Vibration test system for engine fatigue test
By installing a gas cooler in the vibration test system and correcting the flow rate based on temperature and vibration frequency, the problem of insufficient heat dissipation in the vibration test system was solved, and stable operation of the equipment and energy conservation were achieved.
Patent Information
- Application Number
- CN202510887851.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-06-30
- Publication Date
- 2025-09-16
AI Technical Summary
The existing vibration test system does not dissipate enough heat during engine fatigue testing, resulting in large deviations and errors in test parameters. Improvement measures require a major upgrade of equipment, which is costly and environmentally unfriendly.
A gas cooler is installed in the vibration test system to exchange heat with the air through the cooling water channel. The cooling water channel flow is corrected in combination with the temperature and vibration frequency to accurately control the cooling effect.
It effectively reduces the internal temperature of the vibration table, avoids equipment overheating, improves equipment operation stability, reduces energy consumption and production costs, and avoids large-scale equipment modification.
Smart Images
Figure CN120651458A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to engine fatigue testing technology, and more particularly to a vibration testing system for engine fatigue testing. Background Art
[0002] Engine fatigue testing is a crucial component of automotive manufacturing and R&D. It assesses an engine's ability to withstand cyclic loads during long-term operation. The goal of fatigue testing is to predict potential failure modes, such as fatigue cracks and fractures, that may occur in actual engine use, thereby ensuring engine reliability and lifespan. Vibration testing systems are primarily used to simulate the vibration conditions experienced by an engine during actual operation. These systems can assess the durability and reliability of engine components (such as the crankshaft, connecting rod, and crank bearings) over long periods of operation. Therefore, they are essential testing items during engine design.
[0003] A vibration test system consists of a power amplifier, a vibration table, and a cooling fan. The power amplifier primarily supplies power to the vibration table and controls its vibration amplitude. Due to the heavy weight of the engine, the overall power consumption of the vibration test system is high. If these components are not cooled promptly during prolonged engine testing, the vibration frequency of the vibration test system will be affected, leading to deviations in test parameters and significant test errors. Current vibration test systems primarily rely on cooling fans for cooling. However, as engine testing becomes increasingly demanding and test times lengthen, the cooling fan's heat dissipation approach is no longer sufficient to meet the heat dissipation requirements of the vibration test system. Furthermore, engine testing is typically conducted in a dedicated machine room (primarily due to the high noise levels during testing, necessitating such a facility to minimize noise pollution). This internal space is limited, and high temperatures are common during testing. Therefore, air flow requires appropriate aerodynamic equipment. Simply increasing air volume would require not only modifications to the vibration test system's cooling fan but also upgrades to the corresponding aerodynamic equipment. This would result in significant modifications and increased testing time, increasing energy consumption during subsequent testing and contradicting existing energy conservation and environmental protection concepts. Summary of the Invention
[0004] The technical problem to be solved by the present invention is to provide a vibration test system for engine fatigue testing in view of the deficiencies in the prior art, which greatly reduces the modification cost and modification time.
[0005] The vibration test system for engine fatigue testing according to the present invention comprises a power amplifier, a vibration table, and a cooling fan, and further comprises:
[0006] A gas cooler is installed on the periphery of the cooling fan, and an air cooling module is provided in front of the air inlet end of the cooling fan. The air cooling module consists of cooling water channels and ventilation holes located between the cooling water channels. The cooling water channels are connected to an external water source through pipes;
[0007] A temperature sensor is installed on the power component of the vibration table and is used to collect the real-time temperature of the electric component of the vibration table;
[0008] A controller is used to calculate the initial frequency of the vibration table and calibrate the initial flow of the cooling water channel according to the initial frequency; the controller collects the real-time vibration frequency and real-time temperature of the vibration table, and simultaneously obtains a first corrected flow according to the real-time temperature, and obtains a second corrected flow according to the real-time vibration frequency, and corrects the current flow of the cooling water channel with the first corrected flow and the second corrected flow to obtain the target flow.
[0009] Preferably, the cooling water channel is composed of longitudinal water channels and transverse water channels that are crisscrossed, and the longitudinal water channels are connected to the transverse water channels, and ventilation holes are provided between two adjacent water channels.
[0010] Preferably, the cooling water channel is a copper tube or an aluminum tube.
[0011] Preferably, the initial frequency of the vibration table is calculated by the following formula:
[0012]
[0013] Where ω0 is the initial frequency, m1 is the weight on the vibration table, m2 is the weight of the dynamic coil of the vibration table, and K is the stiffness of the dynamic coil frame.
[0014] Preferably, the first corrected flow rate is obtained according to the real-time temperature, specifically:
[0015] Calculating the temperature change rate within a set first time period according to the real-time temperature to obtain a temperature rise value;
[0016] Determine whether the temperature rise value is within the set temperature rise range. If so, assign the first correction flow rate to 0; otherwise, calculate the temperature rise time based on the temperature rise value and the maximum operating temperature of the vibration table power component, use the inverse of the temperature rise time as the correction coefficient, and take the product of the correction coefficient and the current flow rate of the cooling water channel as the first correction flow rate.
[0017] Preferably, the second corrected flow rate is obtained according to the real-time vibration frequency, specifically:
[0018] Calculating a frequency change rate within a set second time period based on the real-time vibration frequency;
[0019] If the frequency change rate is a negative value or a zero value, the second corrected flow rate is assigned a value of 0; otherwise, the product of the frequency change rate and the current flow rate of the cooling water channel is used as the second corrected flow rate.
[0020] Preferably, the first time period is shorter than the second time period.
[0021] Preferably, a maximum flow rate through the cooling water channel is set. When the target flow rate is greater than the maximum flow rate through the cooling water channel, the second corrected flow rate is assigned to 0; if the target flow rate is still greater than the maximum flow rate through the cooling water channel, the first corrected flow rate is assigned to 0.
[0022] Beneficial effects
[0023] The advantages of the present invention are as follows: by installing a gas cooler, the cooling water in the cooling water channel of the gas cooler completes heat exchange with the air, cooling the air, so that it can better cool the inside of the vibration table, avoiding the problem of high temperature inside the vibration table. Moreover, the added gas cooler does not require changes to the original structure of the vibration test system, nor does it require upgrades to the aerodynamic equipment, greatly reducing the cost and time of the modification. In addition, for the modified gas cooler, the present invention also combines the correction of flow rate by temperature and vibration frequency, which can more accurately control the cooling flow rate. Effective cooling can prevent the equipment from overheating, thereby improving the operating stability of the equipment; and by optimizing the cooling flow rate, energy consumption can be reduced, reducing production costs. BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Figure 1 This is a schematic diagram of the internal structure of the vibration table of the vibration test system;
[0025] Figure 2 Schematic diagram of the dynamic structure of the vibration table;
[0026] Figure 3 This is a schematic diagram of the gas cooler installation structure of the present invention;
[0027] Figure 4 Schematic diagram of the cross-sectional structure of the gas cooler of the present invention;
[0028] Figure 5 This is a schematic diagram of the front structure of the gas cooler of the present invention. DETAILED DESCRIPTION
[0029] The present invention will be further described below in conjunction with the embodiments, but this does not constitute any limitation to the present invention. Any limited number of modifications made by anyone within the scope of the claims of the present invention are still within the scope of the claims of the present invention.
[0030] See Figure 1-Figure 5The present invention provides a vibration test system for engine fatigue testing, comprising a power amplifier, a vibration table 1, a cooling fan 2, a gas cooler 3, a temperature sensor and a controller. Figure 1 As shown in the figure, it mainly consists of a base, a magnetic cylinder bottom, a table, an excitation coil, a magnetic cylinder cover, an upper cover ring and a moving coil. Figure 2 The vibration table 1 is the main component for realizing fatigue test on the engine. The upper part of the dynamic coil is equipped with a table to prevent the engine to be tested from vibrating.
[0031] The gas cooler 3 is installed on the periphery of the cooling fan 2. Specifically, an air cooling module 4 is provided on the front side of the air inlet end of the cooling fan 2, which is used to cool the intake air. In this embodiment, the air cooling module 4 is composed of a cooling water channel and ventilation holes 7 located between the cooling water channels, and the cooling water channel is connected to an external water source through a pipe. When the air passes through the ventilation holes 7 between the cooling water channels, the cooling water in the cooling water channel completes heat exchange with the air, cooling the air so that it can better cool the inside of the vibration table 1, avoiding the problem of high temperature inside the vibration table 1. Moreover, the added gas cooler 3 does not require changes to the original structure of the vibration test system, nor does it require upgrading of the aerodynamic equipment, which greatly reduces the cost and time of the transformation. Among them, the cooling water is provided by an external water source, and low-temperature water or low-temperature coolant can be used. Furthermore, the cooling water channels are composed of a crisscross pattern of longitudinal channels 5 and transverse channels 6. These channels are interconnected, and ventilation holes 7 are provided between adjacent channels. This design increases the contact area between the air and the cooling water channels, effectively cooling the air. In this embodiment, the cooling water channels utilize copper pipes, which facilitate rapid heat exchange between the air and the cooling water.
[0032] The temperature sensor of this embodiment is installed on the power component of the vibration table 1 to collect the real-time temperature of the electric component of the vibration table 1. Specifically, it can be installed on the table body, but should be placed where it will not be subject to strong electromagnetic interference.
[0033] The controller is an additional control component used to independently control the flow in the cooling water channel, avoiding the problem of insufficient internal resource allocation caused by the reuse of the control components of the original vibration test system. The controller of this embodiment is used to calculate the initial frequency of the vibration table 1 and calibrate the initial flow of the cooling water channel according to the initial frequency. The advantage of this is that the corresponding flow can be matched according to the different dead weights of the engine to be tested. This matching mechanism is a dynamic matching mechanism that can achieve better cooling effect. The controller collects the real-time vibration frequency and real-time temperature of the vibration table 1, and obtains the first corrected flow according to the real-time temperature, and obtains the second corrected flow according to the real-time vibration frequency. The current flow of the cooling water channel is corrected with the first corrected flow and the second corrected flow to obtain the target flow. This embodiment combines the correction of flow by temperature and vibration frequency, which can more accurately control the cooling flow. Effective cooling can prevent the equipment from overheating, thereby improving the operating stability of the equipment; and by optimizing the cooling flow, energy consumption can be reduced and production costs can be reduced.
[0034] In this embodiment, the initial frequency of the vibration table 1 is calculated by the following formula:
[0035]
[0036] Where ω0 is the initial frequency, m1 is the weight of the vibration table, m2 is the weight of the dynamic coil, and K is the stiffness of the dynamic coil frame. The frequency calculated in this way is a fixed frequency, based on the ratio of the weight of the vibration table (i.e., the combined weight of the table and engine) to the weight of the dynamic coil. This frequency is more suitable for the vibration table's starting frequency and prevents the adverse effects of excessive starting power on the equipment caused by artificially set vibration frequencies.
[0037] In this embodiment, the first corrected flow rate is obtained according to the real-time temperature as follows:
[0038] The temperature change rate within a set first time period is calculated based on the real-time temperature to obtain a temperature rise value. A determination is then made as to whether the temperature rise value is within the set temperature rise range. If so, the first correction flow rate is set to 0. Otherwise, the temperature rise time is calculated based on the temperature rise value and the maximum operating temperature of the vibration table's power components. The inverse of the temperature rise time is used as a correction factor, and the product of the correction factor and the current flow rate in the cooling water channel is used as the first correction flow rate. During operation, heat accumulates within the vibration table, gradually increasing its temperature. Therefore, when the vibration table's temperature rise is excessive, the first correction flow rate is introduced to increase the flow rate in the cooling water channel to prevent excessive temperature rise. If the temperature rise gradually decreases after the first correction flow rate is introduced, it indicates that the internal temperature of the vibration table has stabilized. Therefore, as long as the temperature remains within the set range, the correction flow rate can be discontinued, thereby reducing power consumption. Similarly, when the vibration table's frequency decreases, its power consumption also decreases, and the temperature rise becomes negative. However, if the temperature rise is outside the set range, the first correction flow rate is also introduced, but this time the correction flow rate is negative, meaning that the flow rate in the cooling water channel is reduced, thus preventing excessive cooling of the vibration table. It can be seen from this that when setting the temperature rise range, the temperature rise value of 0 is taken as the midpoint. For example, it can be set to ±5℃ as its normal temperature rise range.
[0039] In this embodiment, the second corrected flow rate is obtained according to the real-time vibration frequency as follows:
[0040] The frequency change rate within a set second time period is calculated based on the real-time vibration frequency. If the frequency change rate is negative or zero, the second corrected flow rate is assigned a value of 0; otherwise, the second corrected flow rate is the product of the frequency change rate and the current cooling water channel flow rate. Simply lowering the vibration table's vibration frequency will reduce the power consumption of its internal coils, which will also cause its temperature rise to appear negative. Therefore, in this case, simply introducing a temperature-rise-to-flow correction method can gradually reduce the cooling water channel flow rate, thereby maintaining the vibration table's internal temperature at a suitable operating point. However, when the frequency change rate is positive, power consumption increases. To prevent sudden temperature rises in the vibration table due to frequency fluctuations, the second corrected flow rate is combined with the first corrected flow rate and the cooling water channel flow rate is corrected simultaneously. This means that when the frequency changes, the gas is cooled at a higher flow rate to prevent the vibration table from heating too quickly.
[0041] Preferably, the first time period is shorter than the second time period. That is, the period for calculating the frequency change rate is longer than the period for calculating the temperature rise. This is primarily because frequency changes are affected by many factors, such as those caused by equipment overheating, test requirements, and external interference. Therefore, setting an excessively large second time period can better account for frequency changes caused by these factors, preventing sudden changes in the ultimately calculated frequency change rate and avoiding abnormal flow corrections.
[0042] In addition, this embodiment sets a maximum flow rate for the cooling water channel. When the target flow rate exceeds the maximum flow rate, the second correction flow rate is set to 0. If the target flow rate is still greater than the maximum flow rate, the first correction flow rate is set to 0. Specifically, when the flow rate reaches the maximum, the correction flow rate is gradually removed to ensure that the flow rate in the cooling water channel does not exceed the maximum flow rate. This prevents overload in the cooling water channel and reduces the risk of pipe bursts and leaks.
[0043] The above is only a preferred embodiment of the present invention. It should be pointed out that for those skilled in the art, several modifications and improvements can be made without departing from the structure of the present invention. These modifications and improvements will not affect the effect of the implementation of the present invention and the practicality of the patent.
Claims
1. A vibration test system for engine fatigue testing, comprising a power amplifier, a vibration table (1) and a cooling fan (2), characterized in that: Also includes: A gas cooler (3) is installed on the periphery of the cooling fan (2), and an air cooling module (4) is provided in front of the air inlet end of the cooling fan (2). The air cooling module (4) is composed of cooling water channels and ventilation holes (7) located between the cooling water channels. The cooling water channels are connected to an external water source through pipelines. A temperature sensor, mounted on a power component of the vibration table (1), for collecting the real-time temperature of the electric component of the vibration table (1); A controller, configured to calculate an initial frequency of the vibration table (1) and calibrate an initial flow rate of the cooling water channel according to the initial frequency; The controller collects the real-time vibration frequency and real-time temperature of the vibration table (1), obtains a first corrected flow rate according to the real-time temperature, obtains a second corrected flow rate according to the real-time vibration frequency, and corrects the current flow rate of the cooling water channel with the first corrected flow rate and the second corrected flow rate to obtain a target flow rate.
2. A vibration test system for engine fatigue testing according to claim 1, characterized in that: The cooling water channel is composed of longitudinal water channels (5) and transverse water channels (6) that are crisscrossed, and the longitudinal water channels (5) are connected to the transverse water channels (6), and a ventilation hole (7) is provided between two adjacent water channels.
3. A vibration test system for engine fatigue testing according to claim 2, characterized in that: The cooling water channel is a copper tube or an aluminum tube.
4. A vibration test system for engine fatigue testing according to claim 1, characterized in that: The initial frequency of the vibration table (1) is calculated by the following formula: Where ω0 is the initial frequency, m1 is the weight on the vibration table, m2 is the weight of the dynamic coil of the vibration table, and K is the stiffness of the dynamic coil frame.
5. The vibration test system for engine fatigue testing according to claim 1, characterized in that: The first corrected flow rate is obtained according to the real-time temperature, specifically: Calculating the temperature change rate within a set first time period according to the real-time temperature to obtain a temperature rise value; Determine whether the temperature rise value is within the set temperature rise range. If so, assign the first correction flow rate to 0; otherwise, calculate the temperature rise time based on the temperature rise value and the maximum operating temperature of the vibration table power component, use the inverse of the temperature rise time as the correction coefficient, and take the product of the correction coefficient and the current flow rate of the cooling water channel as the first correction flow rate.
6. A vibration test system for engine fatigue testing according to claim 5, characterized in that: The second corrected flow rate is obtained according to the real-time vibration frequency, specifically: Calculating a frequency change rate within a set second time period based on the real-time vibration frequency; If the frequency change rate is a negative value or a zero value, the second corrected flow rate is assigned a value of 0; otherwise, the product of the frequency change rate and the current flow rate of the cooling water channel is used as the second corrected flow rate.
7. A vibration test system for engine fatigue testing according to claim 6, characterized in that: The first time period is shorter than the second time period.
8. The vibration test system for engine fatigue testing according to claim 6, characterized in that: Assuming a maximum flow rate through the cooling water channel, when the target flow rate is greater than the maximum flow rate through the cooling water channel, the second corrected flow rate is assigned to 0; if the target flow rate is still greater than the maximum flow rate through the cooling water channel, the first corrected flow rate is assigned to 0.