Electric Wheel Test Bed Portal Frame and Drum Simulation
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Solution Overview
Problem
Current methods for testing electric vehicles, such as real vehicle road simulation, computer simulation, and laboratory bench tests, face challenges like high costs, low reproducibility, and reliability issues, necessitating a comprehensive test bed for electric wheels to simulate various driving conditions effectively.
Innovation Solution
A test bed comprising a base, portal frame, main pin arm, and rotation shaft with integrated road simulation, inertia simulation, driving power, steering, and perpendicular loading mechanisms, allowing for simultaneous simulation of road, braking, and steering conditions, enhancing the accuracy of electric wheel testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If real vehicle road simulation is used, then the test results are reliable, but the test cost is high and the research cycle is long
Solution Approach 1:
The patent creates a virtual copy of the road surface through the drum mechanism that replicates actual road conditions (rough roads, smooth roads, gravel roads) without requiring actual road testing. This allows reliable simulation of road conditions in a controlled laboratory environment, eliminating the need for long-term real vehicle road simulation while maintaining test validity.
Solution Approach 2:
The patent replaces the complex mechanical system of actual vehicle road testing with a simplified bench test system that uses a rotating drum to simulate road surfaces. The drum mechanism substitutes for real road conditions, allowing reliable testing without the time-consuming nature of actual road simulations.
2Reliability
If real vehicle road simulation is used, then the test results are reliable, but the test cost is high
Solution Approach 1:
The patent creates a virtual copy of the road surface through the drum mechanism that replicates actual road conditions (rough roads, smooth roads, gravel roads) without requiring actual road testing. This allows reliable simulation of road conditions in a controlled laboratory environment, eliminating the need for long-term real vehicle road simulation while maintaining test validity.
Solution Approach 2:
The patent replaces the complex mechanical system of actual vehicle road testing with a simplified bench test system that uses a rotating drum to simulate road surfaces. The drum mechanism substitutes for real road conditions, allowing reliable testing without the time-consuming nature of actual road simulations.
3Productivity
If computer simulation test is used, then the test is simple and fast, but the reliability is not high
Solution Approach 1:
The patent segments the testing process into distinct controllable components: the drum for road simulation, the flywheel for inertia simulation, and the electric dynamometer for braking simulation. This segmentation allows each parameter to be independently controlled and measured, providing both the speed of computer simulation and the reliability of physical testing through precise parameter control.
Solution Approach 2:
The patent incorporates sensors to detect rotational speed, torque, and steering force, providing real-time feedback that enhances the reliability of the simulation. This feedback mechanism allows for accurate measurement and control of test parameters, bridging the gap between simple computer simulation and reliable physical testing.
4Productivity
If traditional bench test is used, then the test cycle is short and cost is low, but the comprehensiveness of simulation is limited
Solution Approach 1:
The patent creates a multi-functional test bed that can perform multiple types of simulations: road simulation through the drum, inertia simulation through the flywheel, braking simulation through the electric dynamometer, and steering simulation through the motor-driven pin arm. This universal system maintains the advantages of traditional bench tests (short cycle, low cost) while significantly enhancing simulation comprehensiveness.
Solution Approach 2:
The patent merges multiple simulation functions (road, inertia, braking, steering) into a single integrated test bed system. The drum, flywheel, electric dynamometer, and steering mechanism work together in coordination, allowing comprehensive simulation of various driving conditions while maintaining the efficiency and cost-effectiveness of bench testing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables comprehensive and accurate simulation of electric wheel performance under various driving conditions, improving test results by allowing bidirectional loading, inertia, and braking simulations, thereby enhancing the reliability and reproducibility of electric vehicle research.
Implementation Method 1
both the drum and the electric wheel have their circumferential surfaces with a tangent contact each other; the electric wheel always keeps tangent contact with the drum
Implementation Method 2
the drum and the torque and rotational-speed sensor are connected via the bearings and the shaft couplings
Implementation Method 3
The inertia simulation mechanism comprises a flywheel and a clutch coaxially connected with each other
Implementation Method 4
The inertia simulation mechanism comprises a flywheel and a clutch coaxially connected with each other
Implementation Method 5
The driving power mechanism is selectably in a motor mode or in a power generation mode, comprises an electric dynamometer: in the motor mode for braking simulation, further comprises a power source for supplying power to the electric dynamometer; in the power generation mode of the driving power mechanism, further comprises an energy dissipation device for consuming energy generated by the electric dynamometer
Implementation Method 6
the ball screw and the worm case are engaged with each other to transfer rotation to linear motion
Implementation Method 7
a rotary shaft of the motor is rotatably engaged with the worm case and drives a worm in the worm case to rotate
Data Source
AI summary
A test bed for electric wheel comprehensive performance is characterized in that the test bed comprises a foundation, a portal frame set on the foundation and including a cross beam and two columns supporting both ends of the cross beam individually, a main pin arm movably connected to the portal frame, and a main rotation shaft revolvably and perpendicularly mounted on the top of the main pin arm, wherein the electric wheel is mounted on the main pin arm and is located inside of the portal frame and right below the main rotation shaft. The test bed further comprises at least one of a road simulation mechanism, an inertia simulation mechanism, a driving power mechanism, a perpendicular loading mechanism, and a steering mechanism which take the simulation test on the electric wheel.