Active air-inlet grille testing device

Abstract

The invention belongs to the technical field of automobile part testing, and discloses an active air-inlet grille testing device. A butt joint frame is installed on one side of the main body frame, an active air inlet grille is installed on the butt joint frame, supporting beams are installed on the two opposite sides of the main body frame, a cross beam is installed between the supporting beams, a fixed pulley is installed on the cross beam, and a connecting rope is wound around the fixed pulley. One end of the connecting rope is connected with a blade of the active air-inlet grille, the other end of the connecting rope is connected with a counter weight in a hanging manner, and a motor is mounted on the active air-inlet grille testing device and is in transmission connection with the blade; the problem of high cost of building a wind tunnel to test the service life of the active air inlet grille in the prior art is solved.

Description

Technical Field

[0001] This invention relates to the field of automotive parts testing technology, and in particular to an active air intake grille testing device. Background Technology

[0002] The grille is an important component of a car's front styling, influencing the overall design and serving as the air intake for the engine compartment. Currently, most vehicles have fixed grilles, while active grilles are devices that measure engine coolant temperature, oil temperature, air conditioning system status, and intake air temperature, using a motor to control the opening and closing of the grille's louvers at a specific angle.

[0003] New energy vehicles do not require engine cooling, but they do need to cool the battery, motor, and electronic control system ("three-electric system"). When driving at low speeds or under low loads (such as in urban congestion), the three-electric system generates little heat. Closing the active grille can reduce wind resistance and prevent excessive cold air from entering, which could cause the battery temperature to drop too low (low temperatures can significantly reduce battery capacity). When driving at high speeds or fast charging, the three-electric system generates more heat, so the active grille opens again to increase the air intake, balancing wind resistance control and heat dissipation needs. This can increase the range of pure electric vehicles by 3%-8%.

[0004] The active grille shutter is not a simple "on / off" switch. Instead, it receives real-time signals from the vehicle's ECU (Electronic Control Unit) such as water temperature, battery temperature, vehicle speed, load, and air conditioning status, and dynamically adjusts according to priority: Priority 1 (Safety): When core components overheat, the active grille shutter opens first to ensure heat dissipation; Priority 2 (Efficiency): During cold starts / low loads, the active grille shutter closes to prioritize warming up the engine and reducing wind resistance; Priority 3 (Experience): During high-speed cruising, it balances wind resistance and wind noise, adjusting to the optimal opening degree.

[0005] In the performance testing of the active air intake grille, durability is one of the most important performance indicators. The grille needs to undergo 400,000 blade opening and closing cycles, taking approximately three months. This is crucial to ensuring the grille's reliable functionality throughout its lifespan. During operation, the active air intake grille continuously withstands airflow pressure, which varies with vehicle speed and blade opening. This simulates the dynamic pressure generated during vehicle movement. This dynamic pressure acts on the blades, causing resistance during opening and closing. Dynamic pressure (Pa) is the additional pressure generated by airflow movement; the faster the speed, the greater the dynamic pressure. Placing the active air intake grille in a wind tunnel to test the dynamic pressure at specific speeds would be prohibitively expensive due to the unacceptable lifespan cost. Furthermore, the high cost of building a wind tunnel increases the final development cost and adds complexity to the experiment. Summary of the Invention

[0006] The purpose of this invention is to provide an active air intake grille testing device, which solves the problem of high cost of building a wind tunnel to test the lifespan of active air intake grilles under the existing technology.

[0007] To achieve this objective, the present invention adopts the following technical solution: The present invention provides an active air intake grille testing device, including a main frame, a docking frame installed on one side of the main frame, an active air intake grille installed on the docking frame, support beams installed on opposite sides of the main frame, a crossbeam installed between the support beams, a fixed pulley installed on the crossbeam, a connecting rope wound around the fixed pulley, one end of the connecting rope being connected to the blades of the active air intake grille, and a counterweight being hung at the other end, and a motor installed on the active air intake grille testing device, the motor being drivenly connected to the blades.

[0008] Preferably, a first fixing plate is installed on the upper and lower sides of the docking frame, a second fixing plate is installed between the first fixing plates on the upper and lower sides, and the active air intake grille is installed on the second fixing plate.

[0009] Preferably, along the length of the first fixing plate, the first fixing plate has at least one set of first screw holes, and the second fixing plate has a first through hole, and the first screw passes through the first through hole and is screwed into the first screw hole.

[0010] Preferably, along the length of the second fixing plate, at least one set of second screw holes are provided on the second fixing plate, and the second screw passes through the active air intake grille and is screwed into the second screw hole.

[0011] Preferably, the support beam is installed obliquely on the main frame, a slide rail is installed on the support beam, sliders are installed at both ends of the crossbeam, the sliders are slidably installed in the slide rail, a limit block is inserted into the slide rail, and the slider abuts against the limit block.

[0012] Preferably, two sets of fixed pulleys are installed on the crossbeam, and each fixed pulley corresponds to one of the blades.

[0013] Preferably, the top of the slide rail is higher than the active air intake grille.

[0014] Preferably, casters are installed on the underside of the main frame.

[0015] Preferably, the active air intake grille testing device also includes an environmental chamber, in which the main frame is placed and the environmental chamber can change its internal temperature.

[0016] Preferably, a hook is installed on the top of the counterweight, a first hanging ring is installed on the bottom of the counterweight, a second hanging ring is installed on the connecting rope, and the hook is attached to the first hanging ring or the second hanging ring.

[0017] Beneficial effects: By attaching a counterweight to the connecting rope, the weight of the counterweight can pull the blades connected to the other end of the rope to form a constant tension, simulating the airflow pressure generated by the active air intake grille on the vehicle during vehicle operation. This replaces the wind tunnel to truly simulate the effect of airflow pressure, reducing the experimental cost of active air intake grille performance testing. Attached Figure Description

[0018] Figure 1 This is a main body diagram of the active air intake grille test device of the present invention.

[0019] In the diagram: 1. Main frame; 2. Connecting frame; 3. Active air intake grille; 31. Blade; 4. Support beam; 5. Crossbeam; 6. Fixed pulley; 7. Connecting rope; 8. Counterweight; 9. First fixing plate; 91. First screw hole; 10. Second fixing plate; 101. Second screw hole; 20. Slide rail; 30. Caster wheel. Detailed Implementation

[0020] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, and not all of the structures.

[0021] In the description of this invention, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0022] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0023] In the description of this embodiment, the terms "upper," "lower," "right," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention. In addition, the terms "first" and "second" are used only for distinction in description and have no special meaning.

[0024] Under current technological conditions, performance verification of active air intake grilles typically requires simulating the wind pressure environment experienced during driving to accurately reproduce their airflow effect in actual vehicle conditions. Currently, wind tunnel testing is widely used as the primary testing method in the industry; however, this method has significant limitations: the construction and maintenance costs of wind tunnels are extremely high, and they require stringent space requirements, necessitating large air supply systems and measurement devices, resulting in substantial overall investment. Furthermore, wind tunnel testing often involves complex scheduling processes and lengthy preparation periods, making it difficult to quickly respond to high-frequency, multi-condition R&D verification needs. With the accelerating pace of automotive R&D, especially the higher demands placed on thermal management and aerodynamic performance by new energy vehicles, traditional wind tunnel testing is no longer adequate for the efficient, flexible, and low-cost modern R&D system. There is an urgent need to explore a lighter, easier-to-implement, and more economical alternative testing solution.

[0025] To solve the above problems, such as Figure 1 As shown, the present invention provides an active air intake grille testing device, including a main frame 1, a docking frame 2 installed on one side of the main frame 1, an active air intake grille 3 installed on the docking frame 2, support beams 4 installed on opposite sides of the main frame 1, a crossbeam 5 installed between the support beams 4, a fixed pulley 6 installed on the crossbeam 5, a connecting rope 7 wound around the fixed pulley 6, one end of the connecting rope 7 being connected to the blade 31 of the active air intake grille 3, and a counterweight 8 hanging on the other end, and a motor installed on the active air intake grille testing device, the motor being drivenly connected to the blade 31.

[0026] To achieve performance testing of the active air intake grille 3 under real driving conditions, while avoiding the high cost and complex site requirements of traditional wind tunnel experiments, a high-efficiency and low-cost simulation testing system was developed. The core of this system is to accurately reproduce the aerodynamic loads borne by the grille during dynamic driving in a static environment through mechanical structures, thereby effectively evaluating its reliability, response characteristics and durability.

[0027] The construction of the entire test platform begins with a main frame 1. On this main frame 1, a docking frame 2 is designed and installed. This docking frame 2 is used to fix the active air intake grille 3 to be tested, ensuring its position is stable throughout the test and that its installation posture is consistent with the actual vehicle installation state, providing a reliable foundation for subsequent simulation tests.

[0028] The key to simulating airflow impact lies in applying loads to the blades 31. Each blade 31 of the active air intake grille 3 is connected to a high-strength connecting rope 7. At the other end of these connecting ropes 7, precisely calculated counterweights 8 are suspended. The core function of these counterweights 8 is to simulate the wind pressure generated by airflow acting on the blades 31 at different vehicle speeds. According to physical principles, the wind pressure during driving creates a continuous pushing force on the blades 31, while the counterweights 8, through gravity, apply a constant, directionally controllable tension to the connecting ropes 7 and the connected blades 31. By precisely adjusting the mass of the counterweights 8, we can simulate wind pressure levels under different operating conditions, from low-speed cruising to high-speed driving, thereby achieving a quantitative simulation of the real driving environment.

[0029] After the load simulation is complete, the next step is to drive blade 31 to complete its core action—rotational opening and closing. This process is performed by a motor. The motor, through a set of precision transmission components (which may include gear sets, linkage mechanisms, or worm gears, etc.), converts the motor's rotational output into stable and reliable rotational motion of blade 31. Under the constant "wind pressure" load simulated by counterweight 8, we control the motor to repeatedly drive blade 31, performing a cycle from fully open to fully closed, and then to opening at a specific angle.

[0030] This comprehensive testing process allows us to continuously observe and record the operating status of the blades 31 of the active air intake grille 3 under simulated wind pressure loads in the laboratory without starting a large wind tunnel facility. We can assess whether its rotation is smooth and without jamming; whether the transmission mechanism can withstand continuous loads and whether there is wear or deformation; and the fatigue durability performance of the entire system under long-term cyclic operation.

[0031] In summary, this testing system, based on the main frame 1, docking frame 2, counterweight load, and motor drive, successfully constructs an economical, convenient, and highly controllable testing environment. It effectively addresses the pain points of high cost and long cycle time in traditional wind tunnel testing, providing a powerful and low-cost verification method for the active air intake grille 3 during product development, quality control, and performance optimization stages. This significantly improves R&D efficiency and reduces upfront investment costs, demonstrating significant practical value in the field of automotive component testing.

[0032] The calculation formula for counterweight 8 is the Bernoulli equation, which is a well-established formula in fluid mechanics. The pressure value is usually q, where ρ is the air density and V is the vehicle speed. The above formula can be used to accurately calculate the air pressure value generated by the blade 31 at different vehicle speeds. At the same time, a hook is installed on the top of the counterweight 8, a first hanging ring is installed on the bottom of the counterweight 8, and a second hanging ring is installed on the connecting rope 7. The hook is attached to the first hanging ring or the second hanging ring, and the counterweights 8 can be connected to each other. Through the above hooks and the first hanging ring, the counterweights 8 can be connected to each other in sequence, so that the tension on the blade 31 can be flexibly adjusted.

[0033] To achieve precise and flexible adjustment of the tension on blade 31, the testing system was designed with a highly modular and easily adjustable counterweight connection mechanism. The core of this design is that each counterweight unit is designed as an independent, freely combinable standard module.

[0034] Specifically, a sturdy U-shaped or J-shaped hook is installed at the top of each counterweight 8. This top hook is the main stress point when it functions as an independent unit. At the bottom of the counterweight 8, a first hanging ring, typically made of high-strength round steel, is fixedly installed and securely attached to the body of the counterweight 8. Meanwhile, a second hanging ring is also installed at an appropriate position on the connecting rope 7—the main rope directly connected to the blade 31.

[0035] Independent connection mode: This is the most basic mode. The hook on the top of the counterweight 8 is directly attached to the second loop on the connecting rope 7. At this time, the entire weight of a single counterweight 8 is the tension acting on the blade 31.

[0036] Series stacking mode: This is key to achieving a significant increase in tensile force. When simulating greater wind pressure, there's no need to create a large, bulky monolithic counterweight. Simply attach the hook at the top of the first counterweight 8 to the second loop of the connecting rope 7, and then attach the hook at the top of the second counterweight 8 to the first loop at the bottom of the first counterweight 8. And so on, multiple counterweights 8 can be connected in series like a chain by "hooking the hooks to the next level's bottom loops." In this way, the tensile force acting on the blade 31 is the sum of the weights of all the series-connected counterweights 8, achieving a linear superposition of tensile forces.

[0037] Distributed connection mode: In order to simulate non-uniform wind pressure more precisely or to conduct special load distribution tests, multiple counterweight units (whether independent or in series) can be hung on different second hanging ring positions on the connecting rope 7 to achieve complex working conditions that apply differentiated tension to different parts of a single blade 31 or to different blades 31.

[0038] In this way, testers can freely and quickly assemble the counterweight system. By simply adding or removing counterweight modules, or changing their connection order and mounting points, the tensile force can be adjusted infinitely (in practice, it is stepped, but the step differences are very small) over a wide range, from the smallest unit to several times its original value. This design not only greatly improves the flexibility and efficiency of testing, allowing for rapid response to different testing conditions, but also makes the management, storage, and transportation of the entire counterweight system more convenient and economical, fully demonstrating the ingenuity and practical value of this low-cost testing solution.

[0039] The docking frame 2 has first fixing plates 9 installed on its upper and lower sides, and a second fixing plate 10 installed between the first fixing plates 9 on the upper and lower sides. An active air intake grille 3 is installed on the second fixing plate 10. The active air intake grille 3 and the main frame 1 can be connected through the first fixing plates 9 and the second fixing plate 10, reducing the installation difficulty.

[0040] Along the length of the first fixing plate 9, at least one set of first screw holes 91 are provided on the first fixing plate 9, and a first through hole is provided on the second fixing plate 10. A first screw passes through the first through hole and is screwed into the first screw hole 91. By providing multiple sets of first screw holes 91, the position of the second fixing plate 10 can be adjusted, allowing the distance between the two sets of second fixing plates 10 to be flexibly adjusted. This enables the device to adapt to active air intake grilles 3 of different sizes and signals, improving the versatility of the active air intake grille testing device. At the same time, the first screws facilitate disassembly and fixing, reducing the difficulty of assembly and disassembly.

[0041] Along the length of the second fixing plate 10, at least one set of second screw holes 101 are provided on the second fixing plate 10. The second screw passes through the active air intake grille 3 and is screwed into the second screw hole 101. The second fixing plate 10 is perpendicular to the horizontal plane in the figure. Because it is provided with multiple sets of second screw holes 101, the installation height of the active air intake grille 3 can be freely adjusted so that each connecting rope 7 is perpendicular to the surface of the blade 31 of the active air intake grille 3, so that the counterweight 8 can apply pressure to the blade 31.

[0042] The support beam 4 is inclinedly mounted on the main frame 1. A slide rail 20 is installed on the support beam 4. Slider blocks are installed at both ends of the crossbeam 5, and these sliders slide within the slide rail 20. Limit blocks are inserted into the slide rail 20, and the sliders abut against the limit blocks. Because the blades 31 on the active air intake grilles 3 of different signals and sizes are installed in different positions, the height of the crossbeam 5 can be adjusted by setting movable sliders. This ensures that each connecting rope 7 remains horizontal to the ground during connection with the blade 31, guaranteeing that the pulling force of the counterweight 8 on the blade 31 remains constant. After the slider finds a suitable position, limiters are snapped onto both sides of the slider to prevent movement, ensuring the stability of the fixed pulley 6 during operation.

[0043] Two sets of fixed pulleys 6 are installed on the crossbeam 5. The fixed pulleys 6 correspond one-to-one with the blades 31, so that the connecting ropes 7 on each set of fixed pulleys 6 can be equipped with a set of blades 31, and each set of blades 31 can feel the tension of the counterweight 8.

[0044] The top of the slide rail 20 is higher than the active air intake grille 3, which ensures that the fixed pulley 6 can move to a height higher than the active air intake grille 3. This allows each set of blades 31 to receive a tension parallel to the horizontal plane, simulating the wind resistance encountered by the vehicle during driving, thereby improving the realism of the test and the accuracy of the final test results.

[0045] The main frame 1 is equipped with casters 30 on its lower side, which can drive the main frame 1 to move freely. The active air intake grille test device of the present invention also includes an environmental chamber. The main frame 1 is placed in the environmental chamber. The environmental chamber can change the internal temperature. By changing the temperature inside the environmental chamber, the stable environment in which the vehicle is in motion can be simulated. For the different gas densities at different temperatures, multiple environmental factors are taken into account, thereby improving the accuracy of the test.

[0046] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art will be able to make various obvious changes, readjustments, and substitutions without departing from the scope of protection of the present invention. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. An active air intake grille testing device, characterized in that, The device includes a main frame (1), a docking frame (2) installed on one side of the main frame (1), an active air intake grille (3) installed on the docking frame (2), support beams (4) installed on opposite sides of the main frame (1), a crossbeam (5) installed between the support beams (4), a fixed pulley (6) installed on the crossbeam (5), a connecting rope (7) wound around the fixed pulley (6), one end of the connecting rope (7) being connected to the blade (31) of the active air intake grille (3) and the other end being attached to a counterweight (8), and a motor installed on the active air intake grille test device, the motor being connected to the blade (31) in a transmission connection.

2. The active air intake grille testing device according to claim 1, characterized in that, The docking frame (2) is equipped with a first fixing plate (9) on the upper and lower sides, and a second fixing plate (10) is installed between the first fixing plates (9) on the upper and lower sides. The active air intake grille (3) is installed on the second fixing plate (10).

3. The active air intake grille testing device according to claim 2, characterized in that, Along the length of the first fixing plate (9), at least one set of first screw holes (91) are provided on the first fixing plate (9), and a first through hole is provided on the second fixing plate (10). A first screw passes through the first through hole and is screwed into the first screw hole (91).

4. The active air intake grille testing device according to claim 3, characterized in that, Along the length of the second fixing plate (10), at least one set of second screw holes (101) are provided on the second fixing plate (10), and the second screw passes through the active air intake grille (3) and is screwed into the second screw hole (101).

5. The active air intake grille testing device according to claim 1, characterized in that, The support beam (4) is installed obliquely on the main frame (1). A slide rail (20) is installed on the support beam (4). Slider blocks are installed at both ends of the crossbeam (5). The sliders are slidably installed in the slide rail (20). A limit block is inserted into the slide rail (20). The slider abuts against the limit block.

6. The active air intake grille testing device according to claim 5, characterized in that, Two sets of fixed pulleys (6) are installed on the crossbeam (5), and the fixed pulleys (6) correspond one-to-one with the blades (31).

7. The active air intake grille testing device according to claim 5, characterized in that, The top of the slide rail (20) is higher than the active air intake grille (3).

8. The active air intake grille testing device according to claim 1, characterized in that, The main frame (1) is equipped with casters (30) on its lower side.

9. The active air intake grille testing device according to claim 1, characterized in that, The active air intake grille test device also includes an environmental chamber, and the main frame (1) is placed inside the environmental chamber, which can change the internal temperature.

10. The active air intake grille testing device according to claim 1, characterized in that, The counterweight (8) has a hook installed on its top and a first hanging ring installed on its bottom. The connecting rope (7) has a second hanging ring installed on it, and the hook is attached to the first hanging ring or the second hanging ring.

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