Method and system for predicting gluing sealing performance of transmission assembly for automobile

Abstract

The invention relates to the technical field of vehicles, and provides a method and system for predicting the gluing sealing performance of a transmission assembly for an automobile. The method comprises the following steps: acquiring to-be-forecasted transmission sealing simulation data; constructing a to-be-forecasted transmission sealing simulation model based on the sealing simulation data; loading a to-be-forecasted transmission sealing simulation model: based on the load data, obtaining the meshing force of each gear, and applying the meshing force of each gear to the corresponding position in the simulation model to simulate the stress state of the transmission during torque transmission in actual work; according to the processed to-be-forecasted transmission sealing simulation model, sealing simulation calculation of the to-be-forecasted transmission is completed, and a simulation result data file is output; and processing and checking the sealing simulation result of the transmission to be forecasted based on the simulation result data file. According to the invention, the gluing sealing performance of the transmission assembly shell can be rapidly evaluated and optimized.

Description

Technical Field

[0001] This application relates to the field of vehicle technology, and in particular to a method and system for predicting the adhesive sealing performance of automotive transmission assemblies. Background Technology

[0002] As a core component of power transmission, the reliability of automotive transmissions directly impacts the overall vehicle's operating efficiency and lifecycle cost. Transmission seal failure can lead to serious problems such as lubricant leakage, contaminant intrusion, and system performance degradation. Statistics show that approximately 20%-30% of automotive transmission failures are directly related to sealing system failure. Cracking of the sealant at the transmission housing mating surface is a typical failure mode in commercial vehicle transmissions, further highlighting the importance of ensuring the sealant performance of automotive transmission assemblies.

[0003] Currently, the verification method for the adhesive sealing performance of transmissions mainly relies on experimental testing, but this method has limitations such as long evaluation cycle, slow response, and high testing cost. In the field of simulation analysis, existing research focuses on the strength performance verification of transmissions, with less attention paid to the simulation analysis of sealing performance. Among the patent literature related to transmission sealing performance simulation retrieved, the existing technology has the following key problems in both simulation modeling and result evaluation: ① Simulation modeling: Most studies only apply decomposed loads to the bearing holes of the gear shaft when modeling with finite element method, resulting in oversimplification of the model and failure to consider the influence of gear shaft stiffness. This modeling method not only increases the step time of load decomposition but also leads to low simulation accuracy, making it difficult to accurately reflect actual working conditions; ② Result evaluation: Existing research mainly focuses on the vertical performance of the sealing mating surface (such as opening amount and surface pressure), while rarely analyzing tangential performance. In the patent "Method, Device and Equipment for Detecting Oil Leakage Risk of Transmission Molding Surface" (patent number CN113591222A), although the influence of shear force on the mating surface is considered, only empirical formulas are used to calculate the overall mating surface condition, which cannot accurately locate the dangerous area.

[0004] Based on the above, there is an urgent need for a method and system for predicting the adhesive sealing performance of automotive transmission assemblies, which can quickly evaluate and optimize the adhesive sealing performance of transmission assembly housings. Summary of the Invention

[0005] The purpose of this invention is to provide a method and system for predicting the adhesive sealing performance of automotive transmission assemblies, which can quickly evaluate and optimize the adhesive sealing performance of transmission assembly housings. The specific solution is as follows:

[0006] A method for predicting the adhesive sealing performance of automotive transmission assemblies, the method comprising the following steps:

[0007] S1: Collect the sealing simulation data of the transmission to be predicted; the sealing simulation data includes at least: three-dimensional geometric data of the transmission assembly, structural material data, sealant parameters, and load data; the three-dimensional geometric data includes the transmission housing assembly, transmission gear shaft structure, and connecting structural components;

[0008] S2: Construct a sealing simulation model of the transmission to be predicted based on sealing simulation data;

[0009] S3: Loading the simulated model of the transmission seal to be predicted: Based on the load data in step S1, the meshing force of each gear is obtained, and the meshing force of each gear is applied to the corresponding position in the simulation model to simulate the force state of the transmission when transmitting torque in actual operation.

[0010] S4: Based on the sealing simulation model of the transmission to be predicted processed in step S3, complete the sealing simulation calculation of the transmission to be predicted and output the simulation result data file;

[0011] S5: Based on the simulation result data file, process and verify the sealing simulation results of the transmission to be predicted.

[0012] Optionally, step S2 specifically includes:

[0013] S201: Steps for structural simplification include:

[0014] Finite element simulation software was used to process the simulated model of the transmission seal to be predicted, remove unnecessary structures, simplify non-critical structures, and correct minor modeling defects in the housing sealing interface. Among them, unnecessary structures include at least the shifting mechanism; non-critical structures include at least the gear shaft structure related to stiffness.

[0015] Optionally, step S2 further includes:

[0016] S202: The step of mesh generation for the simplified simulation model of the transmission seal to be predicted, derived from step S201, includes:

[0017] A differentiated mesh generation strategy was used to generate the target mesh model for the transmission assembly;

[0018] For the force transmission structural components, a simplified alternative model is constructed using the stiffness equivalence principle; the force transmission structural components are gear shaft structures of transmission gearboxes.

[0019] For the critical areas of the transmission housing, high-precision meshing is performed using second-order elements with optimized dimensions. For the non-critical areas of the transmission housing, first-order elements are used for appropriate coarsening.

[0020] Optionally, step S2 further includes:

[0021] S203: Steps for defining material properties, including:

[0022] Based on the structural material data in step S1, each mesh of the transmission assembly generated in step S202 is assigned material properties corresponding to its actual material.

[0023] The material properties include at least: elastic modulus and Poisson's ratio.

[0024] Optionally, it also includes:

[0025] S204: Assembly steps for the assembly model, including:

[0026] For each structural component after mesh generation, the interaction relationships between each structural component are predefined; the interaction relationships include: contact relationships and constraint relationships.

[0027] The contact relationships include: bearing clearance / interference fit, friction coefficient of the contact surfaces, separation conditions, and relative sliding; wherein, the contact of the glued sealing surfaces is simulated by adjusting their friction coefficient; the value of the friction coefficient is obtained through comparative analysis of simulation and experimental accuracy.

[0028] The constraint relationships are defined based on the bolt connection method and the rigid fixing method.

[0029] Optionally, step S3 specifically includes:

[0030] Based on the load data in S1, the specifications and torque of the connecting bolts are obtained. The bolt preload is calculated using the relationship between the bolt preload torque and the preload force. The preload force is then applied to each bolt through the preload module.

[0031] Calculate the gear transmission torque conditions based on the bolt preload; the gear transmission torque conditions include: first gear forward and reverse gear, specifically:

[0032] The input torque and gear parameters for each gear of the transmission are obtained based on the load data in S1.

[0033] Based on the input torque and gear parameters of each gear in the transmission, the circumferential force, radial force and axial force of each gear are calculated using the gear meshing force formula;

[0034] Based on the gear transmission characteristics, the directions of the circumferential force, radial force, and axial force of each gear position are determined, and then applied to each pair of gear meshing positions through the force load application module.

[0035] Optionally, step S4 specifically includes:

[0036] Export the S3-processed transmission sealing simulation model to be predicted as a standard input file that can be recognized by finite element simulation software; the standard input file includes: material properties, mesh data, constraint conditions, and load settings;

[0037] Import the standard input file into the solver of the finite element simulation software to generate a simulation result data file; the simulation result data file includes key performance indicators.

[0038] Optionally, step S5 specifically includes:

[0039] Step S501: Post-process the simulation result data file to extract and fit key performance indicators; the key performance indicators include the values ​​of contact surface gap, pressure, and slip, as well as their visual distribution cloud maps;

[0040] Step S502: Analyze key performance indicators and identify oil leakage risk points by identifying areas where the gap and slippage exceed the threshold and locations where the contact pressure distribution is discontinuous.

[0041] Step S503: Verify the analysis results of step S502.

[0042] Optionally, S502 specifically includes:

[0043] Import the simulation result data file into the visualization module, read the extreme values ​​of the contact surface gap and contact surface pressure index, and view the distribution cloud map of the extreme values ​​on the sealing joint surface;

[0044] The contact surface slippage of each unit node in the visualization distribution cloud map is calculated through a sub-module within the visualization module. This contact surface slippage includes slippage under pre-tightening and shifting conditions. The formula for calculating the contact surface slippage under pre-tightening conditions is as follows: ,in, , The relative slippage in the first tangential direction and the second tangential direction under the preload condition; the calculation formula for the contact surface slippage under the gear condition is: ,in, , These represent the relative slippage in the first tangential direction and the second tangential direction, respectively, for the gear operation.

[0045] in, , The sliding direction is the projection of the global coordinate system x-axis onto the contact surface. , and The sliding direction is perpendicular to the contact surface.

[0046] A system for predicting the adhesive sealing performance of automotive transmission assemblies, the system comprising:

[0047] The data acquisition module is configured to collect simulation data of the transmission seal to be predicted; the simulation data includes at least: three-dimensional geometric data of the transmission assembly, structural material data, sealant parameters, and load data; the three-dimensional geometric data includes the transmission housing assembly, transmission gear shaft structure, and connecting structural components;

[0048] The model building module is configured to build a simulation model of the transmission seal to be predicted based on the seal simulation data.

[0049] The loading module is configured to load the transmission sealing simulation model to be predicted: based on the load data, the meshing force of each gear is obtained, and the meshing force of each gear is applied to the corresponding position in the simulation model;

[0050] The calculation module is configured to perform sealing simulation calculations on the transmission to be predicted based on the processed sealing simulation model of the transmission to be predicted, and output simulation result data files.

[0051] The processing and verification module is configured to process and verify the sealing simulation results of the transmission to be predicted based on the simulation result data file.

[0052] The above solution achieves the following beneficial technical effects:

[0053] This application provides a method for predicting the performance of adhesive-coated seals in automotive transmission assemblies. First, it collects sealing simulation data of the transmission to be predicted. Then, it constructs a sealing simulation model of the transmission based on the data. The simulation model is then loaded, and the model performs sealing simulation calculations for the transmission, outputting simulation result data files. Based on these data files, the sealing simulation results are processed and verified. Compared to existing technologies, this application effectively replaces traditional physical testing, using simulation methods for precise simulation, analysis, and evaluation. During transmission design and optimization, it ensures the reliable and durable performance of the adhesive-coated sealing housing while quickly identifying potential leakage risks, guiding design and optimization, significantly shortening the development cycle and reducing costs. Attached Figure Description

[0054] Figure 1 A flowchart for predicting the adhesive sealing performance of automotive transmission assemblies;

[0055] Figure 2 A schematic diagram of a transmission simulation model provided by the present invention;

[0056] Figure 3 A schematic diagram of the gap distribution of the adhesive sealing contact surface of a simulated transmission is provided for this invention.

[0057] Figure 4 A schematic diagram of the pressure distribution cloud map of the adhesive sealing contact surface of a simulated transmission is provided for this invention.

[0058] Figure 5 This invention provides a schematic diagram of the slip distribution cloud map of the adhesive sealing contact surface of a simulated transmission. Detailed Implementation

[0059] To make the purpose, technical solution, and advantages of this application clearer, the following will be described in conjunction with the appendix. Figures 1-5 This application will be described in further detail. It is obvious that the described embodiments are merely some, not all, of the embodiments described herein. All other embodiments obtained by those skilled in the art based on the embodiments described herein without inventive effort are within the scope of protection of this application.

[0060] The terminology used in the embodiments of this application is for the purpose of describing particular embodiments only and is not intended to limit the application. The singular forms “a,” “said,” and “the” used in the embodiments of this application and the appended claims are also intended to include the plural forms, and “multiple” generally includes at least two unless the context clearly indicates otherwise.

[0061] It should be understood that the term "and / or" used in this article is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this article generally indicates that the preceding and following related objects have an "or" relationship.

[0062] It should be understood that although the terms first, second, third, etc., may be used in the embodiments of this application, these descriptions should not be limited to these terms. These terms are only used to distinguish the descriptions. For example, first may also be referred to as second without departing from the scope of the embodiments of this application, and similarly, second may also be referred to as first.

[0063] Depending on the context, the words “if” or “suppose” as used here can be interpreted as “when” or “in response to determination” or “in response to detection.” Similarly, depending on the context, the phrases “if determination” or “if detection (of the stated condition or event)” can be interpreted as “when determination” or “in response to determination” or “when detection (of the stated condition or event)” or “in response to detection (of the stated condition or event).”

[0064] It should also be noted that the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that an article or device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such an article or device. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the article or device that includes said element.

[0065] It should be noted that any symbols and / or numbers present in the specification that are not marked in the accompanying drawings are not reference numerals.

[0066] The optional embodiments of this application are described in detail below with reference to the accompanying drawings.

[0067] Figure 1 The method shown is for predicting the adhesive sealing performance of an automotive transmission assembly, and the method includes the following steps:

[0068] S1: Collect the sealing simulation data of the transmission to be predicted; the sealing simulation data includes at least: three-dimensional geometric data of the transmission assembly, structural material data, sealant parameters, and load data; the three-dimensional geometric data includes the transmission housing assembly, transmission gear shaft structure, and connecting structural components;

[0069] The structural components in the 3D geometric data should be assembled according to the design assembly relationships and output as .stp format assembly files conforming to the STEP standard. The main structural components include the transmission front housing, transmission middle housing, transmission rear housing, bearing caps, top cover, cover plates, main and auxiliary gear shafts, gears for each gear, bolts, etc.; structural material data, including material grades and standards in the 3D geometry, with parameters such as elastic modulus and Poisson's ratio provided as comprehensively as possible; sealant parameters, including the maximum elongation at break and static thickness of the sealant between housings; load data, including the specifications and tightening torque of the housing connecting bolts under transmission preload conditions, the input torque and gear parameters for each gear condition, with gear parameters referring to the number of teeth, end face pressure angle at the pitch circle, pitch circle diameter, helix angle at the pitch circle, and helix angle direction, etc., as shown in the design drawings.

[0070] S2: Construct a sealing simulation model of the transmission to be predicted based on sealing simulation data;

[0071] It can be understood that the transmission sealing simulation model to be predicted refers to the transmission model obtained by using simulation modeling software to simulate and model the transmission assembly to be predicted based on simulation data.

[0072] S3: Loading the simulation model of the transmission seal to be predicted: Based on the load data in step S1, the meshing force of each gear is obtained, and the meshing force of each gear is applied to the corresponding position in the simulation model to simulate the stress state of the transmission when transmitting torque in actual operation; among them, the accuracy of the load determines whether the simulation results can reflect the real sealing performance.

[0073] S4: Based on the sealing simulation model of the transmission to be predicted processed in step S3, complete the sealing simulation calculation of the transmission to be predicted and output the simulation result data file;

[0074] S5: Based on the simulation result data file, process and verify the sealing simulation results of the transmission to be predicted.

[0075] This application first collects sealing simulation data of the transmission to be predicted, then constructs a sealing simulation model of the transmission based on the data, loads the simulation model, performs sealing simulation calculations on the transmission, and outputs simulation result data files. Based on these data files, the sealing simulation results are processed and verified. Compared to existing technologies, this application can effectively replace traditional physical testing, using simulation methods for accurate simulation, analysis, and evaluation. During transmission design and optimization, it ensures the reliable and durable performance of the adhesive-coated sealing shell while quickly identifying potential leakage risks, guiding design and optimization, significantly shortening the development cycle and reducing costs.

[0076] In one specific embodiment, step S2 specifically includes:

[0077] S201: Steps for structural simplification include:

[0078] Finite element simulation software was used to process the simulated model of the transmission seal to be predicted, remove unnecessary structures, simplify non-critical structures, and correct minor modeling defects in the housing sealing interface. Among them, unnecessary structures include at least the shifting mechanism; non-critical structures include at least the gear shaft structure related to stiffness.

[0079] Specifically, this application processes the simulation model of the gearbox seal to be predicted through structural simplification steps, thereby reducing the complexity of the model while ensuring computational accuracy.

[0080] It is understood that in this embodiment, the preprocessing for transmission sealing simulation is performed based on the three-dimensional geometric data provided in step S101. First, the geometric model of the transmission assembly is simplified in a targeted manner based on the simulation target. Hypermesh software is used to complete professional geometric cleaning, focusing on removing unnecessary structures such as the shift mechanism that have no substantial impact on the sealing performance analysis. Second, non-critical structural components such as gear shafts that affect stiffness are locally simplified (such as removing small details), which significantly reduces the complexity of the model while ensuring the calculation accuracy.

[0081] In addition, through systematic geometric quality checks, minor modeling defects in key structures such as the shell (e.g., the shell sealing interface) are precisely corrected, ensuring the geometric integrity and computational reliability of the simulation model and laying the foundation for subsequent high-precision sealing analysis.

[0082] In one specific embodiment, step S2 further includes:

[0083] S202: The step of mesh generation for the simplified simulation model of the transmission seal to be predicted, derived from step S201, includes:

[0084] A differentiated mesh generation strategy was used to generate the target mesh model for the transmission assembly;

[0085] For the force transmission structural components, a simplified alternative model is constructed using the stiffness equivalence principle; the force transmission structural components are gear shaft structures of transmission gearboxes.

[0086] For the critical areas of the transmission housing, high-precision meshing is performed using second-order elements with optimized dimensions. For the non-critical areas of the transmission housing, first-order elements are used for appropriate coarsening.

[0087] Specifically, in this embodiment, a differentiated meshing strategy is used to generate the target mesh model of the transmission assembly for the simplified structure, achieving a balance between computational accuracy and efficiency. For non-critical force-transmitting structural components such as gear shafts, a simplified alternative model is constructed based on the principle of stiffness equivalence, significantly reducing the number of meshes while ensuring accurate mechanical transmission characteristics. For critical areas such as the transmission housing, especially the sealing mating surfaces, which directly affect sealing performance, high-precision meshing is performed using size-optimized second-order elements, achieving fine meshing with a recommended mesh size of 2-4 mm, thus significantly improving computational accuracy. For other non-critical structural components in non-critical areas of the transmission housing, first-order elements are uniformly used for moderate coarsening, with a recommended mesh size of 5-8 mm. The advantage of this design is that, through a multi-scale meshing method, it has been verified that while effectively reducing the total number of model elements, it can accurately calculate the core mechanical properties related to sealing, shorten simulation computation time, and achieve an optimal balance between computational accuracy and efficiency.

[0088] It should be further noted that this embodiment introduces a gear shaft system model, which is simplified based on the principle of stiffness equivalence to ensure that the model can reflect the true stiffness characteristics while maintaining computational efficiency. A differentiated meshing strategy is adopted, using a high-precision mesh in key areas (such as sealing surfaces) and appropriately coarsening the mesh in non-critical areas to balance simulation accuracy and computational speed.

[0089] In one specific embodiment, step S2 further includes:

[0090] S203: Steps for defining material properties, including:

[0091] Based on the structural material data in step S1, each mesh of the transmission assembly generated in step S202 is assigned material properties corresponding to its actual material.

[0092] The material properties include at least: elastic modulus and Poisson's ratio.

[0093] Specifically, in this embodiment, based on the structural material data provided in step S1, each grid of the structural components of the transmission assembly generated in step S202 is assigned a material property corresponding to its actual material. It can be understood that by assigning a material property that matches the actual material to each structural component after grid division, it can be ensured that the behavior of the transmission sealing simulation model to be predicted is consistent with the mechanical performance of the real transmission assembly.

[0094] In one specific embodiment, it further includes:

[0095] S204: Assembly steps for the assembly model, including:

[0096] For each structural component after mesh generation, the interaction relationships between each structural component are predefined; the interaction relationships include: contact relationships and constraint relationships.

[0097] The contact relationships include: bearing clearance / interference fit, friction coefficient of the contact surfaces, separation conditions, and relative sliding; wherein, the contact of the glued sealing surfaces is simulated by adjusting their friction coefficient; the value of the friction coefficient is obtained through comparative analysis of simulation and experimental accuracy.

[0098] The constraint relationships are defined based on the bolt connection method and the rigid fixing method.

[0099] Specifically, this application determines the connection relationships between various structural components through the assembly steps of the assembly model, such as the contact of adhesive surfaces, bearing fit, and fixing constraints. The sealing simulation model needs to be adjusted according to the specific design characteristics and simulation objectives of the transmission to ensure the quality of the simulation model so as to accurately capture the transmission's response under load.

[0100] Furthermore, this embodiment accurately simulates the contact behavior between various structures. The contact relationships include factors such as bearing clearance / interference fit, friction coefficient of the contact surface, separation conditions, and relative sliding, thereby reflecting the interaction under real loads. For the sealing contact surface of the shell coated with sealant, which is of particular concern, since the sealant thickness is negligible compared to a rigid shell, this invention simplifies the structure by adjusting the friction coefficient properties of the sealant-coated contact surface to simulate the actual interaction. The specific value of the friction coefficient is obtained through comparative analysis of simulation and experimental accuracy. It should be further noted that in this embodiment, the simulation modeling of the shell sealant contact surface uses an equivalent friction model for efficient simulation, and its values ​​are determined through comparison of simulation and experiments. This simplified method effectively improves the calculation efficiency of contact nonlinear analysis while maintaining computational accuracy, balancing the needs of engineering practicality and simulation realism.

[0101] Furthermore, by reasonably setting constraints such as bolted connections and rigid fixation, we ensure that the boundary conditions of the support structure, shell, and installation points conform to the actual assembly state.

[0102] It is understandable that by completing the above steps, the modeling of the transmission sealing performance simulation is completed, and the corresponding simulation model of the transmission is obtained. Figure 2 This is a schematic diagram of a simulation transmission model provided in an embodiment of the present invention. The model shown in the figure is a simulation transmission model obtained by simulating the over-sealing performance of the transmission to be predicted.

[0103] In one specific embodiment, step S3 specifically includes:

[0104] Based on the load data in S1, the specifications and torque of the connecting bolts are obtained. The bolt preload is calculated using the relationship between the bolt preload torque and the preload force. The preload force is then applied to each bolt through the preload module.

[0105] Calculate the gear transmission torque conditions based on the bolt preload; the gear transmission torque conditions include: first gear forward and reverse gear, specifically:

[0106] The input torque and gear parameters for each gear of the transmission are obtained based on the load data in S1.

[0107] Based on the input torque and gear parameters of each gear in the transmission, the circumferential force, radial force and axial force of each gear are calculated using the gear meshing force formula;

[0108] Based on the gear transmission characteristics, the directions of the circumferential force, radial force, and axial force of each gear position are determined, and then applied to each pair of gear meshing positions through the force load application module.

[0109] It is understandable that in order to reproduce the actual stress state of the transmission during operation in the transmission sealing simulation model, the transmission sealing simulation includes two types of working conditions: bolt preload and gear torque transmission.

[0110] Among them, the bolt pre-tightening condition: based on the bolt specifications and torque provided in step S1, the bolt pre-tightening force is calculated from the relationship between bolt pre-tightening torque and pre-tightening force, and the pre-tightening force is applied to each bolt through the Hypermesh Pre-Tension function;

[0111] Gear torque transmission condition: This condition is calculated based on the bolt preload condition and includes first gear forward and reverse gear conditions. Based on the input torque and gear parameters of each gear condition provided in step S1, the circumferential force, radial force and axial force of each gear are calculated by the gear meshing force formula. According to the gear transmission characteristics, the direction of the load is determined and applied to each pair of gear meshing positions through the Hypermesh Force function.

[0112] It is understood that in this embodiment, the equivalent gear force load is used to replace the traditional bearing hole decomposed load. This not only includes the magnitude of the force, but also considers the direction and point of application of the force, so as to more accurately simulate the force state of the transmission during the torque transmission process. At the same time, it considers various force conditions such as bolt preload condition and gear torque transmission condition (first gear forward condition and reverse gear condition), thereby improving the reliability of the simulation results.

[0113] In one specific embodiment, step S4 specifically includes:

[0114] Export the S3-processed transmission sealing simulation model to be predicted as a standard input file that can be recognized by finite element simulation software; the standard input file includes: material properties, mesh data, constraint conditions, and load settings;

[0115] Import the standard input file into the solver of the finite element simulation software to generate a simulation result data file; the simulation result data file includes key performance indicators.

[0116] Specifically, in this embodiment, the simulation model processed in step S3 is output as a standard input .inp file that can be recognized by the ABAQUS software. This file fully encapsulates all the key parameters of the simulation model in a structured data format, including material properties, mesh data, constraints, and load settings. After the ABAQUS solver calculates the .inp file, the system generates a .odb simulation result data file, which records the detailed response of the model during the simulation process. The detailed response includes key performance indicators related to displacement and contact, in order to provide detailed data support for subsequent evaluation and analysis.

[0117] In one specific embodiment, step S5 specifically includes:

[0118] Step S501: Post-process the simulation result data file to extract and fit key performance indicators; the key performance indicators include the values ​​of contact surface gap, pressure, and slip, as well as their visual distribution cloud maps;

[0119] Step S502: Analyze key performance indicators and identify oil leakage risk points by identifying areas where the gap and slippage exceed the threshold and locations where the contact pressure distribution is discontinuous.

[0120] Step S503: Verify the analysis results of step S502.

[0121] Specifically, in this embodiment, the simulation results data file of the sealing performance is first post-processed to extract and fit key sealing quantification indicators, including the values ​​of contact surface gap, pressure, and slippage, as well as their visualized distribution cloud maps. These indicators can intuitively reflect the sealing performance of the transmission. Then, through a comprehensive evaluation and analysis of the sealing calculation results, the rationality of the design is verified instead of physical tests. By quickly locating potential leakage risks through simulation, design and optimization can be guided, significantly shortening the development cycle and reducing costs.

[0122] In one specific embodiment, S502 specifically includes:

[0123] Import the simulation result data file into the visualization module, read the extreme values ​​of the contact surface gap and contact surface pressure index, and view the distribution cloud map of the extreme values ​​on the sealing joint surface;

[0124] The contact surface slippage of each unit node in the visualization distribution cloud map is calculated through a sub-module within the visualization module. This contact surface slippage includes slippage under pre-tightening and shifting conditions. The formula for calculating the contact surface slippage under pre-tightening conditions is as follows: ,in, , These represent the relative slippage in the first tangential direction and the second tangential direction under the preload condition, respectively; the formula for calculating the slippage of the contact surface under the shift condition is: ,in, , These represent the relative slippage in the first tangential direction and the second tangential direction, respectively, for the gear operation.

[0125] in, , The sliding direction is the projection of the global coordinate system x-axis onto the contact surface. , and The sliding direction is perpendicular to the contact surface.

[0126] Specifically, in this implementation, the contact surface gap and contact surface pressure indicators can be directly read by importing the .odb result data into the ABAQUS Visualization module to view extreme values ​​and distribution cloud maps. The innovative addition of an optimized contact surface slip distribution evaluation indicator requires calculation of the values ​​of each node in the visualized distribution cloud map using the ABAQUS Create FieldOutput function module (a sub-module within the visualization module), thereby identifying oil leakage risk points. Based on this, for the identified high-risk areas, the contact state and pressure distribution uniformity can be effectively improved by locally enhancing the stiffness of the transmission housing or optimizing the size, quantity, and arrangement of bolt connections, thereby improving the overall sealing performance of the transmission housing assembly and meeting the durability and reliability requirements of the engineering design.

[0127] See Figures 3-5 In this embodiment, the analysis results of step S502 are verified, specifically by evaluating the results using extreme values ​​and distribution cloud maps. The maximum values ​​of the contact surface gap and contact surface slippage must be less than their respective preset thresholds, which are determined based on sealant parameters and experience. There must be no discontinuous areas in the contact surface pressure distribution. The locations of the maximum values ​​of the contact surface gap and contact surface slippage, as well as the locations of discontinuous contact surface pressure distribution, all indicate potential oil leakage risks, providing a theoretical basis for subsequent sealing structure design optimization. Furthermore, through extensive engineering data accumulation and comparative verification with physical bench tests, the sealing prediction results of this application are highly reliable. After simulation, the first-pass rate of the sealing bench test reaches 100%, completely replacing bench tests. This ensures that the sealing performance of the transmission housing assembly meets usage requirements, saves assembly bench test costs and prototype manufacturing costs, reduces assembly development time, and shortens the assembly development process.

[0128] In summary, the method for predicting the adhesive sealing performance of automotive transmission assemblies provided in this embodiment is based entirely on computer simulation and has been verified through experimental comparison. The simulation results highly match those of bench tests, completely replacing traditional testing, significantly shortening the development cycle and reducing costs. It is applicable to the optimized design of sealing performance for transmissions in gasoline, hybrid, and pure electric vehicles. It can be applied to scenarios such as transmission development and oil leak risk prediction, helping companies reduce costs and increase efficiency.

[0129] On the other hand, this application provides a system for predicting the adhesive sealing performance of automotive transmission assemblies, the system comprising:

[0130] The data acquisition module is configured to collect simulation data of the transmission seal to be predicted; the simulation data includes at least: three-dimensional geometric data of the transmission assembly, structural material data, sealant parameters, and load data; the three-dimensional geometric data includes the transmission housing assembly, transmission gear shaft structure, and connecting structural components;

[0131] The model building module is configured to build a simulation model of the transmission seal to be predicted based on the seal simulation data.

[0132] The loading module is configured to load the sealed simulation model of the transmission to be predicted: based on the load data, the meshing force of each gear is obtained, and the meshing force of each gear is applied to the corresponding position in the simulation model to simulate the force state of the transmission when transmitting torque in actual operation.

[0133] The calculation module is configured to perform sealing simulation calculations on the transmission to be predicted based on the processed sealing simulation model of the transmission to be predicted, and output simulation result data files.

[0134] The processing and verification module is configured to process and verify the sealing simulation results of the transmission to be predicted based on the simulation result data file.

[0135] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of this patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this application should be determined by the appended claims.

Claims

1. A method for predicting the adhesive sealing performance of an automotive transmission assembly, the method comprising the following steps: S1: Collect simulation data of the transmission seal to be predicted; The sealing simulation data includes at least: three-dimensional geometric data of the transmission assembly, structural material data, sealant parameters, and load data; the three-dimensional geometric data includes the transmission housing assembly, transmission gear shaft structure, and connecting structural components; S2: Construct a sealing simulation model of the transmission to be predicted based on sealing simulation data; S3: Loading the simulated model of the transmission seal to be predicted: Based on the load data in step S1, the meshing force of each gear is obtained, and the meshing force of each gear is applied to the corresponding position in the simulation model to simulate the force state of the transmission when transmitting torque in actual operation. S4: Based on the sealing simulation model of the transmission to be predicted processed in step S3, complete the sealing simulation calculation of the transmission to be predicted and output the simulation result data file; S5: Based on the simulation result data file, process and verify the sealing simulation results of the transmission to be predicted.

2. The method according to claim 1, characterized in that, Step S2 specifically includes: S201: The steps for structural simplification include: Finite element simulation software was used to process the simulated model of the transmission seal to be predicted, remove unnecessary structures, simplify non-critical structures, and correct minor modeling defects in the housing sealing interface. Among them, unnecessary structures include at least the shifting mechanism; non-critical structures include at least the gear shaft structure related to stiffness.

3. The method according to claim 2, characterized in that, Step S2 further includes: S202: The step of mesh generation for the simplified simulation model of the transmission seal to be predicted, derived from step S201, includes: A differentiated mesh generation strategy was used to generate the target mesh model for the transmission assembly; For the force transmission structural components, a simplified alternative model is constructed using the stiffness equivalence principle; the force transmission structural components are gear shaft structures of transmission gearboxes. For the critical areas of the transmission housing, high-precision meshing is performed using second-order elements with optimized dimensions. For the non-critical areas of the transmission housing, first-order elements are used for appropriate coarsening.

4. The method according to claim 3, characterized in that, Step S2 further includes: S203: Steps for defining material properties, including: Based on the structural material data in step S1, each mesh of the transmission assembly generated in step S202 is assigned material properties corresponding to its actual material. The material properties include at least: elastic modulus and Poisson's ratio.

5. The method according to claim 4, characterized in that, Also includes: S204: Assembly steps for the assembly model, including: For each structural component after mesh generation, the interaction relationships between each structural component are predefined; the interaction relationships include: contact relationships and constraint relationships. The contact relationships include: bearing clearance / interference fit, friction coefficient of the contact surfaces, separation conditions, and relative sliding; wherein, the contact of the glued sealing surfaces is simulated by adjusting their friction coefficient; the value of the friction coefficient is obtained through comparative analysis of simulation and experimental accuracy. The constraint relationships are defined based on the bolt connection method and the rigid fixing method.

6. The method according to claim 5, characterized in that, Step S3 specifically includes: Based on the load data in S1, the specifications and torque of the connecting bolts are obtained. The bolt preload is calculated using the relationship between the bolt preload torque and the preload force. The preload force is then applied to each bolt through the preload module. Calculate the gear transmission torque conditions based on the bolt preload; the gear transmission torque conditions include: first gear forward and reverse gear, specifically: The input torque and gear parameters for each gear of the transmission are obtained based on the load data in S1. Based on the input torque and gear parameters of each gear in the transmission, the circumferential force, radial force and axial force of each gear are calculated using the gear meshing force formula; Based on the gear transmission characteristics, the directions of the circumferential force, radial force, and axial force of each gear position are determined, and then applied to each pair of gear meshing positions through the force load application module.

7. The method according to claim 6, characterized in that, Step S4 specifically includes: Export the S3-processed transmission sealing simulation model to be predicted as a standard input file that can be recognized by finite element simulation software; the standard input file includes: material properties, mesh data, constraint conditions, and load settings; Import the standard input file into the solver of the finite element simulation software to generate a simulation result data file; the simulation result data file includes key performance indicators.

8. The method according to claim 7, characterized in that, Step S5 specifically includes: Step S501: Post-process the simulation result data file to extract and fit key performance indicators; the key performance indicators include the values ​​of contact surface gap, pressure, and slip, as well as their visual distribution cloud maps; Step S502: Analyze key performance indicators and identify oil leakage risk points by identifying areas where the gap and slippage exceed the threshold and locations where the contact pressure distribution is discontinuous. Step S503: Verify the analysis results of step S502.

9. The method according to claim 8, characterized in that, S502 specifically includes: Import the simulation result data file into the visualization module, read the extreme values ​​of the contact surface gap and contact surface pressure index, and view the distribution cloud map of the extreme values ​​on the sealing joint surface; The contact surface slippage of each unit node in the visualization distribution cloud map is calculated through a sub-module within the visualization module. This contact surface slippage includes slippage under pre-tightening and shifting conditions. The formula for calculating the contact surface slippage under pre-tightening conditions is as follows: ,in, , These represent the relative slippage in the first tangential direction and the second tangential direction under the preload condition, respectively; the formula for calculating the slippage of the contact surface under the shift condition is: ,in, , These represent the relative slippage in the first tangential direction and the second tangential direction, respectively, for the gear operation. in, , The sliding direction is the projection of the global coordinate system x-axis onto the contact surface. , and The sliding direction is perpendicular to the contact surface.

10. A system for predicting the adhesive sealing performance of automotive transmission assemblies, characterized in that, The system includes: The data acquisition module is configured to collect simulation data of the transmission seal to be predicted; the simulation data includes at least: three-dimensional geometric data of the transmission assembly, structural material data, sealant parameters, and load data; the three-dimensional geometric data includes the transmission housing assembly, transmission gear shaft structure, and connecting structural components; The model building module is configured to build a simulation model of the transmission seal to be predicted based on the seal simulation data. The loading module is configured to load the transmission sealing simulation model to be predicted: based on the load data, the meshing force of each gear is obtained, and the meshing force of each gear is applied to the corresponding position in the simulation model; The calculation module is configured to perform sealing simulation calculations on the transmission to be predicted based on the processed sealing simulation model of the transmission to be predicted, and output simulation result data files. The processing and verification module is configured to process and verify the sealing simulation results of the transmission to be predicted based on the simulation result data file.

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