A simulated load for durability testing

Abstract

The utility model relates to a kind of simulation loaders for doing durability experiment, belong to hydraulic braking system pressure building durability experiment technical field.Pressurizing device is fixedly connected in the middle part outside of rack, limiting device one end is connected with the middle part of rack through linear bearing, other end is connected with pressurizing device, pressure piece is sleeved on limiting device.Advantage is novel structure, through function simplification and fatigue resistance design, stripping real caliper redundant mechanical function, only keep core hydraulic load simulation characteristic, make vulnerable part and main structure separate, realize "directional loss, local replacement", reduce experimental cost and promote test efficiency.It can reliably cycle under the same pressure condition≥100 million times, and only need to replace spring and main cylinder vulnerable part, replacement cost is low, maintenance cost is reduced by more than 70% compared with traditional caliper, and service life is long.

Description

Technical Field

[0001] This utility model belongs to the fields of electro-hydraulic braking system (EHB), integrated electro-hydraulic braking system (IEHB), and pressure build-up durability testing technology, and particularly relates to a simulated load device for conducting durability tests. Background Technology

[0002] With the rapid development of new energy vehicles and intelligent driving technologies, electro-hydraulic braking systems (EHB) and integrated electro-hydraulic braking systems (IEHB) have become core technologies in the automotive braking field due to their high integration, energy recovery efficiency, and drive-by-wire characteristics. In pressure build-up durability tests, the reliability, sealing performance, and mechanical life of the braking system need to be verified through high-frequency cyclic pressure build-up and depressurization processes. Current experimental schemes generally use original automotive wheel calipers as the load actuators; however, this approach has the following drawbacks:

[0003] Insufficient lifespan: The caliper is designed for dynamic braking conditions of vehicles. Under high-frequency pressure build-up tests (≥100 times / minute) and constant pressure cycles (0-15MPa), the seals, friction pairs and housing are prone to fatigue failure. The reliable cycle count is only about 300,000 times, which is lower than the system requirement of 1 million cycles.

[0004] High cost: A single set of calipers costs 500-2000 yuan, 4 sets are needed for a single experiment, and 3 sets are needed to complete 1 million experiments, with hardware costs reaching 6000-24000 yuan. Moreover, replacement and maintenance take 2-4 hours, extending the experimental cycle by 30%-50%.

[0005] Functional redundancy interference: The wear compensation and parking linkage functions of the real caliper do not match the experimental requirements, which can easily cause abnormal piston stroke during high-frequency pressure cycling, resulting in data distortion.

[0006] Therefore, there is an urgent need for a simulation load device specifically designed for durability experiments to solve the problems of short lifespan, high cost, and insufficient simulation accuracy of existing solutions, thereby improving experimental efficiency and reliability. Summary of the Invention

[0007] This invention provides a simulated load device for durability testing, which solves the problems of short service life of calipers and high cost of replacing calipers in pressure-building durability testing.

[0008] The technical solution adopted by this utility model is as follows: it includes a pressure applying device, a pressure receiving component, a limiting device, and a frame. The pressure applying device is fixedly connected to the outer side of the middle part of the frame. One end of the limiting device is connected to the middle part of the frame through a linear bearing, and the other end is connected to the pressure applying device. The pressure receiving component is sleeved on the limiting device.

[0009] The pressure application device includes a main cylinder, a piston, and a main cylinder inlet. The main cylinder has a main cylinder inlet, the piston slides inside the main cylinder, and the front end of the piston is fixedly connected to the spring limiting shaft of the limiting device.

[0010] The pressure-bearing component is a load spring.

[0011] The limiting device includes a linear bearing and a spring limiting shaft, wherein the spring limiting shaft is slidably connected to the linear bearing, the linear bearing is fixedly connected to the outer side of the middle part of the rear baffle of the frame, and the load spring is sleeved on the spring limiting shaft.

[0012] The spring limiting shaft has a spring limiting seat.

[0013] The frame includes a front baffle, a rear baffle, and long bolts. The front baffle and the rear baffle are fixedly connected at both ends to form an integral frame by long bolts. The main cylinder of the pressure device is fixedly connected to the outer side of the middle part of the front baffle.

[0014] The advantages of this invention are its novel structure, consisting of a modular loading mechanism comprised of a front baffle, piston, spring-limiting shaft, and rear baffle, along with standardized sealing components and universal connecting parts. This structure, through functional simplification and fatigue-resistant design, eliminates redundant mechanical functions of a real caliper, retaining only the core hydraulic load simulation characteristics. This separates vulnerable parts (load spring, main cylinder) from the main structure, achieving "directional wear and partial replacement," reducing experimental costs and improving testing efficiency. Under the same pressure conditions, it reliably cycles ≥ 1 million times, requiring only replacement of the spring and main cylinder, resulting in low replacement costs and maintenance costs that are more than 70% lower than traditional calipers, while also offering a long service life. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of this utility model;

[0016] Figure 2 This is a cross-sectional view of the present invention. Detailed Implementation

[0017] It includes a pressure applying device 1, a pressure receiving component 2, a limiting device 3, and a frame 4. The pressure applying device 1 is fixedly connected to the outer side of the middle part of the frame 4. One end of the limiting device 3 is connected to the middle part of the frame 4 through a linear bearing 301, and the other end is connected to the pressure applying device 1. The pressure receiving component 2 is sleeved on the limiting device 3.

[0018] The pressure application device 1 includes a main cylinder 101, a piston 102 and a main cylinder inlet 103, wherein the main cylinder 101 has a main cylinder inlet 103, the piston 102 slides inside the main cylinder 101, and the front end of the piston 102 is fixedly connected to the spring limiting shaft 302 of the limiting device 3.

[0019] The pressure-bearing component 2 is a load spring.

[0020] The limiting device 3 includes a linear bearing 301 and a spring limiting shaft 302, wherein the spring limiting shaft 302 is slidably connected to the linear bearing 301, the linear bearing 301 is fixedly connected to the outer side of the middle part of the rear baffle 402 of the frame 4, and the load spring is sleeved on the spring limiting shaft 302.

[0021] The spring limiting shaft 302 has a spring limiting seat 30201.

[0022] The frame 4 includes a front baffle 401, a rear baffle 402 and long bolts 403. The two ends of the front baffle 401 and the rear baffle 402 are fixedly connected to form an integral frame by long bolts 403. The main cylinder 101 of the pressure device 1 is fixedly connected to the outer side of the middle part of the front baffle 401.

[0023] The piston is made of aluminum alloy with a wear-resistant coating to reduce frictional loss during high-frequency reciprocating motion.

[0024] The spring limiting shaft is made of 45 steel. The step structure of the limiting shaft precisely limits the load spring (axial error ≤0.05mm). The other end face is designed with a small round frustum to cooperate with the piston, simulating the elastic load characteristics of a real caliper.

[0025] Working principle:

[0026] Before operation, the master cylinder inlet 103 is connected to the electro-hydraulic braking system EHB and the integrated electro-hydraulic braking system IEHB via a copper pipe. During the pressure build-up durability test, the outlet of the electro-hydraulic braking system EHB and the integrated electro-hydraulic braking system IEHB outputs brake fluid into the master cylinder 101 chamber. As the brake fluid pressure increases, it pushes the piston 102 to move outward. The piston 102 pushes the spring limit shaft 302 to compress the fixed spring 2, converting hydraulic energy into elastic potential energy and storing it. When the electro-hydraulic braking system EHB and the integrated electro-hydraulic braking system IEHB depressurize, the brake fluid pressure output to the master cylinder 101 decreases, and the spring 2 will release the stored elastic potential energy accordingly.

Claims

1. A simulated load bank for conducting durability experiments, characterized by: It includes a pressure-applying device, a pressure-receiving component, a limiting device, and a frame. The pressure-applying device is fixedly connected to the outer side of the middle part of the frame. One end of the limiting device is connected to the middle part of the frame via a linear bearing, and the other end is connected to the pressure-applying device. The pressure-receiving component is sleeved on the limiting device.

2. The simulated load device for conducting durability tests according to claim 1, characterized in that: The pressure application device includes a main cylinder, a piston, and a main cylinder inlet. The main cylinder has a main cylinder inlet, the piston slides inside the main cylinder, and the front end of the piston is fixedly connected to the spring limiting shaft of the limiting device.

3. The simulated load device for conducting durability tests according to claim 1, characterized in that: The pressure-bearing component is a load spring.

4. The simulated load device for conducting durability tests according to claim 1, characterized in that: The limiting device includes a linear bearing and a spring limiting shaft, wherein the spring limiting shaft is slidably connected to the linear bearing, the linear bearing is fixedly connected to the outer side of the middle part of the rear baffle of the frame, and the load spring is sleeved on the spring limiting shaft.

5. A simulated load device for conducting durability tests according to claim 4, characterized in that: The spring limiting shaft has a spring limiting seat.

6. A simulated load device for conducting durability tests according to claim 1, characterized in that: The frame includes a front baffle, a rear baffle, and long bolts. The front baffle and the rear baffle are fixedly connected at both ends to form an integral frame by long bolts. The main cylinder of the pressure device is fixedly connected to the outer side of the middle part of the front baffle.

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