Abstract
To establish the loading spectrum for rig test of a car powertrain, non-contact torque telemeter is adopted to measure the testing data, including target vehicle transmission shaft torque, rotation speed, and engine rotation speed, under the typical cases of customers’ actual usage. Then, the Process Builder module in Tecware is used to establish the gear split batch-processing model and process the customer data into target rotating rainflow counting cyclic matrix and eliminate the small cyclic loads which have relatively smaller influence on the fatigue life. Next, based on the road percentage and data collected in actual customer survey, the total cumulative damage of 90% customer is calculated according to the Weibull distribution equation, and powertrain damage calculation model for fatigue cumulative damage and its probability distribution function is examined by Kolmogorov–Smirnov. Finally, the customer data are compressed into block loading spectrum which can be identified by the rig test based on the fatigue damage equivalent principle, thus achieving the powertrain rig assembly testing life equivalent to the customers’ usage life. The car powertrain rig test can replace the full-vehicle road test, which efficiently lowers the testing cost and shortens the testing period.
Highlights
The reliability test of automotive powertrain system serves as an important measure to evaluate and verify the durability of powertrain
These studies are mainly centered on evaluating the ‘‘vehicles’ structure.’’6–8 In addition, there is a lack of studies on the related mechanism of rig reliability test and full-vehicle road test of powertrain
According to the linear equation of Weibull distribution probability paper and actual customer survey data, the fatigue damage calculation model for customer powertrain with a failure probability of 90% for typical road types used by customers is given as 1⁄2fciDc + feiDe + ftiDt + fgiDg Á Wai = Di ð12Þ
Summary
The reliability test of automotive powertrain system serves as an important measure to evaluate and verify the durability of powertrain. The fatigue damage number of rotations equivalent to each pair of Tin and REVin can be calculated by equation (7) It has been indicated by the analysis results of gear box gears in automobile transmission system that the bending torque which the regional gear is subject to and the number of cycles are linearly related to the input shaft torque and number of rotations. According to the linear equation of Weibull distribution probability paper and actual customer survey data (traveling road percentage and load mass), the fatigue damage calculation model for customer powertrain with a failure probability of 90% for typical road types used by customers is given as 1⁄2fciDc + feiDe + ftiDt + fgiDg Á Wai = Di ð12Þ. Monte Carlo simulation method is used to establish a normal distribution statistical model to calculate the 90% customer target total fatigue damage. The greater the number of simulation calculations, the closer the mean statistical value to the actual value
Sign-in/Register to view highlights & summary Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
