Moment-Free Coupling for Dynamic Chassis Component Testing
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Solution Overview
Problem
Existing test stands for dynamically exciting chassis components in vehicles face accuracy issues due to vibrations and moment transmission, which impair measurement precision and flexibility in testing different components.
Innovation Solution
A device with a moment-free coupling system using a piston rod and connecting element, where the connecting element is coupled to the piston rod in a substantially moment-free manner, allowing for accurate dynamic excitation of components without transmitting bending moments or torques, and utilizing composite materials to minimize mass and vibrations, enabling high accuracy and flexibility in testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a hydraulic cylinder pulser is used for dynamic excitation, then precise and highly dynamic excitations can be achieved, but the system becomes very heavy and generates vibrations that impair measurement accuracy
Solution Approach 1:
The patent replaces the traditional heavy hydraulic cylinder pulser with an electrodynamic actuator that uses electromagnetic fields to generate motion. This substitution of mechanical hydraulic systems with electrodynamic systems achieves the same dynamic excitation function while significantly reducing weight and eliminating the vibration problems associated with hydraulic systems.
2Measurement precision
If the actuator is directly coupled to the component, then dynamic excitation can be applied, but bending moments and torques are transmitted which impairs measurement accuracy
Solution Approach 1:
The patent introduces a connecting element as an intermediary between the actuator and the component under test. This connecting element is specifically designed to transmit only forces while blocking the transmission of bending moments and torques. By using this intermediary, the system achieves accurate dynamic excitation without the harmful moment transmission that would otherwise contaminate the measurements.
3Measurement precision
If the connecting element is short, then the device structure is compact, but angle errors increase during dynamic investigation
Solution Approach 1:
The patent optimizes the length parameter of the connecting element to be greater than or equal to the actuator length. This parameter change has two beneficial effects: it reduces angle errors during dynamic investigation by providing a longer lever arm that maintains better alignment, and it increases the natural frequency of the connecting element itself, reducing its contribution to system vibrations.
4Adaptability or versatility
If a single test stand is used for different components, then versatility is improved, but the natural frequency of the test stand may interfere with component testing
Solution Approach 1:
The patent designs the connecting element with universal coupling capabilities that can accommodate different types of chassis components. The connecting element can be coupled to various components while maintaining the moment-free force transmission characteristic. This universal design allows a single test stand to test different components without compromising measurement accuracy, as long as the natural frequency of the connecting element remains above the test frequency range.
Data Source
AI summary
A device for dynamically exciting a component, in particular a chassis component of a motor vehicle has an actuator (10) with a piston rod (20) and an actuator housing (30). A connecting element (40) is coupled to the piston rod (20) of the actuator (10). A coupling (50) is coupled to the connecting element (40) for connection to the component. The connecting element (40) is coupled to the piston rod (20) in such a manner that the coupling is substantially moment-free.