Vehicle Suspension Drive File Simulation
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Solution Overview
Problem
The current two-stage approach for vehicle suspension durability testing is time-consuming and labor-intensive, necessitating actual road tests at a proving ground for every change in suspension parameters, which delays and increases the costs of vehicle development.
Innovation Solution
An initial actual road test is conducted, and data is used to generate a drive file for subsequent simulated road testing. Acceptability criteria are applied to determine if further actual road testing is needed before additional simulated testing, allowing for reliable suspension parameter changes to be tested in a laboratory without repeated proving ground data acquisition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If actual road tests are conducted at proving ground for every suspension parameter change, then reliability of durability testing is improved, but development time and cost increase
Solution Approach 1:
The patent creates a virtual copy of actual road test conditions through drive files that replicate loading spectra, frequency content, and load cycles in the laboratory simulation rig, allowing repeated testing without repeated proving ground trips
Solution Approach 2:
The patent performs preliminary actual road testing to establish baseline drive files, then uses these pre-generated files for subsequent simulated testing of suspension parameter changes, eliminating the need for repeated actual road tests
2Reliability
If actual road tests are conducted at proving ground for every suspension parameter change, then reliability of durability testing is improved, but testing cost increases
Solution Approach 1:
The patent replicates costly proving ground testing conditions in a more economical laboratory simulation rig using drive files that capture the essential loading characteristics without requiring repeated actual road tests
Solution Approach 2:
The patent introduces drive files as an intermediary that bridges actual road test data and laboratory simulation, allowing the expensive proving ground data to be reused multiple times in cost-effective simulated testing
3Measurement precision
If two-stage testing approach is used for every suspension change, then measurement precision of durability is improved, but productivity decreases
Solution Approach 1:
The patent performs the actual road test and drive file generation as a one-time preliminary action, then reuses these files for multiple simulated testing iterations, achieving both precision and improved productivity
Solution Approach 2:
The patent creates a dynamic testing approach where the same drive file can be adapted for different suspension configurations through simulated testing, allowing flexible retesting without repeating actual road tests
Data Source
AI summary
A method of vehicle suspension testing includes conducting actual road testing of a vehicle including collecting data, and generating a drive file from the collected data for road test simulation. A vehicle suspension parameter is changed to result in a changed vehicle. Initial simulated road testing of the changed vehicle is conducted using the drive file, and results from the simulated and actual road testing are compared using acceptability criteria to determine whether to conduct further actual road testing of the changed vehicle before conducting further simulated road testing of the changed vehicle in response to the changed suspension parameter. Further simulated road testing of the changed vehicle is conducted if the acceptability criteria are met. Otherwise, further actual road testing of the changed vehicle is first conducted to develop a new drive file for use with additional simulated road testing of the changed vehicle.