CN104296974B - A kind of Vehicle headlamp structure analysis of Fatigue-life method - Google Patents
A kind of Vehicle headlamp structure analysis of Fatigue-life method Download PDFInfo
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Abstract
The invention discloses a kind of Vehicle headlamp structure analysis of Fatigue-life method, including: step 1a, road modal data gather and correction；1b, correction way of escape spectrum is simplified, calibrates；Step 2, respectively simulation winter and the ambient temperature in summer, turn on light to headlight and the internal temperature field do not turned on light under two kinds of operating modes emulate, obtain the headlight temperature field data in the case of four kinds；Determined the time scale turned on light He do not turn on light by market survey result, set up temperature field data splitting；Step 3, set up headlight assembly FEM (finite element) model, input the hot physical property of each parts and mechanical characteristic, to contacting with each other between each structure and assembly relation is defined, import temperature field data splitting, apply road spectrum excitation, calculate the thsrmal-mech coupling strain-responsive of vehicle lamp assembly structure in a circulation, and obtain headlight heat engine fatigue life by analysis of fatigue computed in software.The present invention can be in the fatigue life of design phase prediction automobile front.
Description
Technical field
The invention belongs to Automobile Measuring Techniques, be specifically related to a kind of Vehicle headlamp structure analysis of Fatigue-life method.
Background technology
Along with the excitation day by day of automobile market competition, the Fatigue Life Problems of vehicle is increasingly paid attention to by each auto vendor.Automobile front, as the primary illumination equipment of vehicle, its structural reliability, directly affects maneuverability and the safety of vehicle.At present, Vehicle lamp structure mainly considers the realization of the assembly relation with car load and optical property at the design initial stage, only its life-span is estimated by test in the Product Validation stage, lack enough means and predict its fatigue life in the design phase, more because of the headlight fault of fatigue rupture generation on market.
The random load that headlight is come by vehicle body transmission in vehicle travel process, two kinds of typical conditions of mainly turning on light and do not turn on light, under both operating modes, the Temperature Distribution within lamp body is widely different.Meanwhile, headlight also to accept the heat radiation from electromotor, and seasonal variations causes ambient temperature also to have the biggest difference.Headlight housing and internal stent major part all use plastic material, and its material property is the most sensitive to temperature, when calculating the fatigue life of headlight, it is necessary to consider the temperature impact on material property.
Large-scale FEM (finite element) model cannot process long time-domain signal, needs to simplify time-domain signal, and how to ensure to simplify an accuracy always difficult problem for after load.At present, time-domain signal is generally converted into frequency-region signal by the fatigue mechanisms for random load, and utilize based on power spectral density (Power spectral Density, PSD) transfer function method of loading spectrum solves, this method cannot consider the variations in temperature impact on structure, having significant limitation, accuracy fatigue life being used for calculating headlight is relatively low.Headlight carrying out model analysis, finds that the natural frequency of structure is much larger than excitation load frequency, there is not dynamic structure response in headlight, based on this feature, the invention provides a kind of new Vehicle headlamp structure analysis of Fatigue-life method.
Summary of the invention
It is an object of the invention to provide a kind of Vehicle headlamp structure analysis of Fatigue-life method, can be in the fatigue life of design phase prediction automobile front.
Vehicle headlamp structure analysis of Fatigue-life method of the present invention, comprises the following steps:
Step 1, headlight mechanical load process
1a, road modal data gather and correction
With vehicle body junction, three-way vibration acceleration transducer is installed at headlight, section requirement by test site car load road reliability test, gather the combination road spectrum on different stage road surface, and the modal data that satisfies the need is corrected, eliminate the singular point in data and the trend term caused because of systematicness interference factor；
1b, the road spectrum after correction is simplified, calibrates
The feature of the peak load in reservation data, load less than fatigue limit is carried out equivalent process, road spectrum signal before and after simplifying utilizes Fourier transformation be converted into the power spectral density signal of frequency domain and contrast and calibrate, until the root-mean-square value error of the power spectral density signal after road spectrum simplifies and before simplification is within 10%, then the road spectrum after this simplification is equivalence road spectrum；
Step 2, the process of headlight thermal force: simulation winter and the ambient temperature in summer respectively, turn on light to headlight and the internal temperature field do not turned on light under two kinds of operating modes emulate, obtain the headlight temperature field data in the case of four kinds；In conjunction with being determined the time scale turned on light He do not turn on light by market survey result, set up temperature field data splitting；
Step 3, heat engine coupling analysis of Fatigue-life: set up headlight assembly FEM (finite element) model, input the hot physical property of each parts and mechanical characteristic, to contacting with each other between each structure and assembly relation is defined, steps for importing 2 calculated temperature field data splitting, the equivalent road spectrum applying step 1b gained encourages, calculate the thsrmal-mech coupling strain-responsive of an interior vehicle lamp assembly structure of circulation, calculated structure thsrmal-mech coupling strain data is imported in analysis of fatigue software, the fatigue properties of material is set, thsrmal-mech coupling field in the time period that appointment is above analyzed is a Life Cycle load, by being calculated headlight heat engine fatigue life.
Ambient temperature data in described step 2 is collected by vehicle road test in winter and vehicle road test in summer respectively；
Use thermal analysis software to respectively obtain the thermo parameters method considered under ambient temperature simulation analysis headlight closed mode, and consider ambient temperature and the Temperature Distribution under bulb heat radiation simulation analysis headlight opening.
In described step 1a, use high-pass filtering method, balance deflection method and method of least square that the road modal data gathered is corrected.
The invention have the advantages that can be in the fatigue life of design phase prediction automotive headlamp, compared with passing through verification experimental verification with in the Product Validation stage, can cost-effective, shorten the R&D cycle, finding in advance and cause the danger position that headlight structure fatigue life is low, structure optimization and improvement for the design phase provide foundation.
Accompanying drawing explanation
Fig. 1 is the structured flowchart of the present invention.
Detailed description of the invention
The invention will be further described below in conjunction with the accompanying drawings:
Vehicle headlamp structure analysis of Fatigue-life method as shown in Figure 1, comprises the following steps:
Step 1, headlight mechanical load process
1a, road modal data gather and correction: install three-way vibration acceleration transducer at headlight with vehicle body junction, by the section requirement (the road spectrum that this section is combined in proportion by the road surface of the different stages such as hollow road, pebble path, washboard road and Belgium road) of test site car load road reliability test, gather the combination road spectrum on different stage road surface, use high-pass filtering method, balance deflection method and method of least square that the road modal data gathered is corrected, eliminate the singular point in data and the trend term caused because of systematicness interference factor.The concrete grammar of correction is to write algorithm in MATLAB, inputs original road spectrum, i.e. draws correction way of escape spectrum loading after program calculates.
1b, the road spectrum after correction is simplified, calibrate: the road spectrum signal data volume tested due to reality is the biggest, the applying of excitation load during for the ease of analyzing, test data need to be simplified, the feature of the peak load in reservation data, load less than fatigue limit is carried out equivalent process, such as: by fluctuating, less saw-toothed type curve section fits to smooth curve, and the curve of load that will be less than fatigue limit is reduced to straight line so that data volume is in hundreds of magnitude.Road spectrum signal before and after simplifying utilizes Fourier transformation be converted into the power spectral density signal of frequency domain and contrast and calibrate.If the power spectral density signal before Jian Huaing differs bigger with the root-mean-square value of the power spectral density signal after simplification, then need the road spectrum after simplifying is modified, until the root-mean-square value error of the power spectral density signal after road spectrum simplifies and before simplification is within 10%, then it is assumed that the road spectrum after this simplification is equivalence road spectrum.
Step 2, the process of headlight thermal force
Simulation winter and the ambient temperature in summer, turn on light to headlight and the internal temperature field do not turned on light under two kinds of operating modes emulate, obtain the headlight temperature field data in the case of four kinds respectively.Wherein, ambient temperature data is collected by vehicle road test in winter and vehicle road test in summer respectively.Use thermal analysis software (such as: Flotherm) to respectively obtain the thermo parameters method considered under ambient temperature simulation analysis headlight closed mode, and consider ambient temperature and the Temperature Distribution under bulb heat radiation simulation analysis headlight opening.In conjunction with being determined the time scale turned on light He do not turn on light by market survey result, set up temperature field data splitting.
Step 3, heat engine coupling analysis of Fatigue-life
In HyperMesh software, to carry out grid discrete for parts each to headlight, discrete grid model is imported ABAQUS, set up headlight assembly FEM (finite element) model, input the hot physical property of each parts and mechanical characteristic, to contacting with each other between each structure and assembly relation is defined, such as: regulation high beam light angle and the dimming mechanism in direction, the bigger magnitude of interference is there is in its universal ball end in initial assembling, simultaneously by the pretightning force effect of pretension bolt, under original state, just bear bigger mechanical load effect.Steps for importing 2 calculated temperature field data splitting, the equivalent road spectrum applying step 1b gained encourages, calculate the thsrmal-mech coupling strain-responsive of an interior vehicle lamp assembly structure of circulation, calculated structure thsrmal-mech coupling strain data is imported in analysis of fatigue software (such as: MSC.Fatigue), the fatigue properties of material is set, thsrmal-mech coupling field in the time period that appointment is above analyzed is a Life Cycle load, by being calculated headlight heat engine fatigue life.
Claims (3)
1. a Vehicle headlamp structure analysis of Fatigue-life method, it is characterised in that comprise the following steps:
Step 1, headlight mechanical load process
1a, road modal data gather and correction
With vehicle body junction, three-way vibration acceleration transducer is installed at headlight, section requirement by test site car load road reliability test, gather the combination road spectrum on different stage road surface, and the modal data that satisfies the need is corrected, eliminate the singular point in data and the trend term caused because of systematicness interference factor；
1b, the road spectrum after correction is simplified, calibrates
The feature of the peak load in reservation data, small magnitude load less than fatigue limit is carried out equivalent process, road spectrum signal before and after simplifying utilizes Fourier transformation be converted into the power spectral density signal of frequency domain and contrast and calibrate, until the root-mean-square value error of the power spectral density signal after road spectrum simplifies and before simplification is within 10%, then the road spectrum after this simplification is equivalence road spectrum；
Step 2, the process of headlight thermal force: simulation winter and the ambient temperature in summer respectively, turn on light to headlight and the internal temperature field do not turned on light under two kinds of operating modes emulate, obtain the headlight temperature field data in the case of four kinds；In conjunction with being determined the time scale turned on light He do not turn on light by market survey result, set up temperature field data splitting；
Step 3, heat engine coupling analysis of Fatigue-life: set up headlight assembly FEM (finite element) model, input the hot physical property of each parts and mechanical characteristic, to contacting with each other between each structure and assembly relation is defined, steps for importing 2 calculated temperature field data splitting, the equivalent road spectrum applying step 1b gained encourages, calculate the thsrmal-mech coupling strain-responsive of an interior vehicle lamp assembly structure of circulation, calculated structure thsrmal-mech coupling strain data is imported in analysis of fatigue software, the fatigue properties of material is set, thsrmal-mech coupling field in the time period that appointment is above analyzed is a Life Cycle load, by being calculated headlight heat engine fatigue life.
Vehicle headlamp structure analysis of Fatigue-life method the most according to claim 1, it is characterised in that: the ambient temperature data in described step 2 is collected by vehicle road test in winter and vehicle road test in summer respectively；
Use thermal analysis software to respectively obtain the thermo parameters method considered under ambient temperature simulation analysis headlight closed mode, and consider ambient temperature and the Temperature Distribution under bulb heat radiation simulation analysis headlight opening.
Vehicle headlamp structure analysis of Fatigue-life method the most according to claim 1 and 2, it is characterised in that: in described step 1a, use high-pass filtering method, balance deflection method and method of least square that the road modal data gathered is corrected.
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| CN106610355A (en) * | 2015-10-22 | 2017-05-03 | 中国科学院力学研究所 | Heat engine fatigue test method and device |
| CN106768760B (en) * | 2016-12-21 | 2018-12-21 | 航天东方红卫星有限公司 | A kind of spacecraft swept-sine vibration Fatigue Invalidation Analysis method |
| CN107389478B (en) * | 2017-06-22 | 2019-11-12 | 上海工程技术大学 | A kind of prediction technique of the material fatigue life based on wavelet packet analysis |
| CN108573081A (en) * | 2017-07-05 | 2018-09-25 | 常州星宇车灯股份有限公司 | A kind of thermal deformation analysis method of Thermal-mechanical Coupling simulated automotive lamp reflector |
| CN108052717B (en) * | 2017-12-01 | 2021-09-03 | 中国航空工业集团公司沈阳飞机设计研究所 | Fatigue life calibration method based on local stress-strain method |
| CN110598234A (en) * | 2019-05-07 | 2019-12-20 | 重庆长安汽车股份有限公司 | Vehicle dynamics model parameter calibration method |
| CN110414087B (en) * | 2019-07-10 | 2023-01-24 | 北京华安中泰检测技术有限公司 | Electronic product service life evaluation method under multi-stress coupling effect |
| CN112989665B (en) * | 2021-03-23 | 2023-02-07 | 重庆理工大学 | Fatigue life analysis method for electric drive assembly differential mechanism shell |
| CN114297884A (en) * | 2021-11-08 | 2022-04-08 | 常诚车业江苏有限公司 | Car lamp fatigue life simulation evaluation and optimization method for composite vibration at high temperature |
| CN114184405B (en) * | 2021-11-29 | 2023-06-16 | 重庆长安汽车股份有限公司 | Assessment method and system for thermal strain fatigue life of automobile radiator assembly |
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