Chassis Fatigue Test Equipment with Rotary Drum Simulation
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Solution Overview
Problem
Current fatigue durability tests for automobile chassis systems, particularly for wheels and suspension systems, often lack realism as they do not accurately simulate the stress conditions experienced in real-world driving, leading to deviations in test results and high development costs due to the need for separate tests for wheel and suspension components.
Innovation Solution
The development of fatigue test equipment that includes a suspension assembly, loading system, high-speed pavement rotary drum assembly, impact pavement rotary drum assembly, and rotary drum switching assembly, allowing for simultaneous testing of wheel and suspension systems under realistic load conditions, including six-component loading, to replicate the stress experienced by an automobile chassis during road use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate bench tests are conducted for wheel fatigue and suspension fatigue, then specific component durability can be verified, but test time and development cost increase significantly
Solution Approach 1:
The patent combines wheel fatigue testing and suspension fatigue testing into a single integrated test bench. The test bench simultaneously mounts wheels on suspension assemblies and applies coordinated loads to both components during road simulation, enabling parallel verification of both component durabilities in one test run rather than requiring separate test sequences.
Solution Approach 2:
The test bench is designed with universal mounting capabilities that can accommodate different wheel-suspension combinations. The loading system can apply various types of loads (vertical, lateral, longitudinal) to simulate different road conditions, making the same test bench applicable to multiple vehicle types and test scenarios, thereby reducing the need for multiple specialized test setups.
2Measurement precision
If wheel-only mounting is used in bench tests, then wheel fatigue can be tested, but suspension buffering effect is not considered leading to test result deviation
Solution Approach 1:
The test bench integrates both the wheel mounting system and suspension assembly mounting system into a unified structure. The loading system applies forces to both the wheel hub and suspension mounting points simultaneously, reproducing the actual stress transmission path from wheel through suspension to chassis, thereby capturing the suspension's buffering effect on wheel loads.
Solution Approach 2:
The test bench employs dynamic loading capabilities that can reproduce time-varying road forces including vertical bumps, lateral shifts, and longitudinal vibrations. The loading system adjusts force magnitudes and frequencies to match actual road spectra, enabling realistic simulation of how suspension dynamically buffers wheel loads under varying road conditions.
3Reliability
If shaft head loading is used for chassis system testing, then system-level fatigue can be verified, but wheel performance cannot be investigated and test cost increases
Solution Approach 1:
The test bench is segmented into distinct functional modules: a wheel mounting module with six-component force sensors, a suspension mounting module, and a coordinated loading system. This segmentation allows independent adjustment and measurement of wheel-specific loads while maintaining system-level integration, enabling both wheel performance investigation and system-level fatigue verification through modular data collection.
Solution Approach 2:
The loading system is designed with multi-functional capability to apply loads at multiple points simultaneously - both at the shaft head for system-level testing and at the wheel hub for component-level testing. The same test bench can switch between different test configurations (wheel-only, suspension-only, or combined) without requiring separate dedicated test setups, thereby reducing overall test program complexity and cost.
Data Source
AI summary
The present disclosure belongs to the field of automobile chassis suspension system tests, and provides fatigue test equipment for an automobile chassis simulation road test. The fatigue test equipment can simultaneously test the simulation road test fatigue durability of automobile chassis parts such as the wheel and suspension system and the like, ensures that a test state of the tested wheel and suspension system is close to a real automobile state, and simulates and reproduces a load which an automobile chassis bears in the real road running process in a laboratory.