商用车驾驶室虚拟迭代目标谱优化与分解

Optimization and Decomposition of Virtual Iteration Target Spectrum for Cabin of Commercial Vehicle

商用车驾驶室总成载荷谱是影响虚拟疲劳预测精度与计算效率的关键。本文探究了道路载荷谱采集与编辑、高保真动力学建模以及虚拟迭代等重点环节,以期从工程应用角度获取准确、高效的外联点时域载荷。首先,在试验场实车采集了驾驶室总成全路径道路载荷谱,考虑随机误差对原始数据进行归一化拆分并重组,得到统计性较强的试验场总损伤目标;然后,利用等效损伤原则优选出9段工况及其循环数,不仅将误差控制在10%以内,同时时效提高了75%;随后,结合实测减振元件的性能参数,建立了高保真驾驶室刚柔耦合动力学模型,并通过驾驶室7通道道路模拟台架验证了模型精度;最后,通过虚拟迭代完成了优选工况的载荷分解,迭代误差小于10%。基于上述优选并分解得到的外联点载荷,高效完成了驾驶室本体虚拟疲劳计算,并准确预测了驾驶室焊点失效情况,与道路模拟台架耐久试验结果有较高的吻合度,为商用车驾驶室的设计和优化提供了有力的技术支撑。

The load spectrum of commercial vehicle cab assembly is the key factor affecting the accuracy and computational efficiency of virtual fatigue prediction.In this article,key links such as road load spectrum collection and editing,high fidelity dynamic modeling,and virtual iteration are explored,in order to obtain accurate and efficient external point time-domain loads from the engineering application perspective.Firstly,the full path road load spectrum of the driver's cab assembly is collected from the actual vehicle in the test field,and the original data is normalized,split,and reassembled considering random errors to obtain a statistically strong total damage target in the test field.Then,using the principle of equal damage,9 operating conditions and their number of cycles are optimized,which not only controls the error within 10%,but also increases the efficiency by 75%.Subsequently,based on the performance parameters of the measured damping components,a high fidelity rigid flexible coupling dynamic model of the cab is established,and the accuracy of the model is verified through a 7-channel road simulation bench in the cab.Finally,the load decomposition of the optimal operating conditions is completed through virtual iteration,with an iteration error of less than 10%.Based on the above optimization and decomposition of the external connection point load,the virtual fatigue calculation of the cab body is efficiently completed,and the failure of the cab welding points is accurately predicted,which has a high degree of consistency with the durability test results of the road simulation bench,providing strong technical support for the design and optimization of commercial vehicle cabins.