Strut Module Test Machine Using Adjustable Fixture Arms
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Solution Overview
Problem
Current bench test methods for strut modules often simplify vehicle inputs, neglecting accurate in-vehicle forces and moments, and require extensive setup space or limited load applications.
Innovation Solution
A module test machine with a frame, adjustable fixture, and up to two actuators configured to replicate road load data along six axes of force, using adjustable arms and actuators to apply forces and moments accurately without incorporating comprehensive suspension components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If quarter car rigs are used to apply forces in multiple axes, then the testing accuracy of in-vehicle forces is improved, but the floor space occupation and device complexity increase significantly
Solution Approach 1:
The patent segments the complex multi-axis force application into two separate single-axis actuators that work in coordination. Instead of requiring multiple actuators arranged in complex spatial configurations, the invention divides the force application task between a first actuator for longitudinal forces and a second actuator for lateral forces, each operating along a single axis but combined through the fixture geometry to achieve six-axis load replication at the wheel contact patch
Solution Approach 2:
The patent uses the adjustable fixture with multiple arms to create virtual force components in additional dimensions. By adjusting the geometry of the fixture (arm lengths, angles, positions), the system can replicate forces and moments in six degrees of freedom using only two physical actuators, effectively adding dimensional capability through geometric configuration rather than additional actuators
2Measurement precision
If comprehensive suspension components are incorporated in the test setup, then the accuracy of in-vehicle forces is improved, but the device complexity and setup requirements increase
Solution Approach 1:
The patent extracts only the essential function needed for accurate testing - the replication of six-axis loads at the wheel contact patch - while removing unnecessary complexity of incorporating complete suspension components. The invention uses a simplified fixture structure with adjustable arms and two actuators that directly replicate the required force and moment components without needing to include actual suspension linkages, control arms, or other vehicle-specific components
Solution Approach 2:
The patent achieves adaptability to different vehicle configurations through parameter changes in the fixture geometry. The adjustable arm lengths, angles, and positions allow the same basic fixture design to replicate the specific force and moment characteristics of different suspension systems without requiring physical reconfiguration or incorporation of actual suspension components for each vehicle type
3Device complexity
If linear damper machines with side load mechanisms are used, then the device complexity is reduced, but the ability to apply representative side load or moment loads is limited
Solution Approach 1:
The patent introduces dynamic adjustability to the fixture geometry, allowing the system to adapt between different loading configurations. The adjustable arms can be repositioned to change the moment arms and force application points, enabling the same two-actuator system to replicate various side load and moment load scenarios that would otherwise require different dedicated test machines
Solution Approach 2:
The patent creates a universal test fixture that can perform multiple loading functions with a single configuration. The adjustable fixture with two actuators can replicate six-axis loads including longitudinal forces, lateral forces, vertical forces, and their corresponding moments, making it a multi-functional system that replaces what would traditionally require multiple specialized test machines
Data Source
AI summary
A module test machine includes a frame, a fixture, at most two actuators coupled to the fixture, and a controller. The frame is couplable to a first end of a strut module. The fixture is couplable to a second end of the strut module. The fixture includes a plurality of arms with a plurality of adjustable lengths. The at most two actuators are coupled to two of the plurality of arms and configured to impart a plurality of loads along six axes of force at the second end of the strut module. The controller is configured to control the at most two actuators in response to at most two actuator vectors. The plurality of adjustable lengths and the at most two actuator vectors are configured to replicate road load data at the second end of the strut module while under test.