Article(id=1196101744569664235, tenantId=1146029695717560320, journalId=1189918454225211397, issueId=1196101740056593123, articleNumber=null, orderNo=null, doi=10.20104/j.cnki.1674-6546.20230534, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=null, receivedDateStr=null, revisedDate=1714320000000, revisedDateStr=2024-04-29, acceptedDate=null, acceptedDateStr=null, onlineDate=1763102478400, onlineDateStr=2025-11-14, pubDate=1744646400000, pubDateStr=2025-04-15, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1763102478400, onlineIssueDateStr=2025-11-14, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1763102478400, creator=13701087609, updateTime=1763102478400, updator=13701087609, issue=Issue{id=1196101740056593123, tenantId=1146029695717560320, journalId=1189918454225211397, year='2025', volume='', issue='4', pageStart='1', pageEnd='48', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1763102477325, creator=13701087609, updateTime=1763102749153, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1196102880244576759, tenantId=1146029695717560320, journalId=1189918454225211397, issueId=1196101740056593123, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1196102880244576760, tenantId=1146029695717560320, journalId=1189918454225211397, issueId=1196101740056593123, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=36, endPage=43, ext={EN=ArticleExt(id=1196101744817128173, articleId=1196101744569664235, tenantId=1146029695717560320, journalId=1189918454225211397, language=EN, title=Research on Fatigue Life Analysis of In-Wheel-Motor-Driven Electric Vehicle Steering Knuckles, columnId=null, journalTitle=Automotive Engineer, columnName=null, runingTitle=null, highlight=null, articleAbstract=

To effectively evaluate the fatigue life of in-wheel-motor-driven electric vehicle steering knuckles, virtual iterative analysis of suspension multi-body dynamics modeling and road spectrum signals is conducted based on the measured road load spectrum, form which the input file of steering knuckles load spectrum is obtained. Fatigue life analysis on the steering knuckle is conducted by combining the inertia release results, material S-N curve and Miner linear cumulative damage criterion, and Fatigue tests are conducted on the steering knuckles for verification. Findings from both simulations and experiments indicate that the primary fatigue risk areas are at the interfaces between the steering tie rod and the lower shock absorber connecting rod. The steering knuckle design satisfies the requirement for a fatigue-free lifespan over a diriveing distance of 16×104 km.

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为有效评估某轮毂电机驱动电动汽车转向节的疲劳寿命,基于实测道路载荷谱开展悬架多体动力学建模与路谱信号的虚拟迭代分析,获得转向节载荷谱输入文件,并结合惯性释放结果、材料应力-寿命曲线(S-N曲线)和Miner线性累积损伤准则对转向节开展疲劳寿命分析,最后进行了转向节疲劳试验。仿真和试验结果均表明:转向节疲劳危险点主要在转向横拉杆和减振器下端连接杆与转向节相连的区域;转向节满足整车行驶16×104 km后不发生疲劳破坏的设计寿命要求。

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王悦廉(1998—),男,湖北仙桃人,博士研究生,主要研究方向为车辆多体动力学与耐久性,
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道路种类 里程/km 比例/%
高速环形跑道 84.38 56.24
二号环道 20.05 13.36
标准坡道 0.56 0.37
绕8字行驶 1.74 1.16
比利时路 3.95 2.63
长波路 1.00 0.67
扭曲路 0.30 0.20
搓板路 1.60 1.07
蛇形卵石路 0.25 0.17
路拱交叉路 0.01 0.01
大路拱路 0.58 0.39
弯道反向坡道 0.54 0.36
破损颠簸路和井盖路 0.56 0.37
沙石路 0.82 0.55
砾石路 0.56 0.38
模拟市区工况路 13.00 8.67
连续路 20.10 13.40
合计 150.00 100.00
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道路载荷谱信号采集试验里程分配

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道路种类 里程/km 比例/%
高速环形跑道 84.38 56.24
二号环道 20.05 13.36
标准坡道 0.56 0.37
绕8字行驶 1.74 1.16
比利时路 3.95 2.63
长波路 1.00 0.67
扭曲路 0.30 0.20
搓板路 1.60 1.07
蛇形卵石路 0.25 0.17
路拱交叉路 0.01 0.01
大路拱路 0.58 0.39
弯道反向坡道 0.54 0.36
破损颠簸路和井盖路 0.56 0.37
沙石路 0.82 0.55
砾石路 0.56 0.38
模拟市区工况路 13.00 8.67
连续路 20.10 13.40
合计 150.00 100.00
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设备名称 设备型号 传感器
名称
传感器型号 规格
IST试验系统(6-7) SH/TC-AI-D6-07 位移传感器 SH/TC-DT-D6-07 ±75 mm
力传感器 SH/TC-FT-D6-07 ±25 kN
钢直尺 SH/TC-MS-07-11 600 mm
数显扭力扳手 CG-LG00030 340
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转向节节臂力疲劳试验设备

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设备名称 设备型号 传感器
名称
传感器型号 规格
IST试验系统(6-7) SH/TC-AI-D6-07 位移传感器 SH/TC-DT-D6-07 ±75 mm
力传感器 SH/TC-FT-D6-07 ±25 kN
钢直尺 SH/TC-MS-07-11 600 mm
数显扭力扳手 CG-LG00030 340
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试样编号 循环次数/×104 试验节点 试验
结果
备注 试样编号 循环次数/×104 试验节点 试验
结果
备注
P00048341/42-T0033481-001 150 基础循环次数 未失效 旧材料 P00048341/42-T0033481-004 150 基础循环次数 未失效 失效,旧材料
300 试验终止循环次数 未失效 177.542 7 试验终止循环次数 失效
P00048341/42-T0033481-002 150 基础循环次数 未失效 新材料 P00048341/42-T0033481-005 150 基础循环次数 未失效 新材料
300 试验终止循环次数 未失效 300 试验终止循环次数 未失效
P00048341/42-T0033481-003 150 基础循环次数 未失效 旧材料 P00048341/42-T0033481-006 150 基础循环次数 未失效 旧材料
300 试验终止循环次数 未失效 300 试验终止循环次数 未失效
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转向节节臂疲劳试验结果

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试样编号 循环次数/×104 试验节点 试验
结果
备注 试样编号 循环次数/×104 试验节点 试验
结果
备注
P00048341/42-T0033481-001 150 基础循环次数 未失效 旧材料 P00048341/42-T0033481-004 150 基础循环次数 未失效 失效,旧材料
300 试验终止循环次数 未失效 177.542 7 试验终止循环次数 失效
P00048341/42-T0033481-002 150 基础循环次数 未失效 新材料 P00048341/42-T0033481-005 150 基础循环次数 未失效 新材料
300 试验终止循环次数 未失效 300 试验终止循环次数 未失效
P00048341/42-T0033481-003 150 基础循环次数 未失效 旧材料 P00048341/42-T0033481-006 150 基础循环次数 未失效 旧材料
300 试验终止循环次数 未失效 300 试验终止循环次数 未失效
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轮毂电机驱动电动汽车转向节疲劳寿命分析*
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李禄源 1 , 王悦廉 2 , 于学天 2 , 韩萌 1 , 边增远 1 , 庄晔 2
汽车工程师 | 2025,(4): 36-43
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汽车工程师 | 2025, (4): 36-43
轮毂电机驱动电动汽车转向节疲劳寿命分析*
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李禄源1, 王悦廉2 , 于学天2, 韩萌1, 边增远1, 庄晔2
作者信息
  • 1 吉林省产品质量监督检验院,长春 130103
  • 2 吉林大学,汽车底盘集成与仿生全国重点实验室,长春 130022

通讯作者:

王悦廉(1998—),男,湖北仙桃人,博士研究生,主要研究方向为车辆多体动力学与耐久性,
Research on Fatigue Life Analysis of In-Wheel-Motor-Driven Electric Vehicle Steering Knuckles
Luyuan Li1, Yuelian Wang2 , Xuetian Yu2, Meng Han1, Zengyuan Bian1, Ye Zhuang2
Affiliations
  • 1 Jilin Province Product Quality Supervision and Inspection Institute, 130103
  • 2 National Key Laboratory of Automotive Chassis Integration and Bionics, Jilin University, Changchun 130022
出版时间: 2025-04-15 doi: 10.20104/j.cnki.1674-6546.20230534
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为有效评估某轮毂电机驱动电动汽车转向节的疲劳寿命,基于实测道路载荷谱开展悬架多体动力学建模与路谱信号的虚拟迭代分析,获得转向节载荷谱输入文件,并结合惯性释放结果、材料应力-寿命曲线(S-N曲线)和Miner线性累积损伤准则对转向节开展疲劳寿命分析,最后进行了转向节疲劳试验。仿真和试验结果均表明:转向节疲劳危险点主要在转向横拉杆和减振器下端连接杆与转向节相连的区域;转向节满足整车行驶16×104 km后不发生疲劳破坏的设计寿命要求。

电动汽车  /  分布式驱动  /  转向节  /  载荷谱  /  多体动力学  /  虚拟迭代  /  疲劳寿命

To effectively evaluate the fatigue life of in-wheel-motor-driven electric vehicle steering knuckles, virtual iterative analysis of suspension multi-body dynamics modeling and road spectrum signals is conducted based on the measured road load spectrum, form which the input file of steering knuckles load spectrum is obtained. Fatigue life analysis on the steering knuckle is conducted by combining the inertia release results, material S-N curve and Miner linear cumulative damage criterion, and Fatigue tests are conducted on the steering knuckles for verification. Findings from both simulations and experiments indicate that the primary fatigue risk areas are at the interfaces between the steering tie rod and the lower shock absorber connecting rod. The steering knuckle design satisfies the requirement for a fatigue-free lifespan over a diriveing distance of 16×104 km.

Electric vehicle  /  Distributed drive  /  Steering knuckles  /  Load spectrum  /  Multi-body dynamics  /  Virtual iteration  /  Fatigue life
李禄源, 王悦廉, 于学天, 韩萌, 边增远, 庄晔. 轮毂电机驱动电动汽车转向节疲劳寿命分析*. 汽车工程师, 2025 , (4) : 36 -43 . DOI: 10.20104/j.cnki.1674-6546.20230534
Luyuan Li, Yuelian Wang, Xuetian Yu, Meng Han, Zengyuan Bian, Ye Zhuang. Research on Fatigue Life Analysis of In-Wheel-Motor-Driven Electric Vehicle Steering Knuckles[J]. Automotive Engineer, 2025 , (4) : 36 -43 . DOI: 10.20104/j.cnki.1674-6546.20230534
轮毂电机驱动电动汽车将车辆的动力装置、传动装置和制动装置整体布置到轮毂内,简化了车辆的动力总成机械部分,具有结构紧凑、传动效率高、转矩分配灵活的优势。这种布置形式导致簧下质量增加较多、悬架各部件载荷增加,需重点关注各部件的耐久性能。
悬架转向节的耐久性研究过程中,需要确定转向节的连接关系并获取对应连接点的载荷谱,但存在连接点部位的受力载荷谱难以直接通过试验测得的问题。针对悬架内部载荷的提取,常用方法有虚拟试验场(Virtual Proving Ground)技术[1]、约束载荷加载法和虚拟迭代技术。虚拟试验场技术[2]通过全仿真分析的方式求解内部载荷,但准确的虚拟路面的建立难度较大,复杂路面的扫描获取也存在困难。约束载荷加载法将实测轮心激励加载到整车模型的轮心位置,从而提取出转向节连接点处的受力载荷,该方法忽略了部件惯性的影响,对模型的精度要求高,各类准确性不足都会对连接点处的载荷产生很大影响。值得注意的是,该仿真方法无法考虑簧上质量对模型的影响,与实际工况不符,试验与仿真结果存在偏差。虚拟迭代[3]通过轮胎六分力传感器测量获得实车轮心六分力,建立动力学模型,利用FEMFAT软件完成虚拟迭代仿真[4],获得轮心垂向位移,并以此及其余五分力作为动力学模型的驱动载荷,获得目标部件转向节连接点处的载荷,进而在单位载荷加载下对转向节有限元模型进行惯性释放分析。基于惯性释放应力场结果文件、整车载荷分解提取的转向节疲劳分析载荷谱和转向节材料参数,选择合理的方法进行转向节疲劳寿命分析,即可得到转向节疲劳损伤分布云图,找出疲劳危险点。
为了高效准确地获得转向节疲劳寿命,本文采用虚拟迭代仿真分析的方式获取目标部件的载荷谱,对转向节进行疲劳寿命预测仿真,并开展转向节疲劳台架试验,通过转向节在基础循环次数下的试验结果,验证疲劳寿命预测结果的有效性[5]
为了获得精确的整车零部件疲劳载荷,为后续动力学仿真和疲劳仿真提供输入,选取多种典型路面,如高速环形跑道、二号环道、标准坡道等,并按不同权重分配相应的试验里程,如表1所示,不同的强化路面具有代表性和概括性,可充分反映实车行驶状况。
为在车轮轴头处测量车轮六分力,获取整车仿真激励载荷,根据需要的信号种类选取MSC公司的LW12.8-50型车轮力传感器,可同时测量车轮受到的3个方向的力和力矩,并需在车轮轴头处测量加速度信号,以获取轮心响应,验证载荷分解仿真激励结果。传感器布置情况如图1所示。
为监测实际道路试验过程中悬架上部分部位的应力变化情况,还需布置应变测量装置,对于主应力方向明确的应变测量,一般使用应变片即可,但实际工作过程中,主应力的方向并不明确,因此在这些位置布置应变花,统一用数据采集系统采集信号。
通常,采集的路面载荷谱不能直接用于仿真计算。路面测试工况复杂、环境恶劣,信号采集过程中的各种干扰因素会导致最终采集的信号出现各种异常,影响后续分析结果的精度,因此,必须对采集到的信号进行滤波、重新采样、缩减等处理[6]
采集到的原始信号及其处理过程如图2所示:首先初步检查信号的完整性,不存在测试信号丢失的情况;接着进行幅值谱分析,确认信号是否服从正态分布,判断信号的准确性;然后根据信号的类型和分析用途等进行分类,对数据进行简单处理,如根据后续仿真的要求转换信号的单位、根据应变片的布置情况利用应变信号计算主应力等;最后,对获得的数据进行去除毛刺、漂移等处理,以不同的采样频率进行测试,最终选择将信号按256 Hz重新采样,在尽可能简化载荷谱的同时,保留更多的波峰、波谷值,保证耐久性预测结果相对准确,用低通滤波器滤除40 Hz以上的高频信号,去除干扰噪声,处理好的载荷用于虚拟迭代。图2中,FxFyFz分别为车轴轴头在xyz方向的受力,MxMyMz分别为车轴轴头在xyz方向所受力矩。本文测试信号的数据处理主要在nCode Glyph Works及FEMFAT软件中进行。
获得路谱后,通过多体动力学仿真获取目标构件处的受载情况,本文的研究对象为前悬架的转向节部件,故根据实车上测量获得的硬点数据和特性参数,基于Adams/Car软件对前悬架系统进行动力学建模,为了尽可能使模型与实车相符,对减振器阻尼特性、衬套特性等参数进行了试验测量,并在模型中添加相关属性数据。
在轮心处建立垂直向上的位移输入,作为后续虚拟迭代过程中输入的接口,对输入进行不断修正,同样在轮心处添加垂直向上的力响应,用于输出位移驱动下的垂向力数据[7]。完成设置后输出为.adm文件,为后续虚拟迭代作准备,搭建完成的悬架动力学模型如图3所示,值得注意的是,各连接件间的连接关系需保证与实际连接关系一致。
道路试验采集到的载荷谱信号直接用于动力学模型仿真会引起模型倾覆,仿真失败,需要通过虚拟迭代将垂向力信号转换成位移信号进行仿真。虚拟迭代是对非线性系统进行逆向求解的过程,将复杂的动力学系统简化为线性系统进行表达,通过多次迭代求解,对反函数进行修正,使输入信号经过系统后获得的输出信号与实际目标信号逐渐接近[8]
首先,将多体动力学模型作为未知系统,设置白噪声作为位移输入信号u0(s),对系统产生激励响应信号y0(s),求得系统的传递函数为:
$F(s)=y_{0}(s) / u_{0}(s) $
进而可根据式(1)求得逆函数F-1(s)。
其次,以路试实测信号作为目标信号yd(s),根据逆函数F-1(s)计算初始输入信号:
$u_{1}(s)=F^{-1}(s) y_{\mathrm{d}}(s) $
然后,利用初始驱动信号激励多体动力学模型得到响应信号y1(s),因为传递函数不能精确表征多体动力学模型,所以目标信号yd(s)与响应信号y1(s)之间存在一定的误差。
最后,用修正算法固定逆传递函数F-1(s)。将得到的响应值与目标值进行对比判定,误差较大时需要重新计算,通过式(3)进行反复迭代,直到使迭代收敛;对目标信号与响应信号进行时域和频域对比,如果误差均方根值为零或目标信号与响应信号接近,则认为收敛较好;对相对损伤值进行比较,如果迭代信号与试验数据的相对损伤值接近1,则认为收敛较好,如果在0.5~1.5范围内收敛,认为虚拟迭代结果可以接受,停止迭代,最终得到的输入信号即轮心z向位移。迭代公式为:
$u_{k+1}(s)=u_{k}(s)+F^{-1}(s)\left[y_{\mathrm{d}}(s)-y_{k}(s)\right] $
式中:yk(s)为第k次迭代的响应信号,uk(s)为第k次驱动信号。
整个流程可以在FEMFAT软件的虚拟迭代(Virtual Iteration,VI)模块中实现,该模块通过调用Adams/Car中的求解器对搭建的多体动力学模型进行仿真。首先,根据仿真要求输入位移信号,对白噪声进行设置,生成的其中一个通道的白噪声信号如图4所示,将生成的白噪声作为输入,得到响应信号后,求取传递函数。
然后求出逆函数,同时以实测载荷谱作为目标信号进行虚拟迭代,反求出第一次载荷输入,驱动多体模型,将得到的响应值与目标值进行对比,误差较大时重新计算,直到使迭代收敛,得到轮心z向位移。
一般在10~20步内收敛完成,取其中最接近1的一组信号进行后续的动力学驱动求解。迭代过程中,左、右轮的驱动信号收敛过程如图5所示,经过10次迭代计算后收敛到1.2附近,收敛效果较好。
最后一次迭代的驱动信号如图6所示,将其与其余五分力一起作为输入,添加到Adams/Car软件中建立的前悬架动力学模型的轮心处,驱动动力学模型,得到转向节各连接点处各方向的载荷谱。
为获得各连接点处不同载荷输入下转向节各部分的受载情况,需要对转向节部件进行有限元静力分析。获得构件的主要受力部位后,在受力部位施加载荷,以HyperMesh作为前处理器、Nastran为求解器、HyperView为后处理器,开展模型的惯性释放分析。转向节有限元模型的建立主要分为以下几个步骤:
a. 模型导入。将转向节三维模型导入有限元软件。
b. 几何特征的简化及清理。对几何特征缺失的情况进行检查与清理,填补导入过程中破损的面等,并根据半径对倒角、圆角等进行处理,提高分析计算的效率和网格单元的质量。
c. 单元类型的选择。采用3D单元对转向节进行网格划分,结果如图7所示。
d. 连接关系设定。在各连接点处添加铰接点,见图7,将其作为单位力的输入点进行惯性释放,并作为后续疲劳仿真载荷谱的输入点。
e. 材料属性的添加。添加转向节的材料属性,以提高仿真的准确性。
使用HyperWorks软件中的HyperMesh模块建立转向节有限元模型,并使用其中的Optistruct求解器进行转向节惯性释放分析[9]
有限元惯性释放分析中建立的平衡方程为:
$F+M \ddot{\varphi}=0$
式中:F为外部载荷矩阵,$\ddot{\varphi}$为加速度矩阵,M为质量矩阵。
转向节的惯性释放结果如图8所示,得到每个加载点位置载荷单独作用时各节点位移分布情况。
以虚拟迭代得到的轮心处垂向位移和轮心处其余五分力作为驱动对前悬架系统的动力学模型进行激励,仿真获取转向节各连接点处的载荷谱。
悬架系统受随机载荷作用,对于随机载荷谱,名义应力法主要用于应力水平未超过材料屈服强度时的疲劳分析,局部应力应变法能有效考虑结构局部高应力(超过屈服强度)状态下的塑性变形,主要用于结构最大应力超过屈服强度时的疲劳分析。通过应力-寿命(S-N)法对悬架动力学系统进行疲劳分析,平均应力修正方法选择古德曼(Goodman)法[10],分析结果中最大应力未超过屈服强度,故本文疲劳分析选择名义应力法。
目前,疲劳累积损伤理论主要有线性、非线性和双线性累积损伤理论3类。线性疲劳累积损伤理论中的Miner理论[11]是线性累积损伤方式中的经典理论,本文采用Miner理论对悬架系统进行损伤累积计算。
设构件在某载荷水平S下的疲劳寿命为N,则1个循环造成的损伤D为:
$D=1 / N $
在载荷水平Si下经过ni次循环造成的损伤为:
$D_{i}=n_{i} / N_{i}$
式中:Ni为载荷水平Si下的疲劳寿命。
m个应力水平Si作用下各经过ni循环,其总损伤可以表达为:
$D_{m}=\sum_{i=1}^{m} \frac{n_{i}}{N_{i}} $
零件在载荷循环作用下产生的损伤累加值达到1时发生疲劳破坏。
综合部件疲劳载荷谱、有限元分析结果、材料S-N曲线进行零部件疲劳寿命分析[12],得到零部件的疲劳损坏危险点。
值得注意的是,S-N模块需根据实际的材料特性生成相应的S-N曲线,以满足疲劳寿命的计算要求。此外,还需要对疲劳分析方法进行设置,如选择合适的平均应力修正方法、单轴或多轴应力分析等,以得到更为精确的疲劳分析结果。
在nCode中进行结构总的应力分布计算,基本思想是根据有限元计算的结果先求出每个加载点位置载荷单独作用时产生的应力分布,然后将各加载点位置载荷产生的应力进行线性累加得到总的应力加载过程,通过疲劳理论对应力作用的累积结果进行计算。
得到疲劳损伤云图如图9所示,最大损伤值为5.28×10-8,对应载荷段循环次数为1.89×107次,依据循环次数和原始路谱数据等比例选取单次循环长度为0.015 km的强化路面数据,计算可得该转向节在强化路面下的有效行驶里程为28.35×104 km[13]
根据GB/T 18388—2005《电动汽车 定型试验规程》的耐久性要求,电动汽车可靠性行驶里程不得少于5 000 km。同时,本文研究对象的设计要求为在车辆行驶16×104 km的里程范围内不发生疲劳破坏,在强化路面下,转向节在车辆行驶28.35×104 km后发生疲劳破坏,耐久性符合设计目标,且满足国家标准的耐久性要求。
同时可以观察到,损伤值较大的部分出现在转向节节臂处,可通过已有的使用损伤情况、路试试验,以及台架试验对结构的疲劳情况进行比对,确认仿真分析的正确性。
首先截取典型路面的路谱片段,分路况开展虚拟迭代,分解得到转向节各主要连接点处的疲劳载荷谱,之后根据随机载荷的时间长度系数,将各路况下的各连接点处疲劳载荷等效至16×104 km的用户道路情况。最后,结合准静态法和材料的S-N曲线数据开展转向节的疲劳寿命评估。由惯性释放分析结果可知,侧向力载荷为转向节的失效主导载荷。
复杂的工作条件使悬架关键零部件的疲劳寿命很难仅依靠理论计算得到。因此,要检验零部件的疲劳寿命及可靠性能否达到设计要求,必须对其进行疲劳试验。零部件在工作过程中所承受的载荷通常为随机载荷,然而,受试验条件及试验成本等因素的限制,随机疲劳试验难度较大。为此,从寿命等效的原则出发,利用恒幅载荷下的S-N曲线模型及随机载荷下的疲劳寿命预测模型,建立随机载荷作用下零部件可靠性评估的等效应力试验法,在随机应力作用下,转向节的疲劳寿命为N*,根据寿命等效原则,得到疲劳寿命为N*时对应的恒幅等效应力为:
$S_{\mathrm{eq}}=\sqrt[b]{\frac{C}{N^{*}}}$
式中:bC为材料疲劳性能参数,与材料属性、试样形状及加载方式等有关。
对实测道路载荷进行雨流计数,结合实测道路载荷的幅值分布特点以及台架试验循环次数要求进行加速试验谱的编制。
转向节节臂力疲劳试验加载方案为:在转向节与转向横拉杆连接处加载Y方向的力,载荷为对称等幅5.417 1 kN的循环力,试验载荷加载频率为10 Hz,基础循环次数为150×104次,终止循环次数为300×104次。疲劳试验设备信息如表2所示。
固定转向节部件,在其实际工况连接点处施加单一方向的恒幅循环载荷,使用多个样件重复单通道台架试验[14],提高试验的可靠性,设置不同的加载循环次数,测试转向节的疲劳损伤情况,其中一组试验工况的试验过程如图10所示。
具体试验过程及结果如表3所示,通过多次试验确认多数情况下样件在预期循环次数下未失效,其中的失效样件可能存在缺陷等其他因素影响加速了失效,而其失效部位与仿真结果一致,最终通过重复试验确认转向节部件最先发生疲劳破坏的位置与仿真分析得到的结果一致,转向节试验样件在基础循环150×104次时,均未出现疲劳断裂,与转向节疲劳寿命分析结果相同,表明转向节的疲劳寿命满足相关标准要求,验证了转向节疲劳寿命分析仿真结果具有一定的正确性。
本文基于整车试验场耐久性道路实测路谱对轮毂电机驱动电动汽车转向节进行了疲劳寿命分析,并对疲劳寿命结果进行了试验验证,结果表明,转向节疲劳台架试验终止循环次数的试验结果与仿真分析结果中的结构疲劳失效危险点区域基本吻合,仿真误差在可接受范围。
  • * 国家市场监督管理总局科技计划项目(2022MK022)
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doi: 10.20104/j.cnki.1674-6546.20230534
  • 首发时间:2025-11-14
  • 出版时间:2025-04-15
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  • 修回日期:2024-04-29
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* 国家市场监督管理总局科技计划项目(2022MK022)
作者信息
    1 吉林省产品质量监督检验院,长春 130103
    2 吉林大学,汽车底盘集成与仿生全国重点实验室,长春 130022

通讯作者:

王悦廉(1998—),男,湖北仙桃人,博士研究生,主要研究方向为车辆多体动力学与耐久性,
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2种不同金属材料的力学参数

Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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