A cratering simulation test device
By designing a pit-fall simulation test device, the problem of insufficient accuracy in CAE simulation analysis and whole vehicle durability testing has been solved, achieving more efficient and accurate verification of automotive structural strength and meeting the needs of user scenarios.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- JIANGLING MOTORS
- Filing Date
- 2025-05-26
- Publication Date
- 2026-06-23
Smart Images
Figure CN224398985U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of automobile inspection, specifically to a pit-fall simulation test device. Background Technology
[0002] The government is increasingly tightening its regulation of the automotive market. In recent years, the government has successively promulgated a series of laws and regulations regarding vehicle recalls, clarifying that automobile manufacturers must promptly initiate recall procedures when quality and safety hazards are discovered in their products. These regulations detail the scope, procedures, and responsibilities of recalls. At the same time, relevant departments have strengthened supervision and inspection of vehicle recall work to ensure that companies strictly fulfill their recall obligations in accordance with regulations, protecting consumers' right to know and right to choose. Once a safety hazard is discovered in a vehicle that affects its normal use or even endangers the safety of the driver and passengers, a recall should be initiated. Currently, automakers typically use the following methods for strength verification:
[0003] 1) Strength simulation verification is performed using CAE (Computer-Aided Engineering). This involves defining simulation targets, collecting relevant data, constructing a 3D model, meshing, applying appropriate boundary conditions and loads, and running simulation calculations to obtain the stress, deformation, and fatigue life of the structure. However, CAE strength simulations are not always accurate, and the results may mislead the design due to several reasons. First, the accuracy of the model itself is crucial. If the original CAD model is overly simplified or fails to fully reflect the complex details of the actual structure, the simulation results will not reliably predict actual performance. Second, accurate input of material properties has a significant impact on the simulation results; inaccurate material data will directly lead to errors in the simulation output. Third, mesh generation is also a key factor affecting accuracy; inappropriate mesh size and type may result in important stress concentration areas not being fully analyzed, thus affecting the overall accuracy of the results. Fourth, the setting of boundary conditions and loads must accurately simulate the actual working environment; any deviation will cause the simulation results to deviate from reality. Finally, the algorithms and calculation methods of the simulation software itself may also have limitations, especially when dealing with highly nonlinear problems or complex multiphysics problems; simplification of the calculation model and insufficient numerical solution may lead to inaccurate results.
[0004] 2) Verification is conducted during routine vehicle durability testing, i.e., adaptability verification is performed within the vehicle durability testing process. Routine vehicle durability testing and vehicle strength testing are two key verification methods in automotive development. Although both aim to assess vehicle reliability, their focuses differ. Routine vehicle durability testing aims to evaluate and verify the vehicle's overall reliability under simulated real-world usage conditions, focusing on reliability during long-term, long-mileage use. This type of testing helps identify wear, aging, and fatigue failures that may occur due to prolonged use. Vehicle strength testing, on the other hand, focuses more on assessing the strength and rigidity of the vehicle structure, emphasizing the detection of structural safety and integrity when subjected to sudden gravitational impacts. Although the conditions designed for routine vehicle durability testing are somewhat enhanced compared to ordinary user daily use, the enhancement coefficient is too low relative to the strength verification requirements. In one routine durability test, the impact surface height in the case of the highest strength impact was only 5cm. If routine vehicle durability testing were used instead of vehicle strength testing for verification and issuance, it could lead to a large number of strength failures in the aftermarket.
[0005] In summary, while CAE simulation analysis can predict potential structural problems in the early design stage, its results may deviate from reality due to limitations in model assumptions and material properties. Therefore, relying solely on CAE simulation results to assess the structural strength of a vehicle may lead to an incomplete analysis, failing to fully identify potential problems encountered in actual use. Furthermore, vehicle durability verification focuses on identifying problems that may arise during daily use and cannot fully expose potential structural design flaws. Utility Model Content
[0006] To address the aforementioned problems, this utility model provides a crater simulation test device and its specific application. The specific technical solution is as follows:
[0007] A pit-fall simulation test device includes an acceleration section, a pit-fall section, and a deceleration section. The acceleration section is at least 200m long, with a length sufficient to accelerate to the target vehicle speed, and can be extended if necessary. The pit depth is at least 120mm, the pit width is at least 1000mm, and the pit length is at least 400mm greater than the width of the test vehicle, and can be extended if necessary. The pit edge is chamfered at R10, simulating the fact that the edges of real pits on the road are not sharp. The deceleration section is at least 60m long, with a length sufficient to achieve safe deceleration and stopping, and can be extended if necessary.
[0008] Furthermore, the pit is at least 3000m long.
[0009] The beneficial effects of this utility model are as follows: the development and application of the pit-fall simulation test device can be based on user scenario data, and the test results can well reflect the user's usage needs; the design of standard test devices and operating procedures can provide stable boundaries for the design; based on statistical results, one test can replace multiple tests, resulting in very high verification efficiency; and the refined acceptance criteria provide strong support for the consistency evaluation of the test. Attached Figure Description
[0010] Figure 1 A front view of the pit-falling simulation test device of this utility model;
[0011] Figure 2 Left view schematic diagram of the pit-falling simulation test device of this utility model;
[0012] Figure 3 A schematic diagram of the overall vehicle structural strength development process; Detailed Implementation
[0013] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.
[0014] A type of pit-fall simulation test device, such as Figure 1-2 As shown, the device includes an acceleration section, a pit landing section, and a deceleration section. The acceleration section is at least 200m long, with a length sufficient to accelerate to the target vehicle speed, and can be extended if necessary. The pit landing section is at least 120mm deep, at least 1000mm wide, and at least 400mm longer than the width of the test vehicle, with a minimum length of 3000mm, and can be extended if necessary. The pit edge is chamfered at R10, simulating the fact that real pits on the road do not have sharp edges. The deceleration section is at least 60m long, with a length sufficient to achieve safe deceleration and stopping, and can be extended if necessary.
[0015] A schematic diagram of the process for conducting a whole vehicle strength test using the pit-fall simulation test device of this utility model is shown below. Figure 3 As shown, the steps are as follows:
[0016] (1) Analysis and screening of unexpected impact scenarios
[0017] Through T-BOX big data screening, 216 users with high usage scenarios in different cities and county / township roads, high average annual mileage and cumulative mileage, and 167 users who had experienced serious chassis structural failures were selected for telephone surveys on unexpected major impact scenarios. Preliminary findings indicate that "sudden falling into a ditch" and "sudden impact from a high road obstacle" are the most frequent unexpected situations encountered by users in daily use.
[0018] (2) Collect information on road impacts and user driving behavior.
[0019] A questionnaire was designed to collect information on the types and locations of unexpected scenarios. Information on the dimensions of these scenarios and user driving behavior was collected. Based on the location information of potholes provided by users, the dimensions of all collected potholes were measured and the relevant data was recorded. Simultaneously, vehicle driving behavior was monitored for one week for potholes with the highest depth, including vehicle speed and braking behavior. The statistical results are shown in Table 1. Table 1 shows that the highest vehicle speed users reached when passing the deepest potholes (110-120mm) was 65-70 km / h, accounting for approximately 0.2% of all users.
[0020] Table 1 shows the drivability of vehicles traversing different potholes (statistical results).
[0021]
[0022] (3) Falling into the pit simulation test device and operation design
[0023] Diagram of the pit-falling simulation device Figure 1-2 As shown, the pit is 120mm deep, 1000mm wide, and 3000mm long (it must be 400mm wider than the vehicle width; it can be extended if necessary). The pit edge is chamfered at R10 (the edges of real pits on the road are not sharp; chamfering is used to simulate them). The acceleration section is 200m long (the length ensures that the vehicle can accelerate to the target speed; it can be extended if necessary). The deceleration section is 60m long (the length ensures that the vehicle can safely decelerate and stop; it can be extended if necessary).
[0024] Test Operation: Vehicle Condition and Test Facility Matching Check: Ensure that the vehicle's steering, braking, suspension and other systems meet the design intent, and that the assembly process and torque meet the assembly process requirements; if the vehicle's ground clearance may cause interference with potholes, the front and rear bumpers can be removed, and even shims can be used to adjust the pothole depth to a state where chassis parts do not interfere with the edge of the pothole.
[0025] Loading, equipment installation and debugging: Load the vehicle according to the wheel load distribution requirements of full load, and install and debug the GPS / BeiDou speed measurement equipment on the vehicle to ensure that the speed measurement equipment can reflect the vehicle's true speed.
[0026] Pothole simulation test: Drive the vehicle to the starting point of the acceleration section, align the vehicle with the pothole, and accelerate with the accelerator pedal fully open. Maintain the speed of 70km / h (the actual allowable deviation is ±2km / h; if the deviation is exceeded, the test needs to be repeated). After passing the pothole, brake to a stop with maximum deceleration (simulating the user's driving behavior after falling into the pothole).
[0027] (4) Trial acceptance criteria
[0028] After the test, a failure level not exceeding level 8 is considered a pass. The definition of failure severity level is shown in Table 2.
[0029] Table 2 Fault Level Definitions
[0030]
[0031] Taking the front suspension system as an example, the common level 9 and 10 failure modes are shown in the table below.
[0032]
[0033] The preferred embodiments of this patent have been described in detail above. However, this patent is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of this patent.
Claims
1. A crater-falling simulation test device, characterized in that: The device includes an acceleration section, a pit landing section, and a deceleration section. The acceleration section is at least 200m long; the pit landing section is at least 120mm deep, at least 1000mm wide, and at least 400mm longer than the width of the test vehicle; the pit edge is chamfered at R10; and the deceleration section is at least 60m long.
2. The crater simulation test device according to claim 1, characterized in that: The pit is at least 3000m long.