Method and system for managing the service life of a frame die casting

Abstract

The application discloses a kind of service life management method and system of frame die casting, and the application relates to the technical field of service life management, determine the final service life of frame die casting based on the second theoretical service life and the first theoretical service life of frame die casting, guarantee the accuracy of the final service life of frame die casting, therefore, determine multiple damaged features according to the damaged image of frame die casting, predict the remaining service life of frame die casting based on multiple damaged features and the final service life of frame die casting;According to the remaining service life of frame die casting, trigger the service life management of frame die casting, carry out the service life management of frame die casting to frame die casting after being damaged, and fully consider the remaining service life of frame die casting, guarantee the targeted repair of each damaged feature of frame die casting, guarantee the effectiveness of the service life management of frame die casting.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of service life management, and in particular to a service life management method and system of a frame die casting. BACKGROUND

[0002] With the development of science and technology, the frame die casting of a new energy vehicle is one of the components of the new energy vehicle, and the frame die casting is generally made of aluminum material for high-pressure die casting. In the prior art, the frame die casting forms die casting forming data during die casting, and the service life of the frame die casting is predicted along the die casting forming data, realizing single-dimensional prediction, which 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

[0003] The present application aims to overcome the shortcomings of the prior art, and provides a service life management method and system of a frame die casting.

[0004] The present application provides a service life management method of a frame die casting, which comprises:

[0005] According to the model and die casting database of the frame die casting, the die casting forming data of the frame die casting is determined, and the first theoretical service life is determined according to the die casting forming data of the frame die casting;

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

[0007] Based on the second theoretical service life and the first theoretical service life of the frame die casting, the final service life of the frame die casting is determined;

[0008] After the new energy vehicle is involved in a vehicle collision, 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;

[0009] According to the remaining service life of the frame die casting, the service life management of the frame die casting is triggered, and in the service life management of the frame die casting, the repair event of the plurality of damaged features is determined according to the remaining service life of the frame die casting, the plurality of damaged features and the repair mapping relationship.

[0010] The present application provides a service life management system of a frame die casting, which is applied to the service life management method of the frame die casting described above, and comprises:

[0011] A first theoretical service life module is configured to determine the first theoretical service life of the frame die casting according to the die casting forming data of the frame die casting determined according to the model of the frame die casting and the die casting database;

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

[0013] A final service life module is configured to determine the 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;

[0014] A remaining service life module is configured to determine a plurality of damaged features according to the damaged image of the frame die casting after the new energy vehicle is subjected to a vehicle collision, and predict the remaining service life of the frame die casting based on the plurality of damaged features and the final service life of the frame die casting.

[0015] A repair event module is configured to trigger the service life management of the frame die casting according to the remaining service life of the frame die casting, and determine a repair event of the plurality of damaged features according to the remaining service life of the frame die casting, the plurality of damaged features and a repair mapping relationship in the service life management of the frame die casting.

[0016] Compared with the prior art, the present application has the following advantages:

[0017] In the embodiment of the present application, the method in the embodiment of the present application is used to determine the die casting forming data of the frame die casting according to the model of the frame die casting and the die casting database, and determine the first theoretical service life of the frame die casting according to the die casting forming data of the frame die casting; determine the second theoretical service life of the frame die casting according to the use position and the corresponding three-dimensional shape of the frame die casting; and determine the 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, 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 the new energy vehicle is in a vehicle collision, a plurality of damaged features are determined according to a damaged image of the frame die casting, 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, and 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, the repair events of the plurality of damaged features are determined according to the remaining service life of the frame die casting, the plurality of damaged features and the repair mapping relationship, 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 to ensure the targeted repair of the frame die casting to each damaged feature and the effectiveness of the service life management of the frame die casting, so as to realize the periodical management of the service life of the frame die casting. BRIEF DESCRIPTION OF DRAWINGS

[0019] Figure 1 is a flowchart of the service life management method of the frame die casting in the embodiment of the application;

[0020] Figure 2 is a flowchart of step S11 in the service life management method of the frame die casting in the embodiment of the application;

[0021] Figure 3 is a flowchart of step S12 in the service life management method of the frame die casting in the embodiment of the application;

[0022] Figure 4 is a flowchart of step S13 in the service life management method of the frame die casting in the embodiment of the application;

[0023] Figure 5 is a flowchart of step S14 in the service life management method of the frame die casting in the embodiment of the application;

[0024] Figure 6 is a flowchart of step S15 in the service life management method of the frame die casting in the embodiment of the application;

[0025] Figure 7 is a structural composition diagram of the service life management system of the frame die casting in the embodiment of the application. DETAILED DESCRIPTION

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

[0027] Please refer to Figures 1 to 7 A service life management method of a frame die casting, comprising:

[0028] Step S11: Determine the die casting forming data of the frame die casting according to the model of the frame die casting and the die casting database, and determine the first theoretical service life according to the die casting forming data of the frame die casting;

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

[0030] Step S13: Determine the 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;

[0031] Step S14: After the new energy vehicle is involved in a vehicle collision, determine a plurality of damaged features according to the damaged image of the frame die casting, and predict the remaining service life of the frame die casting based on the plurality of damaged features and the final service life of the frame die casting;

[0032] Step S15: Trigger the service life management of the frame die casting according to the remaining service life of the frame die casting, and determine the repair event of the plurality of damaged features according to the remaining service life of the frame die casting, the plurality of damaged features and the repair mapping relationship in the service life management of the frame die casting;

[0033] Reference Figure 2 In step S11, the die casting forming 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 forming data of the frame die casting;

[0034] In the specific implementation process of the present application, the specific steps are as follows:

[0035] S111: In the die casting process of the frame die casting, the corresponding model of the frame die casting is marked, and the die casting forming data of the frame die casting in the die casting process is stored in the die casting database; the die casting database records all the data of the frame die casting;

[0036] S112: 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 forming data of the frame die casting is determined, and at the same time, the mechanical data of the frame die casting is determined according to the mechanical test of the frame die casting;

[0037] S113: Determine the first theoretical service life according to the die casting forming data, the mechanical data and the first life mapping relationship of the frame die casting, which presents the service life of the frame die casting in the comprehensive dimension of die casting and mechanical dimension.

[0038] In the embodiments of the present application, during the die casting process of the frame die casting, the corresponding model of the frame die casting is marked, and the die casting forming data of the frame die casting in the die casting process is stored in the die casting database in an integrated manner; the die casting database records all data of the frame die casting;

[0039] At this time, it is ensured that each frame die casting is uniquely identified, facilitating subsequent data tracing and management; during the die casting process, before or after the molten metal is injected into the mold (depending on the specific situation of the process and equipment), a unique model identification is marked on the frame die casting using laser marking, engraving or other suitable methods, which includes the model code, production date, batch number and other information of the frame die casting; the marking position should be selected under the premise of not affecting the structural strength and appearance of the frame die casting, and the marking should be clear, durable and not easy to be worn or tampered with.

[0040] All key data of the frame die casting in the die casting process are recorded for subsequent analysis and optimization of the manufacturing process; sensors and data acquisition systems are installed on the die casting machine to monitor and record key parameters such as temperature, pressure, time, speed and other key parameters in real time during the die casting process; these data should be associated with the model identification of the frame die casting and stored in the die casting database; at this time, the die casting database is a system specially used to store data related to the frame die casting, which should have functions such as data entry, query, analysis, etc.; each record in the database should contain the model identification of the frame die casting, die casting forming data, test data, service life prediction and other information.

[0041] Optionally, assuming that a frame die casting of a new energy vehicle is being produced, the model is XYZ-001; during the die casting process, XYZ-001-20230401-001 is laser marked on the die casting, where XYZ-001 is the model code, 20230401 is the production date, and 001 is the first die casting in the batch; during the die casting process, the following data are monitored and recorded in real time: die casting temperature: 680℃; injection pressure: 50MPa; cooling time: 60 seconds; mold opening speed: 0.1m / s; these data are associated with the identification XYZ-001-20230401-001 and stored in the die casting database, so that the manufacturing data of this frame die casting can be queried and analyzed at any time for subsequent quality tracing, service life prediction and other operations; through this example, the importance of step S111 is seen: 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] Further, after the completion of the die casting of the frame die casting, the traceability of the die casting database is triggered based on the frame die casting, and the die casting forming data of the frame die casting is determined, and at the same time, the mechanical data of the frame die casting is determined according to the mechanical test of the frame die casting, and the mechanical data of the frame die casting is introduced.

[0043] At this time, it is ensured that all relevant data of a specific frame die casting in the die casting process can be accurately and quickly obtained; at the same time, after the completion of the die casting of the frame die casting, the traceability function of the die casting database is triggered by scanning the model identification (such as bar code, two-dimensional code or laser marking, etc.) on the frame die casting, or by inputting the model code and other related information of the frame die casting; the database system will quickly retrieve and display all die casting forming data related to the frame die casting according to 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 the traceability request; at the same time, the data in the database should be checked and verified to ensure its accuracy and integrity.

[0044] Obtain the key data of the frame die casting in 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 forming data related to the frame die casting, including but not limited to die casting temperature, pressure, time, speed, etc. These data are the basis for subsequent analysis of mechanical testing, service life prediction, etc.

[0045] Evaluate the mechanical properties of the frame die casting to understand its load-carrying capacity and durability in actual use; at the same time, the frame die casting is subjected to mechanical tests such as tensile test, compression test, bending test, impact test, etc. These tests simulate the stress conditions of the frame die casting in actual use, so as to evaluate its mechanical properties; after the test is completed, the test data are recorded and sorted, including yield strength, tensile strength, hardness, toughness, etc. The mechanical test should be carried out according to the 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, assuming that a frame casting of model XYZ-002 is being traced and tested for mechanical properties; scanning the two-dimensional code on the frame casting (which contains the model information of the frame casting), triggering the traceability function of the die casting database; the database system quickly retrieves and displays all die casting data related to the frame casting, such as die casting temperature 690℃, injection pressure 55MPa, cooling time 65 seconds, etc.; carefully check the data displayed by the database system to confirm its accuracy and completeness, these data will be used for subsequent analysis and evaluation; mechanical test: tensile test and impact test are carried out on the frame casting; the tensile test results show that the yield strength of the frame casting is 300MPa, and the tensile strength is 350MPa; the impact test results show that the impact toughness of the frame casting is 15J / cm 2 These mechanical data will be used to evaluate the load-carrying capacity and durability of the frame casting in actual use; through this example, the importance of step S112 is seen: it ensures that all relevant data of a specific frame casting during 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, according to the die casting data of the frame casting, the mechanical data and the first life mapping relationship, the first theoretical service life is determined, which presents the service life of the frame casting in the comprehensive dimension of the die casting dimension and the mechanical dimension, and is compatible with the overall consideration of the die casting data, the mechanical data and the first life mapping relationship of the frame casting, ensuring the accuracy of the first theoretical service life.

[0048] At this time, it is ensured that all necessary data has been collected and sorted out for subsequent analysis and calculation; at the same time, the die casting data of the frame casting (such as die casting temperature, pressure, time, etc.) is obtained from the die casting database, and the mechanical data of the frame casting (such as yield strength, tensile strength, impact toughness, etc.) is obtained through mechanical testing; ensure that these data are accurate, complete and verified.

[0049] The first life mapping relationship between the die casting data, the mechanical data and the service life of the frame casting is established, and the first life mapping relationship is introduced, which is obtained through a large number of experimental data, statistical analysis, machine learning, etc.; the first life mapping relationship is a complex mathematical model that considers the influence of various factors (such as die casting process parameters, material properties, use environment, etc.) on the service life of the frame casting, and this mapping relationship should be fully verified and calibrated to ensure its accuracy and reliability.

[0050] According to 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 forming data and the mechanical data of the frame die casting are input into the first life mapping relationship for calculation, and this process is automatic and also needs 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 certain conditions (such as normal working environment, standard use conditions, etc.).

[0051] Optionally, it is assumed that the first theoretical service life of a frame die casting with model XYZ-003 is being determined; the die casting forming data: die casting temperature 700°C, injection pressure 60MPa, cooling time 70 seconds; the mechanical data: yield strength 320MPa, tensile strength 370MPa, impact toughness 18J / cm 2 ; a first life mapping relationship model has been established through a large amount of experimental data and statistical analysis, which considers multiple factors such as die casting temperature, pressure, time, yield strength, tensile strength, impact toughness, etc., and gives the complex relationship between them and the service life of the frame die casting;

[0052] The collected data is input into the first life mapping relationship model for calculation; after calculation, it is found that the first theoretical service life of the XYZ-003 frame die casting is 10 years, or it can withstand 1 million cycles of cyclic loading under normal working environment and standard use conditions; through this example, the importance of step S113 is seen: it uses the collected data and the first life mapping relationship to provide the first theoretical service life of the frame die casting under a comprehensive dimension based on the die casting dimension and the mechanical dimension, which is the basis for subsequent service life management, maintenance plan development, etc.

[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 First theoretical service life

[0055]

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

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

[0058] In the implementation of the present application, the specific steps are as follows:

[0059] S121: In the new energy vehicle configured with the frame die casting, the use position of the frame die casting is determined according to the distribution map of the new energy vehicle and the use mark of the frame die casting, and the impact resistance coefficient of the frame die casting is determined according to the use position of the frame die casting and the impact resistance coefficient mapping relationship;

[0060] S122: The theoretical form of the frame die casting is determined according to the traceability of the model of the frame die casting, the frame die casting is ring photographed, and the actual form of the frame die casting is generated, and the three-dimensional form of the frame die casting is determined according to the synthesis of the actual form and the theoretical form of the frame die casting;

[0061] S123: The second theoretical service life is determined based on the three-dimensional form of the frame die casting, the impact resistance coefficient and the second life mapping relationship, which presents the service life of the frame die casting in the comprehensive dimension of the form dimension and the impact resistance dimension;

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

[0063] At this time, the specific position 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 position information of each component of the vehicle; By consulting the distribution map, combined with the use mark (such as label, number or position indicator) of the frame die casting, the exact position of the frame die casting in the vehicle is determined; Ensure the accuracy and timeliness of the distribution map, and the clear visibility and easy identification of the frame die casting use mark.

[0064] The impact resistance coefficient of the frame die casting is determined according to 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 load at a specific position is evaluated; at this time, the impact resistance coefficient mapping relationship is a pre-established database or model that provides the corresponding impact resistance coefficient according to the use position (or related parameters such as position type, surrounding environment, etc.) of the frame die casting; 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 limitations of the mapping relationship.

[0065] Optionally, suppose we are evaluating the impact resistance coefficient of a frame die casting for a new energy vehicle named "EcoDrive-X1"; first, the distribution map of "EcoDrive-X1" is consulted, which lists in detail the various components of the vehicle and their positions; in the distribution map, the frame die casting marked as "FD-001" is found, which is located at the front end of the vehicle bottom, close to the impact buffer zone.

[0066] Next, the pre-established impact resistance coefficient mapping relationship is queried; this mapping relationship takes into account the use position of the frame die casting, the surrounding environment (such as whether other structural components provide protection), and the potential impact load type; according to the use position of the "FD-001" frame die casting (front end of the vehicle bottom, close to the impact 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, the importance of step S121 is seen: it helps to determine the specific position of the frame die casting in the new energy vehicle and evaluate its impact resistance capability at that position, which is of great significance for subsequent frame die casting service life evaluation, safety analysis, and maintenance plan development, etc.

[0067] Further, the theoretical morphology of the frame die casting is determined according to the traceability of the model of the frame die casting, the frame die casting is ring photographed, and the actual morphology of the frame die casting is generated, the three-dimensional morphology of the frame die casting is determined according to the synthesis of the actual morphology and the theoretical morphology of the frame die casting, the overall consideration of the synthesis of the actual morphology and the theoretical morphology of the frame die casting is compatible, and the accuracy of the three-dimensional morphology of the frame die casting is guaranteed.

[0068] At this time, the theoretical three-dimensional form of the frame die casting at the time of design or manufacture is determined according to the model traceability of the frame die casting; at the same time, the model of the frame die casting is associated with its design drawings, CAD model or manufacturing specifications; by tracing the model of the frame die casting, its theoretical form is found in the related design database or manufacturing file, which is a three-dimensional model describing the geometric shape, size and material information of the frame die casting.

[0069] The actual three-dimensional form of the frame die casting is captured, including its surface details and any manufacturing defects; at this time, a ring-shaped shooting device or technology is used to shoot the frame die casting from multiple angles; ring-shaped 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, sufficient and uniform light should be ensured to avoid shadows and reflections affecting image quality; at the same time, the accuracy of camera position and angle should be ensured 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 according to 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 the information of both; at this time, three-dimensional modeling software or image processing tools are used to register and compare the actual three-dimensional model or point cloud data obtained by shooting 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 combined into a three-dimensional form that contains both the design intent of the frame die casting and reflects its actual manufacturing state.

[0071] Specifically, suppose a quality check is being conducted on the frame die casting of a new energy vehicle named "EcoFlex-3000"; first, the model "XYZ-1234" of the frame die casting is traced, and the corresponding CAD model is found in the design database; the model describes the geometric shape, size and material composition of the frame die casting in detail; a ring-shaped shooting device is used to shoot the frame die casting from multiple angles; during the shooting process, the uniformity of the light and the accuracy of the camera are ensured; after shooting, a series of two-dimensional images of the frame die casting are obtained.

[0072] The photographed image is imported into a three-dimensional modeling software, and the actual form is aligned with the theoretical form using the registration and comparison tools in the software. During the comparison process, some minor manufacturing defects such as surface scratches and size deviations are found. In order to generate the final three-dimensional form, these defects are smoothed and the size is adjusted. Finally, a three-dimensional form model combining the design intent of the frame die casting and the actual manufacturing state is obtained. Through this example, the importance of step S122 is seen: 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, etc.

[0073] Therefore, the second theoretical service life is determined based on the three-dimensional form, impact resistance coefficient and second life mapping relationship of the frame die casting, which presents the service life of the frame die casting in the comprehensive dimension of form and impact resistance dimensions, and is compatible with the overall consideration of the three-dimensional form, 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 form information and impact resistance data of the frame die casting are collected to provide a basis for subsequent life evaluation. At this time, the three-dimensional form is a three-dimensional form model of the frame die casting obtained through three-dimensional scanning, modeling or design database, which contains detailed information such as the geometric shape, size and surface features of the frame die casting. The impact resistance coefficient is determined through the previous steps (such as S121), which represents the bearing capacity of the frame die casting under specific impact conditions. Ensure the accuracy and completeness of the three-dimensional form, and the reliability and applicability of the impact resistance coefficient.

[0075] Determine the second life mapping relationship to establish a model or relationship that relates the three-dimensional form and impact resistance coefficient of the frame die casting to its service life. At this time, a large amount of use data of the frame die casting is collected, including its three-dimensional form, impact resistance coefficient and actual service life. Statistical methods, machine learning algorithms or physical simulation techniques are used to establish the second life mapping relationship based on the collected data. This relationship is a mathematical formula, lookup table or complex model that is used to predict the service life of the frame die casting based on its three-dimensional form and impact resistance coefficient. Ensure the accuracy and diversity of the data, and the scientificity and effectiveness of the modeling method.

[0076] Based on the three-dimensional morphology and impact resistance coefficient of the frame die casting, and the second life mapping relationship, the expected service life is calculated; at this time, the three-dimensional morphology and impact resistance coefficient of the frame die casting are taken 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 numerical 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, it is assumed that the second theoretical service life of the frame die casting of a new energy vehicle named "EcoSpeed-5000" is being evaluated; the three-dimensional morphology model of the frame die casting is obtained through three-dimensional scanning, which describes the geometric shape and size of the frame die casting in detail; through the previous steps, it is determined that the impact resistance coefficient of the frame die casting is 1.6, indicating that it can withstand impact load equivalent to 1.6 times its own weight.

[0078] The use data of multiple similar frame die castings are collected, including their three-dimensional morphology, impact resistance coefficient and actual service life; a second life mapping relationship model is established using machine learning algorithm according to these data; the model can predict the service life of the frame die casting according to its three-dimensional morphology and impact resistance coefficient; the obtained three-dimensional morphology and impact resistance coefficient are input into the second life mapping relationship model; after calculation, the model outputs the second theoretical service life of the frame die casting as 12 years (under normal use and maintenance conditions); through this example, the importance of step S123 is seen: it combines the three-dimensional morphology 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, helping them understand the performance and durability of the frame die casting, so as to make more reasonable maintenance and replacement plan.

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

[0080] Table 2 Second theoretical service life matching table

[0081] Morphology rating Impact resistance factor 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, morphology level A represents the best morphology, B represents the medium morphology, and C represents the poor morphology; the impact resistance coefficient is determined according to the actual test value of the frame die casting;

[0083] The three-dimensional morphology grade of the frame die casting is determined as A through three-dimensional scanning and morphology analysis; the impact resistance coefficient of the frame die casting is determined as 1.6 through the previous steps (such as S121); in the second theoretical service life matching table, a row with the morphology grade A and the 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] Reference Figure 4 In step S13, 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;

[0085] In the specific implementation of the present application, the specific steps are as follows:

[0086] S131: Collect the second theoretical service life and the first theoretical service life of the frame die casting, match the second theoretical service life and the first theoretical service life of the frame die casting, and determine the corresponding matching coefficient;

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

[0088] S133: Determine the final service life of the frame die casting according to the service life range, the three-dimensional morphology 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 the embodiments of the present application, the second theoretical service life and the first theoretical service life of the frame die casting are collected, matched, and the corresponding matching coefficient is determined, which introduces the matching coefficient.

[0090] At this time, 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, which 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 the two theoretical service lives are compared to evaluate their consistency or difference; the first theoretical service life and the second theoretical service life are compared numerically, which is realized through simple proportional calculation, chart comparison or more complex statistical analysis method; the matching degree between the two theoretical service lives is quantified; the matching coefficient is a simple proportional value (such as the second theoretical service life divided by the first theoretical service life), which is also a comprehensive index obtained by more complex algorithm; the specific calculation method of the matching coefficient depends on the evaluation requirements and goals.

[0092] Specifically, assume that the service life of a new type of frame die casting is being evaluated; by consulting design documents and material performance data, it is known 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, considering multiple dimensions such as the shape, impact resistance, and use environment of the frame die casting, a second theoretical service life of 12 years is obtained, which is more comprehensive and accurate; the first theoretical service life (10 years) and the second theoretical service life (12 years) are compared; through simple proportional calculation, it is found that the second theoretical service life is 20% longer than the first theoretical service life; in this example, the matching coefficient is defined as the ratio of the second theoretical service life to the first theoretical service life, i.e. 1.2 (12 years / 10 years), which indicates that the service life based on a more comprehensive evaluation method is longer than that based on the traditional method; through this example, the importance of S131 step is seen: it helps to collect and compare the theoretical service life of the frame die casting obtained by two different methods, and quantifies their consistency or difference through the matching coefficient, which provides valuable information for subsequent analysis and decision-making.

[0093] Further, if the matching coefficient is higher than the preset matching coefficient threshold, the service life range is determined according to the second theoretical service life and the first theoretical service life, which takes into account the second theoretical service life and the first theoretical service life, ensuring the accuracy of the service life range.

[0094] At this time, according to the comparison result of the matching coefficient and the preset matching coefficient threshold, the service life range of the frame die casting is determined, which 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, the calculated matching coefficient is compared with the preset matching coefficient threshold; the preset matching coefficient threshold is a fixed value, also a range or a dynamically adjusted value.

[0096] In the case where 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, according to the height 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 use environment, maintenance conditions, etc.), a service life range is determined, which is an interval representing the expected safe and effective working years of the frame die casting.

[0097] Specifically, assume that the service life of the new frame casting mentioned earlier is being continuously evaluated; in the previous step, it has been calculated that the matching coefficient is 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; comparing the matching coefficient 1.2 with the preset matching coefficient threshold 1.1, 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 considered that the second theoretical service life (12 years) is closer to the actual service life of the frame casting; at the same time, considering the first theoretical service life (10 years) as the result of the traditional evaluation method, it has 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 of 10 to 12 years is set for the frame casting, which not only considers the result of the advanced evaluation method, but also takes into account the reference value of the traditional method; through this example, the importance of the S132 step is seen: it helps to set a reasonable service life range for the frame casting based on the comparison results of the matching coefficient and the preset matching coefficient threshold, which is not only based on comprehensive evaluation methods, but also takes into account industry experience and safety factors, providing valuable reference for the actual application of the frame casting.

[0098] Therefore, according to the service life range, the three-dimensional form of the frame casting, and the safe use strength of the frame casting, the final service life of the frame casting is determined, which is within the service life range, compatible with the overall consideration of the service life range, the three-dimensional form of the frame casting, and the safe use strength of the frame casting, ensuring the accuracy of the final service life of the frame casting, while compatible with the overall consideration of the second theoretical service life and the first theoretical service life of the frame casting.

[0099] At this time, the service life range, the three-dimensional form of the frame casting, and the safe use strength are comprehensively considered to determine a final service life that meets the actual situation and ensures safety, which is the key step to ensure that the frame casting can perform best in actual application.

[0100] Understand the range of years in which the frame casting is expected to work 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 middle value; at the same time, understand the impact of the physical structure of the frame casting on its service life; through methods such as three-dimensional scanning, form analysis, or expert evaluation, determine whether the three-dimensional form of the frame casting is conducive to extending the service life, or whether there are potential defects that lead to early failure.

[0101] To ensure that the frame casting can meet the safety performance requirements within the expected service life; to evaluate the safety performance of the frame casting under different use intensities based on factors such as the design specifications, material properties, and use environment of the frame casting, which involves methods such as strength testing, fatigue analysis, or safety evaluation; to set a final service life for the frame casting that is both realistic and safe based on the above analysis; at this time, a suitable value within the service life range is selected as the final service life, which should take into account factors such as the three-dimensional form, safe use intensity, and maintenance conditions of the frame casting; the final service life should be within the service life range, but not necessarily the middle or average value of the range, but rather the result of a trade-off and selection based on specific circumstances.

[0102] Specifically, suppose the service life of the new frame casting mentioned earlier is being continuously evaluated, and it has been determined that its service life range is 10 to 12 years; it is known that the frame casting is expected to be safe and effective for a period of 10 to 12 years; through three-dimensional scanning and form analysis, it is found that the three-dimensional form design of the frame casting is reasonable, which is conducive to stress dispersion and prolonging the service life; there are no obvious potential defects that would cause early failure.

[0103] Based on the design specifications and material properties, strength testing and fatigue analysis are performed; the results show that the frame casting can maintain stable performance under safe use intensity and has sufficient margin to cope with unexpected situations; based on the above analysis, it is decided to choose 11 years as the final service life of the frame casting, which is within the service life range and takes into account the three-dimensional form and safe use intensity of the frame casting; it is considered that 11 years is a realistic and safe expected service life that can provide valuable reference for the actual application of the frame casting; through this example, the importance of S133 step is seen: it helps to comprehensively consider multiple factors to set a final service life for the frame casting that is both realistic and safe, which can provide important guidance for the design, manufacture, and use of the frame casting, ensuring that it can perform optimally in actual application.

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

[0105] Table Three Frame Casting Service Life Matching Table

[0106] Service life range (years) Stereo morphology assessment Safety use strength assessment Final service life (years) 10-12 Excellent High 12 10-12 Good High 11 10-12 Medium High 10.5 10-12 Excellent Medium 11.5 10-12 Good Medium 10.75 10-12 Medium Medium 10

[0107] Assuming that the service life of the frame die casting is 10-12 years, the stereoscopic form evaluation is "good", and the safe use strength evaluation is "high"; according to the matching table, the corresponding final service life of 11 years is found.

[0108] Reference Figure 5 In step S14, after the new energy vehicle collides with other vehicles, 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.

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

[0110] S141: The new energy vehicle is driving on the road and collides with other vehicles, at which time the frame die casting is impacted and damaged; the frame die casting is ring-shaped photographed and the damaged image of the frame die casting is collected;

[0111] S142: The damaged areas are determined according to the damaged image of the frame die casting and the stereoscopic form of the frame die casting, and the plurality of damaged features are determined according to the identification of each damaged area, and the damaged grades and spatial positions of the plurality of damaged features are marked;

[0112] S143: The primary change amount of service life is determined based on the damaged grades of the plurality of damaged features and the final service life of the frame die casting, the life reduction amount is predicted according to the primary change amount of service life and the spatial positions of the plurality of damaged features, and the remaining service life of the frame die casting is predicted according to the final service life of the frame die casting and the life reduction amount.

[0113] In the embodiment of the present application, the new energy vehicle is driving on the road and collides with other vehicles, at which time the frame die casting is impacted and damaged; the frame die casting is ring-shaped photographed and the damaged image of the frame die casting is collected, and the damaged image of the frame die casting is introduced.

[0114] At this time, after the new energy vehicle is involved in a traffic accident, the frame die casting is damaged and ring-shaped photographed to collect the damaged image; the following is a detailed description of each step: at this time, the new energy vehicle is driving normally on the road, and due to various reasons (such as driver operation error, poor road conditions, other vehicle violations, etc.), it collides with other vehicles; 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, lateral or rear, depending on the context of the accident.

[0115] During the collision, the frame die casting, as a key structural component of the vehicle, bears the main impact force; therefore, the frame die casting may be deformed, cracked, broken, or damaged in other ways; at this time, the extent of damage depends on the severity of the collision, the material properties of the frame die casting, the manufacturing process, and the design structure, etc.; in some cases, the frame die casting is only slightly damaged, while in other cases, it is completely damaged.

[0116] In order to comprehensively record the damage of the frame die casting, it is necessary to take a ring shot, which means taking pictures of the frame die casting from multiple angles and positions to ensure that all damaged details are captured; at this time, the ring shot uses a professional camera or a smartphone, and requires a tripod, a flash, and other auxiliary equipment; sufficient light should be ensured during shooting to clearly show the damaged area; the choice of shooting angle and position should be adjusted according to the shape of the frame die casting and the damage situation.

[0117] Save the damaged images obtained by shooting to the designated storage device for subsequent analysis and processing, these images will be used to assess the extent of damage to the frame die casting, determine the repair scheme, and predict the remaining service life of the frame die casting, etc.; at this time, the damaged images should be saved in high-resolution format to maintain clarity when zoomed in; at the same time, the naming and storage structure of the image files should be orderly to facilitate subsequent quick search and use.

[0118] Specifically, assume that a new energy vehicle collides with another vehicle on a highway; after the accident, the technician quickly arrives at the scene and follows the S141 steps: the technician observes that the left side of the new energy vehicle has collided with the right side of the other vehicle, and there are scattered debris and liquid on the scene; after preliminary inspection, the technician finds that the frame die casting has been severely impacted in the collision, and the part of the frame near the left side door has obvious deformation and cracks; at the same time, the technician uses a professional camera to take a ring shot of the damaged frame die casting; 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 light to clearly show the damaged details; the technician saves the damaged images obtained by shooting to the designated storage device; they name and classify the images in chronological order and shooting angle for subsequent analysis and processing, which will be used to assess the extent of damage to the frame die casting, develop a repair plan, and predict the remaining service life of the frame die casting, etc.; through the above steps and examples, it is clear that S141 is important in the new energy vehicle accident handling; the ring shot and the collection of damaged images provide key information for subsequent analysis and processing, which helps to ensure that the frame die casting is correctly evaluated and repaired.

[0119] Further, according to the damaged image of the frame die casting and the three-dimensional form of the frame die casting, the damaged area is determined, and a plurality of damaged features are determined according to the identification of each damaged area, and the damaged grades and spatial positions of the plurality of damaged features are marked, which is compatible with the overall consideration of the damaged image of the frame die casting and the three-dimensional form of the frame die casting, and ensures the accuracy of the damaged area.

[0120] At this time, according to the collected damaged image of the frame die casting, combined with the three-dimensional form of the frame die casting (such as design drawings, three-dimensional models or physical observation), the specific area of damage is determined; At this time, this step requires the technician to have a deep understanding of the structure of the frame die casting, and can accurately identify the relationship between the damaged part in the image and the overall structure of the frame die casting; It involves operations such as magnification, comparison, labeling, etc.

[0121] After determining the damaged area, further identify a plurality of damaged features in the area, which include cracks, deformations, depressions, fractures, scratches, etc.; When identifying damaged features, each detail in the image needs to be observed carefully to distinguish the form and performance of different features; Professional image analysis software or tools are needed to assist in identification.

[0122] Each identified damaged feature is evaluated for damage level; The damage level is determined according to the severity, range, and impact on the overall structure of the frame die casting, etc.; At the same time, the damage level is divided into different levels such as slight, moderate and severe; When evaluating, relevant industry standards and experience data need to be referred to to ensure the accuracy and consistency of the evaluation results.

[0123] Determine the specific spatial position of each damaged feature on the frame die casting, which involves labeling the image to record the position information of each feature; At the same time, when marking the spatial position, coordinate system, grid lines, scale, etc. are used to assist positioning; Ensure that the position information of each feature is accurate and correct for subsequent analysis and processing.

[0124] Specifically, suppose a technician is evaluating the damage of a frame die casting of a new energy vehicle according to the S142 step: The technician first observed the collected damaged image and found that there were obvious impact marks on the left front area of the frame die casting; Combined with the three-dimensional form of the frame die casting and the design drawings, they determined that the specific damaged area was the left front longitudinal beam and the part of the cross beam connected to it; After determining the damaged area, the technician carefully observed the details in the image and identified a plurality of damaged features; Including the cracks on the left front longitudinal beam, the depressions and deformations of the cross beam, and the fractures of some connecting parts.

[0125] The damage level of each identified damaged feature is assessed; the crack is assessed as moderately damaged because it significantly affects the strength of the frame casting; the dents and distortions are assessed as slightly damaged because their impact on the overall structure is relatively small; the breakage of the connector is assessed as severely damaged because it leads to a decrease in the overall stability of the frame casting; the technician uses image annotation tools to label each damaged feature on the damaged image and records their specific location information; for example, the crack is located in the middle upper part of the left front longitudinal beam, the dents and distortions are located in the left front end of the cross beam, and the breakage of the connector is located at the connection between the cross beam and the longitudinal beam; through the above steps and examples, the importance of S142 in the damage assessment of the frame casting is clearly understood; determining the damaged area, identifying the damaged features, marking the damage level and spatial position provides key information for subsequent analysis and processing, which helps to ensure that the frame casting is correctly evaluated and repaired.

[0126] Therefore, based on the damage level of multiple damaged features and the final service life of the frame casting, the primary change amount of service life is determined, the service life reduction amount is predicted according to the primary change amount of service life and the spatial position of multiple damaged features, and the remaining service life of the frame casting is predicted according to the final service life of the frame casting and the service life reduction amount, which is compatible with the overall consideration of the damage level of multiple damaged features and the final service life of the frame casting, and ensures the accuracy of the primary change amount of service life.

[0127] At this time, according to the damage level of multiple damaged features of the frame casting and the influence degree of these features on the overall structure of the frame, a preliminary service life change amount is determined, which reflects the direct impact of damaged features on the service life of the frame casting; At this time, the severity, location, number of each damaged feature and their interaction need to be considered comprehensively; It also needs to refer to factors such as material performance, manufacturing process, historical maintenance records of the frame casting; The higher the damage level, the greater the impact on the service life, so the determination of the primary change amount requires certain experience and professional knowledge.

[0128] After determining the primary change amount of service life, the service life reduction amount of the frame casting is further predicted in combination with the spatial position of multiple damaged features, which considers the distribution of damaged features on the frame, the mutual influence between adjacent features and the stability of the overall structure of the frame; At this time, when predicting the service life reduction amount, professional service life prediction models or algorithms need to be used, which are based on a large amount of experimental data, simulation analysis and empirical formula, and can comprehensively consider the influence of multiple factors on the service life of the frame; The consideration of spatial position is particularly important because damaged features in different positions have different effects on the overall stability of the frame.

[0129] The remaining useful life of the frame castings is calculated based on the end-of-life (i.e., the expected useful life before damage) and the predicted life reduction, which reflects the actual available time or mileage of the frame after damage; at this time, the remaining useful life is calculated by subtracting the predicted life reduction from the end-of-life; at the same time, the potential risks and maintenance requirements of the frame castings in subsequent use also need to be considered; for example, if the damaged features cause the frame to be more prone to failure under certain conditions, the remaining useful life needs to be further adjusted.

[0130] Specifically, assuming that a technician is predicting the remaining useful life of the frame castings of a new energy vehicle, the technician first estimates the change in useful life based on the damage level of the identified damaged features (such as cracks, dents, fractures, etc.) and the impact of these features on the overall structure of the frame; for example, the crack is evaluated as moderately damaged, causing the frame strength to decrease by about 10%; the dent and fracture are evaluated as severely damaged, causing the overall stability of the frame to decrease by about 20%; considering these factors, the technician preliminarily estimates that the useful life of the frame castings will decrease by about 25%.

[0131] After determining the primary change, the technician further considers the spatial location of the damaged features; they find that the crack is located at a key load-bearing part of the frame, while the dent and fracture are located in adjacent areas; the interaction between these features causes the frame to be more prone to failure under certain conditions; therefore, the technician uses a professional life prediction model to predict that the life reduction of the frame castings is about 30%, combined with the location, number and severity of the damaged features.

[0132] The technician calculates the remaining useful life of the frame castings based on the end-of-life of the frame castings (assuming 10 years) and the predicted life reduction (30%); they conclude that the remaining useful life of the frame castings after damage is about 7 years (i.e., 10 years * 70%); at the same time, they also suggest that the owner should strengthen inspection and maintenance during subsequent use to ensure the safety and stability of the frame castings; through the above steps and examples, it is clear that S143 is important in predicting the remaining useful life of the frame castings; determining the primary change in useful life, predicting life reduction and remaining useful life provides key information for subsequent decision-making and maintenance, which helps to ensure the safety and reliability of the vehicle.

[0133] In one embodiment of the present application, a damaged feature matching table is formulated according to the damaged features of the frame die casting, which lists the damaged features, damaged levels, and corresponding life change coefficients; then, in combination with the final service life of the frame die casting, the primary change amount of the service life is determined through the damaged feature matching table, and the life reduction amount and the remaining service life are further predicted; the life change coefficient matching table is shown in Table Four:

[0134] Table Four Damaged Feature Matching Table

[0135] Damaged features Damage rating Life change factor Cracks Mild 0.05 Cracks Moderate 0.15 Cracks Severe 0.30 Dents Mild 0.03 Dents Moderate 0.10 Dents Severe 0.20 Breaks Any rating 0.50

[0136] Suppose the final service life of the frame die casting is 10 years, according to the matching table of damaged features, the influence of each damaged feature on the life is calculated; for example, if there is 1 moderate crack and 2 slight depressions on the frame, then: the primary change amount = (1 0.15 + 2 0.03) * 10 years = 1.5 years + 0.6 years = 2.1 years.

[0137] After the primary change amount is determined, the influence of the spatial position of the damaged feature on the life also needs to be considered, which involves more complex analysis, but for the sake of simplicity, it is assumed that the influence of the spatial position on the life is adjusted by an additional coefficient; for example, if the damaged features are concentrated in the key parts of the frame, it is assumed that the life reduction amount is 20% higher than the primary change amount; the life reduction amount = 2.1 years * 1.20 = 2.52 years. Finally, according to the final service life of the frame die casting and the predicted life reduction amount, the remaining service life is calculated; the remaining service life = final service life - life reduction amount = 10 years - 2.52 years = 7.48 years.

[0138] Reference 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, and in the service life management of the frame die casting, the 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 application, the specific steps are as follows:

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

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

[0142] S153: determining the repair events for the plurality of damaged features based on the repair level, the damage levels of the plurality of damaged features, and the spatial locations.

[0143] In embodiments of the present application, the remaining useful life of the frame casting is compared with a pre-set remaining useful life threshold. If the remaining useful life of the frame casting is higher than the pre-set remaining useful life threshold, the life management of the frame casting is triggered.

[0144] At this time, the remaining useful life of the frame casting needs to be obtained from the previous analysis (such as the S143 step). This value is a time range (such as years) or mileage, indicating how long the frame casting is expected to be used without further damage. The pre-set remaining useful life threshold is a pre-set standard for determining whether the frame casting needs to enter the 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, or a range.

[0145] The remaining useful life of the frame casting is compared with the pre-set remaining useful life threshold. If the remaining useful life is higher than the threshold, it means that the frame casting has enough remaining life and does not need to enter the strict life management program temporarily. If the remaining useful life is lower than or equal to the threshold, the life management program of the frame casting is triggered.

[0146] Specifically, assume that there is a frame casting, and its remaining useful life is 6 years after previous analysis (such as the S143 step). At the same time, according to the manufacturer's recommendations and industry standards, a pre-set remaining useful life threshold of 5 years is set. The remaining useful life is 6 years, and the pre-set remaining useful life threshold is 5 years. Comparing the remaining useful life of 6 years with the pre-set threshold of 5 years, it is found that the remaining useful life is higher than the pre-set threshold. Therefore, according to the judgment of the S151 step, this frame casting does not need to enter the strict life management program temporarily. However, this does not mean that its maintenance and management can be ignored. It only means that within the current remaining life, it can be managed and maintained according to the regular maintenance plan. At the same time, as time goes by and the use conditions change, the remaining useful life of the frame casting will change, so it needs to be re-evaluated and updated regularly. This example illustrates the importance of the S151 step in practical application, which helps decision-makers determine whether the frame casting needs to enter a more strict life management program, thereby ensuring the safety and reliability of the vehicle.

[0147] Further, in the service life management of the 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 frame die casting and the preset repair mapping relationship, which takes into account the overall consideration of the remaining service life of the frame die casting and the preset repair mapping relationship, and ensures the accuracy of the corresponding repair level.

[0148] At this time, a preset repair mapping relationship table or algorithm is obtained, which is formulated according to historical data of the frame die casting, manufacturer's recommendations, industry standards or expert knowledge; it defines the corresponding relationship between different remaining service life intervals and repair levels; the repair level is divided into several levels, such as slight repair, moderate repair, severe repair or emergency repair, etc., and each level corresponds to different repair measures and costs.

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

[0150] According to the repair mapping relationship, the repair level is determined, and the remaining service life of the frame die casting is matched with the preset repair mapping relationship to determine the corresponding repair level, which is realized by looking up the mapping relationship table or running the algorithm; according to the matching result, the repair level required by the frame die casting at present is determined, which will guide the subsequent repair measures and plans.

[0151] Specifically, assuming that there is a frame die casting, and its remaining service life is 7 years after previous calculation (such as S143 step); 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 service life (years) Repair rating >10 Minor repair 6-10 Moderate repair 3-5 Severe repair <3 Emergency repair

[0154] The 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 interval of 6-10 years; therefore, according to the mapping relationship table, it is determined that the repair level required by the frame die casting at present is moderate repair, which illustrates the importance of S152 step in practical application; 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 the safety and use requirements after repair, and also helps to optimize maintenance cost and time.

[0155] Therefore, based on the repair level, the damage levels of the plurality of damaged features, and the spatial positions, the repair events of the plurality of damaged features are determined, which comprehensively considers the repair level, the damage levels of the plurality of damaged features, and the spatial positions, ensures the accuracy of the repair events of the plurality of damaged features, at the same time, fully considers the remaining service life of the frame die casting, ensures the targeted repair of the frame die casting for each damaged feature, ensures the effectiveness of the service life management of the frame die casting, so as to realize the periodical management of the service life of the frame die casting.

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

[0157] Firstly, the repair level of the frame die casting needs to be obtained from the previous step (S152); the repair level is determined according to the remaining service life of the frame die casting and the preset repair mapping relationship, which reflects the repair degree currently required by the frame die casting; next, the damage levels of the plurality of damaged features on the frame die casting need to be analyzed; the damage level is determined according to the size, depth, number, and other factors of the damaged feature, which reflects the influence degree of the damaged feature on the performance and safety of the frame die casting.

[0158] In addition to the damage level, the spatial position of the damaged feature on the frame die casting also needs to be considered; the spatial position is crucial for making the repair event, because it affects the difficulty, time and cost of repair, and the influence on the overall performance of the frame die casting after repair; based on the repair level, the damage levels and spatial positions of the plurality of damaged features, the specific repair event is determined; the repair event refers to the repair measures taken for each damaged feature, such as welding cracks, filling depressions, replacing damaged parts, etc.; the making of the repair event needs to consider factors such as safety, economy, feasibility, and timeliness.

[0159] Specifically, assuming that there is a frame die casting, its repair level is determined to be moderate repair through the previous steps, and the following two damaged 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 depression with a diameter of 3 cm, located near the side door frame of the frame; now, the repair event is determined according to step S153.

[0160] The repair level is moderate repair; the damage level of the crack is moderate because it is relatively long and moderately deep, which has some impact on the structural strength of the frame; the damage level of the dent is light because although it is relatively large in diameter, it is shallow, which has less 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 that needs special attention to the repair quality and strength recovery; the dent is located near the side door frame of the frame, although it is not a critical part, but it needs to be repaired to ensure that it does not affect the opening and sealing performance of the door.

[0161] For the crack: repair by welding technology to ensure that the crack is completely welded, and polish and rust-proof treatment are performed on the welding area;

[0162] For the dent: use a suction cup or crowbar to pull out the dent area, then use filler to level it, and polish and paint to restore the appearance, which illustrates the importance of S153 steps in practical application; by considering the repair level, the damage level of multiple damaged features, and the spatial position, a suitable repair event is determined for each damaged feature to ensure that the frame casting meets safety and use requirements after repair.

[0163] In an embodiment of the present application, the repair event matching table determines the final repair measures by matching the repair level, damage level, and spatial position with the preset repair events; the repair event matching table is shown in Table Six:

[0164] Table Six Repair Event Matching Table

[0165] Repair rating Damage rating Spatial position Repair event Minor repair Mild Non-critical location Cosmetic repair, such as sanding, painting Minor repair Moderate Non-critical location Reinforcing repair, such as reinforcement installation Moderate repair Mild Critical location Precision repair, such as local welding, sanding Moderate repair Moderate Critical location Structural repair, such as overall replacement of damaged parts Severe repair Any rating Any location Overall inspection, overall repair or replacement if necessary

[0166] Suppose there is a frame casting with a moderate repair level, and two damaged features: a moderate crack on the front of the frame (critical part) and a light dent on the rear of the frame (non-critical part); according to the repair event matching table, the following repair events are determined: for the moderate crack on the front of the frame: precise repair such as local welding and polishing; for the light dent on the rear of the frame: cosmetic repair such as polishing and painting.

[0167] Please refer to Figure 7 , Figure 7 is a structural composition diagram of the service life management system of the frame casting in the embodiment of the present application; the service life management system of the frame casting comprises:

[0168] a first theoretical service life module 21 for determining the die casting forming data of the frame casting according to the model of the frame casting and the die casting database, and determining the first theoretical service life according to the die casting forming data of the frame casting;

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

[0170] The final service life module 23 is configured to determine the 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] The remaining service life module 24 is configured to determine a plurality of damaged features according to the damaged image of the frame die casting after the new energy vehicle is subjected to a vehicle collision, and predict the remaining service life of the frame die casting based on the plurality of damaged features and the final service life of the frame die casting.

[0172] The repair event module 25 is configured to trigger the service life management of the frame die casting according to the remaining service life of the frame die casting, and determine a repair event of the plurality of damaged features according to the remaining service life of the frame die casting, the plurality of damaged features and a repair mapping relationship in the service life management of the frame die casting.

[0173] Any combination of the technical features of the above embodiments is possible. In order to make the description simple, not all combinations of the technical features in the above embodiments are described, however, as long as the combination of the technical features does not exist, it should be considered as the scope of the present disclosure.

Claims

1. A method for managing the service life of a vehicle frame die casting, characterized by, The application relates to a vehicle frame die casting piece life management method. The application relates to a vehicle frame die casting piece life management method. The application relates to a vehicle frame die casting piece life management method. The application relates to a vehicle frame die casting piece life management method. The application relates to a vehicle frame die casting piece life management method. The application relates to a vehicle frame die casting piece life management method.

2. The service life management method of the vehicle frame die casting according to claim 1, characterized by, The application relates to a vehicle frame die casting piece life management method. The application relates to a vehicle frame die casting piece life management method.

3. The service life management method of the vehicle frame die casting according to claim 2, characterized by, The application relates to a vehicle frame die casting piece life management method. The application relates to a vehicle frame die casting piece life management method. The application relates to a vehicle frame die casting piece life management method. The application relates to a vehicle frame die casting piece life management method. The application relates to a vehicle frame die casting piece life management method. The application relates to a vehicle frame die casting piece life management method. The application relates to a vehicle frame die casting piece life management method. The application relates to a vehicle frame die casting piece life management method. The application relates to a vehicle frame die casting piece life management method. The application relates to a vehicle frame die casting piece life management method. 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4. The service life management method of the vehicle frame die casting according to claim 1, characterized by, The method comprises the following steps: determining a plurality of damaged features according to the damaged image of the frame die casting after the new energy vehicle is involved in a vehicle collision; and predicting the remaining service life of the frame die casting based on the plurality of damaged features and the final service life of the frame die casting. The new energy vehicle is running on the road and is involved in a vehicle collision with another vehicle, at which time the frame die casting is impacted and damaged; the frame die casting is ring photographed, and the damaged image of the frame die casting is collected.

5. The service life management method of the vehicle frame die casting according to claim 4, characterized by, The method further comprises the following steps: determining a damaged area according to the damaged image of the frame die casting and the three-dimensional shape of the frame die casting; determining a plurality of damaged features according to the identification of each damaged area; and marking the damage level and the spatial position of the plurality of damaged features. The primary change amount of the service life is determined based on the damage level of the plurality of damaged features and the final service life of the frame die casting; the life reduction amount is predicted according to the primary change amount of the service life and the spatial position of the plurality of damaged features; and the remaining service life of the frame die casting is predicted according to the final service life of the frame die casting and the life reduction amount. The method further comprises the following steps: 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 the service life management of the frame die casting.

6. The service life management method of the vehicle frame die casting according to claim 1, characterized by, The method further comprises the following steps: collecting a preset repair mapping relationship in the service life management of the frame die casting; determining a corresponding repair level according to the remaining service life of the frame die casting and the preset repair mapping relationship; and determining the repair event of the plurality of damaged features based on the repair level, the damage level and the spatial position of the plurality of damaged features. The service life management system of the frame die casting is applied to the service life management method of the frame die casting as claimed in any one of claims 1-7, and the service life management system of the frame die casting comprises:

7. The service life management method of the vehicle frame die casting according to claim 6, characterized by, ​ ​ ​ 8. A system for managing the service life of a frame die casting, characterized by, ​ The first theoretical service life module is configured to determine the die casting forming data of the frame die casting according to the model of the frame die casting and the die casting database, and determine the first theoretical service life according to the die casting forming data of the frame die casting. The first theoretical service life module includes the following steps: marking the corresponding model of the frame die casting during the die casting process of the frame die casting, and storing the die casting forming data of the frame die casting during the die casting process in the die casting database; the die casting database records all data of the frame die casting; after the die casting of the frame die casting is completed, triggering the traceability of the die casting database based on the frame die casting, and determining the die casting forming data of the frame die casting, and simultaneously determining the mechanical data of the frame die casting according to the mechanical test of the frame die casting; determining the first theoretical service life according to the die casting forming data, the mechanical data of the frame die casting and the first life mapping relationship, which presents the service life of the frame die casting in the comprehensive dimension of the die casting dimension and the mechanical dimension; The second theoretical service life module is configured to determine the second theoretical service life according to the use position and the corresponding three-dimensional shape of the frame die casting. The second theoretical service life module includes the following steps: in the new energy vehicle configured with the frame die casting, determining the use position of the frame die casting according to the distribution map of the new energy vehicle and the use mark of the frame die casting, and determining the impact resistance coefficient of the frame die casting according to the use position of the frame die casting and the impact resistance coefficient mapping relationship; determining the theoretical shape of the frame die casting according to the traceability of the model of the frame die casting, performing ring shooting on the frame die casting, and generating the actual shape of the frame die casting, determining the three-dimensional shape of the frame die casting according to the synthesis of the actual shape and the theoretical shape of the frame die casting; determining the second theoretical service life based on the three-dimensional shape, the impact resistance coefficient of the frame die casting and the second life mapping relationship, which presents the service life of the frame die casting in the comprehensive dimension of the shape dimension and the impact resistance dimension; The final service life module is configured to determine the 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; The remaining service life module is configured to determine a plurality of damaged features according to the damaged image of the frame die casting after the new energy vehicle is subjected to vehicle collision, and predict the remaining service life of the frame die casting based on the plurality of damaged features and the final service life of the frame die casting; The repair event module is configured 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 event of the plurality of damaged features is determined according to the remaining service life of the frame die casting, the plurality of damaged features and the repair mapping relationship.

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