service life threshold is set at 5 years; the remaining service life is 6 years; the preset remaining service life threshold is 5 years; the remaining service life of 6 years is compared with the preset threshold of 5 years, and it is found that the remaining service life is higher than the preset threshold; therefore, according to the judgment of step S151, this frame die-casting does not need to enter a strict service life management procedure for the time being; however, this does not mean that its maintenance and management should be ignored, but only means that it should be managed and maintained according to the regular maintenance plan within the current remaining service life; at the same time, as time goes by and the usage conditions change, the remaining service life of the frame die-casting will change, so it is necessary to regularly re-evaluate and update the relevant information. This example illustrates the importance of step S151 in practical applications. It helps decision makers determine whether the frame die-casting needs to enter a more stringent service life management procedure to ensure the safety and reliability of the vehicle.

[0147] Furthermore, in the service life management of the frame die-castings, the preset repair mapping relationship is collected, and the corresponding repair level is determined according to the remaining service life of the frame die-castings and the preset repair mapping relationship, which is compatible with the overall consideration of the remaining service life of the frame die-castings and the preset repair mapping relationship, and ensures the accuracy of the corresponding repair level.

[0148] At this point, a preset repair mapping relationship table or algorithm is obtained. This mapping relationship is developed based on historical data of the frame die-casting, manufacturer's recommendations, industry standards or expert knowledge; it defines the correspondence between different remaining service life intervals and repair levels; the repair level is divided into several levels, such as minor repair, moderate repair, major repair or emergency repair, etc., and each level corresponds to different repair measures and costs.

[0149] Determine the remaining service life of the frame die casting. This step requires the remaining service life of the frame die casting calculated in the previous step (such as S143). This value is a time range (such as years) or mileage, indicating how long the frame die casting is expected to be used without further damage.

[0150] The repair level is determined based on the repair mapping relationship. The remaining service life of the frame die-casting is matched with the preset repair mapping relationship to determine the corresponding repair level. This is achieved by looking up the mapping relationship table or running an algorithm. Based on the matching results, the repair level currently required for the frame die-casting is determined. This level will guide subsequent repair measures and plans.

[0151] Specifically, assuming that there is a frame die-casting, the remaining service life is 7 years according to the previous calculation (such as step S143); at the same time, there is a preset repair mapping relationship table as shown in Table 5:

[0152] Table 5 Repair mapping relationship table

[0153] Remaining useful life (years) Restoration level >10 Minor fixes 6-10 Moderate repair 3-5 Major repair <3 Emergency Repair

[0154] The above-mentioned repair mapping relationship table is obtained; the remaining service life is 7 years; the remaining service life of 7 years is matched with the repair mapping relationship table, and it is found that it falls within the range of 6-10 years; therefore, according to the mapping relationship table, it is determined that the current repair level required for the frame die-casting is moderate repair. This example illustrates the importance of step S152 in practical applications; by collecting the preset repair mapping relationship and determining the repair level according to the remaining service life of the frame die-casting, clear guidance is provided for subsequent repair measures and plans, which helps to ensure that the frame die-casting can meet safety and usage requirements after repair, and also helps to optimize maintenance costs and time.

[0155] Therefore, the repair events of multiple damaged features are determined based on the repair level, the damage level and the spatial position of the multiple damaged features, which is compatible with the overall consideration of the repair level, the damage level and the spatial position of the multiple damaged features, ensuring the accuracy of the repair events of the multiple damaged features. At the same time, the remaining service life of the frame die-casting is fully considered, ensuring the targeted repair of each damaged feature of the frame die-casting, and ensuring the effectiveness of the service life management of the frame die-casting, so as to realize the cycle management of the service life of the frame die-casting.

[0156] At this time, step S153 is a key step in making a repair decision for the vehicle frame die casting, which determines a specific repair event based on the previously determined repair level (step S152) and the damage level and spatial position of multiple damaged features.

[0157] First, the repair level of the frame die-casting needs to be obtained from the previous step (S152); the repair level is determined based on the remaining service life of the frame die-casting and the preset repair mapping relationship, which reflects the current degree of repair required for the frame die-casting; next, the damage level of multiple damaged features on the frame die-casting needs to be analyzed; the damage level is determined based on factors such as the size, depth, and number of the damaged features, which reflects the degree of impact of the damaged features on the performance and safety of the frame die-casting.

[0158] In addition to the damage grade, the spatial position of the damaged feature on the frame die-casting also needs to be considered; the spatial position is crucial to the formulation of repair events because it affects the difficulty of repair, the time and cost required, and the impact on the overall performance of the frame die-casting after repair; specific repair events are determined based on the repair grade, the damage grade and spatial position of multiple damaged features; a repair event refers to the repair measures taken for each damaged feature, such as welding cracks, filling dents, replacing damaged parts, etc.; the formulation of repair events requires comprehensive consideration of factors such as safety, economy, feasibility and timeliness.

[0159] Specifically, assume that there is a frame die-casting, and its repair level is determined to be moderate repair through the previous steps, and the following two damage features are identified: a crack with a length of 5 cm and a depth of 2 mm, located on the front longitudinal beam of the frame; a dent with a diameter of 3 cm, located near the side door frame of the frame; now, determine the repair event according to step S153.

[0160] The repair level is moderate repair; the damage level of the crack is moderate, because it is long and of moderate depth, which has a certain impact on the structural strength of the frame; the damage level of the dent is light, because although it has a large diameter, it is shallow in depth, which has little impact on the overall performance of the frame; the crack is located on the front longitudinal beam of the frame, which is a critical part and requires special attention to its repair quality and strength recovery; the dent is located near the side door frame of the frame. Although it is not a critical part, it is necessary to ensure that it does not affect the opening and closing and sealing performance of the door during repair.

[0161] For cracks: Use welding technology to repair, ensure that the cracks are completely welded, and grind and rust-proof the welding area;

[0162] For dents: Use a suction cup or crowbar to pull out the dented area, then smooth it with filler, and then polish and paint to restore the appearance. This example illustrates the importance of step S153 in practical application. By comprehensively considering the repair level, the damage level and spatial location of multiple damaged features, an appropriate repair event is formulated for each damaged feature to ensure that the frame die-casting can meet safety and usage requirements after repair.

[0163] In one embodiment of the present application, the repair event matching table determines the final repair measure by matching the repair level, damage level, and spatial location with the preset repair event; the repair event matching table is shown in Table 6:

[0164] Table 6 Repair event matching table

[0165] Restoration level Damage level Spatial location Repair Event Minor fixes Mild Non-critical parts Appearance repair, such as sanding and painting Minor fixes Moderate Non-critical parts Enhanced repairs, such as reinforcement installation Moderate repair Mild Key parts Precision repairs, such as local welding and grinding Moderate repair Moderate Key parts Structural repairs, such as complete replacement of damaged parts Major repair Any level Any location Comprehensive inspection, and overall repair or replacement if necessary

[0166] Assume that there is a frame die-casting with a repair level of medium repair and two damage features: a medium crack located at the front of the frame (a critical part); a slight dent located at the rear of the frame (a non-critical part); according to the repair event matching table, the following repair events are determined: for the medium crack at the front of the frame: perform precision repairs, such as local welding and grinding; for the slight dent at the rear of the frame: perform appearance repairs, such as grinding and painting.

[0167] See also Figure 7 , Figure 7 : is a schematic diagram of the structural composition of the service life management system of the vehicle frame die casting in an embodiment of the present invention; the service life management system of the vehicle frame die casting includes:

[0168] A first theoretical service life module 21 is used to determine die-casting data of the frame die-casting according to the model of the frame die-casting and the die-casting database, and to determine a first theoretical service life according to the die-casting data of the frame die-casting;

[0169] A second theoretical service life module 22 is used to determine a second theoretical service life according to the use position and corresponding three-dimensional shape of the frame die-casting;

[0170] A final service life module 23 is used to determine a final service life of the frame die casting based on the second theoretical service life and the first theoretical service life of the frame die casting;

[0171] a remaining useful life module 24 for determining, after a new energy vehicle collision occurs, a plurality of damage features based on a damaged image of the frame die-casting, and predicting the remaining useful life of the frame die-casting based on the plurality of damage features and the ultimate useful life of the frame die-casting;

[0172] The repair event module 25 is used to trigger the service life management of the frame die-casting according to the remaining service life of the frame die-casting. In the service life management of the frame die-casting, the repair events of multiple damaged features are determined according to the remaining service life of the frame die-casting, multiple damaged features and the repair mapping relationship.

[0173] The technical features of the above embodiments may be combined arbitrarily. To make the description concise, not all 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, they should be considered to be within the scope of this specification.

Claims

1. A method for managing the service life of a vehicle frame die casting, characterized in that: include: Determining die-casting data of the frame die-casting according to the model of the frame die-casting and a die-casting database, and determining a first theoretical service life according to the die-casting data of the frame die-casting; The second theoretical service life is determined according to the use position and corresponding three-dimensional shape of the frame die-casting; determining a final service life of the frame die casting based on the second theoretical service life and the first theoretical service life of the frame die casting; After a new energy vehicle is involved in a vehicle collision, multiple damage features are determined based on a damage image of a frame die-casting, and the remaining service life of the frame die-casting is predicted based on the multiple damage features and the ultimate service life of the frame die-casting; The service life management of the frame die casting is triggered according to the remaining service life of the frame die casting. In the service life management of the frame die casting, repair events of multiple damaged features are determined according to the remaining service life of the frame die casting, multiple damaged features and a repair mapping relationship.

2. The service life management method of the vehicle frame die casting according to claim 1, characterized in that: The step of determining die-casting data of the vehicle frame die-casting according to the model of the vehicle frame die-casting and a die-casting database, and determining the first theoretical service life according to the die-casting data of the vehicle frame die-casting, comprises: During the die-casting process of the vehicle frame die-casting, the corresponding model is marked on the vehicle frame die-casting, and the die-casting molding data of the vehicle frame die-casting during the die-casting process is completely stored in the die-casting database; the die-casting database records all the data of the vehicle frame die-casting; After the die-casting of the frame die-casting is completed, the die-casting database is traced based on the frame die-casting, and the die-casting molding data of the frame die-casting is determined. At the same time, the mechanical data of the frame die-casting is determined based on the mechanical test of the frame die-casting; A first theoretical service life is determined based on the die-casting molding data, mechanical data and first life mapping relationship of the frame die-casting component. The first theoretical service life presents the service life of the frame die-casting component in a comprehensive dimension of die-casting dimension and mechanical dimension.

3. The service life management method of the vehicle frame die casting according to claim 1, characterized in that: Determining the second theoretical service life according to the use position and the corresponding three-dimensional shape of the frame die-casting comprises: In a new energy vehicle equipped with the frame die-casting, a use position of the frame die-casting is determined according to a distribution map of the new energy vehicle and a use mark of the frame die-casting, and an impact resistance coefficient of the frame die-casting is determined according to a mapping relationship between the use position of the frame die-casting and the impact resistance coefficient; The theoretical form of the frame die-casting is determined by tracing the model of the frame die-casting, the frame die-casting is photographed in a circular manner, and the actual form of the frame die-casting is generated. The three-dimensional form of the frame die-casting is determined based on the synthesis of the actual form and the theoretical form of the frame die-casting; The second theoretical service life is determined based on the three-dimensional shape, impact resistance coefficient and second life mapping relationship of the frame die-casting. The second theoretical service life presents the service life of the frame die-casting in the comprehensive dimension of shape dimension and impact resistance dimension.

4. The method for managing the service life of a vehicle frame die casting according to claim 1, wherein: The method of determining the final service life of the vehicle frame die casting based on the second theoretical service life and the first theoretical service life of the vehicle frame die casting comprises: The second theoretical service life and the first theoretical service life of the frame die casting are collected, the second theoretical service life and the first theoretical service life of the frame die casting are matched, and a corresponding matching coefficient is determined.

5. The method for managing the service life of a vehicle frame die casting according to claim 4, characterized in that: The final service life of the frame die casting is determined based on the second theoretical service life and the first theoretical service life of the frame die casting, and further includes: If the matching coefficient is higher than a preset matching coefficient threshold, determining a service life range based on the second theoretical service life and the first theoretical service life; The ultimate service life of the frame die casting is determined based on the service life range, the three-dimensional shape of the frame die casting and the safe use strength of the frame die casting, and the ultimate service life is within the service life range.

6. The service life management method of a vehicle frame die casting according to claim 1, characterized in that: After a new energy vehicle is involved in a vehicle collision, a plurality of damage features are determined based on a damaged image of the frame die-casting, and a remaining service life of the frame die-casting is predicted based on the plurality of damage features and the ultimate service life of the frame die-casting, including: A new energy vehicle is driving on the road and collides with another vehicle. At this time, the frame die-casting is impacted and damaged. A circular shot of the frame die-casting is taken, and images of the damaged frame die-casting are collected.

7. The method for managing the service life of a vehicle frame die casting according to claim 6, wherein: The method further includes determining a plurality of damage features according to a damage image of the frame die-casting after a new energy vehicle collision, and predicting the remaining service life of the frame die-casting based on the plurality of damage features and the ultimate service life of the frame die-casting. Determining a damaged area based on a damaged image of the frame die-casting and a three-dimensional morphology of the frame die-casting, determining a plurality of damaged features based on identification of each damaged area, and marking damage levels and spatial positions of the plurality of damaged features; A primary change in service life is determined based on the damage levels of the plurality of damaged features and the ultimate service life of the frame die casting, and a life reduction is predicted based on the primary change in service life and the spatial positions of the plurality of damaged features, and a remaining service life of the frame die casting is predicted based on the ultimate service life and the life reduction of the frame die casting.

8. The service life management method of a vehicle frame die casting according to claim 1, characterized in that: The service life management of the frame die-casting is triggered according to the remaining service life of the frame die-casting. In the service life management of the frame die-casting, repair events of the multiple damaged features are determined according to the remaining service life of the frame die-casting, the multiple damaged features, and the repair mapping relationship, including: The remaining service life of the frame die casting is compared with a preset remaining service life threshold. If the remaining service life of the frame die casting is higher than the preset remaining service life threshold, the service life management of the frame die casting is triggered.

9. The method for managing the service life of a vehicle frame die casting according to claim 8, characterized in that: The method triggers the service life management of the frame die casting according to the remaining service life of the frame die casting, wherein in the service life management of the frame die casting, repair events of the multiple damaged features are determined according to the remaining service life of the frame die casting, the multiple damaged features, and the repair mapping relationship, and further includes: In the service life management of vehicle frame die castings, the preset repair mapping relationship is collected, and the corresponding repair level is determined according to the remaining service life of the vehicle frame die castings and the preset repair mapping relationship; Repair events for the plurality of damaged features are determined based on the repair level, the damage levels, and the spatial locations of the plurality of damaged features.

10. A service life management system for vehicle frame die castings, characterized in that: The service life management system of the vehicle frame die casting is applied to the service life management method of the vehicle frame die casting according to any one of claims 1 to 9, and the service life management system of the vehicle frame die casting includes: A first theoretical service life module is used to determine die-casting data of the frame die-casting according to the model of the frame die-casting and the die-casting database, and to determine a first theoretical service life according to the die-casting data of the frame die-casting; A second theoretical service life module is used to determine the second theoretical service life according to the use position and corresponding three-dimensional shape of the frame die-casting; a final service life module, used for determining a final service life of the frame die casting based on a second theoretical service life and a first theoretical service life of the frame die casting; a remaining useful life module for determining a plurality of damage features based on a damaged image of a frame die-casting after a new energy vehicle collision, and predicting the remaining useful life of the frame die-casting based on the plurality of damage features and the ultimate useful life of the frame die-casting; The repair event module is used to trigger the service life management of the frame die-casting according to the remaining service life of the frame die-casting. In the service life management of the frame die-casting, the repair events of multiple damaged features are determined according to the remaining service life of the frame die-casting, multiple damaged features and the repair mapping relationship.

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