汽车耐久性试验技术

第三开发部2结构耐久性在整车开发中的应用客户关联（公共道路数据库）耐久性DVP矩阵可靠性的18种工具3第一部分：结构耐久在整车开发过程中的应用客户需求设计CAE试验室道路设计验证公共道路定义客户需求制定DVP执行DVP整车系统部件道路（试验场）试验里程累积试验客户关联载荷谱采集CAE分析试验室试验1.产品寿命2.驾驶习惯3.路面4.环境1.设计2.材料3.加工制造4.质量控制7第二部分：客户关联（公共道路数据库）客户关联用来定义了客户使用车辆过程中的操作频率，载荷以及环境。它界定了系统/子系统/部件必须服从的操作状况分布。客户关联可以是针对整车，也可以针对系统、部件，它的输出物是客户使用应力分布，整车试验场耐久性试验程序，关键寿命试验方法等等8公共道路数据库是指通过一种或者几种基准载荷谱采集样车，对公共道路进行载荷谱采集，从而形成整车结构强度基准数据库；9RequiredTest客户需求设计设计验证客户需求设计设计验证客户需求设计验证设计验证客户需求设计验证设计验证10客户1客户2客户3客户???……采集样车公共道路11市场调查目的：确定特定市场的路面状况高速公路比例一般公路比例坏路比例乘客数量以及行李重量各种典型道路选定特定市场有代表性的车型调查方法电子邮件电话面谈每个特定市场至少1000名客户12数据采集通道选择六分力车身扭曲应力集中点的应变信号典型通道减震器安装座控制臂球头转向横拉杆及连接杆减震器及螺旋弹簧发动机悬置13开发运转工况及进行试验场测量失效及统计分析试验场程序公共道路数据M.R.E.R.S.R.客户调查14CAE/试验室试验020406080100BodyTrimA/CElectricDriveShaftsClutchManualTransm.AutomaticTransm.ExhaustMountsFuelInjectionFEADBaseengineSuspensionFuelsystemBrakesSteering90%-ilePASCAR试验场试验极端客户15第三部分：耐久性DVP矩阵任何一种试验都有其局限性。为了建立足够Robust的耐久性DVP计划，必须建立耐久性DVP矩阵，考虑所有的Noisefactor。16零部件系统整车结构耐久性试验PT耐久性试验抗腐蚀性试验强度试验17181920212223RoadCycleDynamometerDurabilityTestDearborn-CologneDurabilityCycle-NoThermalOverlayFIEDynamometerTestCrankshaftDurabilityTest180HourHighSpeedDurabilityCycle100HourHighSpeedEnduranceCylinderHeadJointKeyLifeTest(KLT)DeepThermalShockExhaustManifoldThermalCycleDearborn-CologneDurabilityCycle-WithThermalOverlayDeepColdStartsSimulatedTransmissionShiftCycleFEADDurabilityWideRangeTemperature(WRT)WearTestOneHourBearingLinerTest(20/20/20)Dynamometer400HourSludgeTestLowSpeedDurability--Cam&TappetPistonColdScuffPistonHotScuffAcceleratedPistonHotScuffPiston&CylinderHeadGasketTestPurposeToevaluatethedurabilityandreliabilitycharacteristicsofanengineatspeedsandloadstypicalofcustomeruse.Accessoriesareloadedandenginecoolantisforce-cooled.ToinvestigatethedurabilityandreliabilityoftheentireenginesystematspeedandloadconditionsderivedfromanAutobahndrivecycle.Toinvestigatethestructuralintegrityofanengineatsustainedhighspeedandhighloadconditions.Toevaluatethedurabilityofenginecomponentswhilerunningwithmaximumcrankshafttorsionalvibrationamplitudes.Toinvestigatethestructuralfatiguedurabilityofanengine(and/orcomponentparts)athighenginespeeds.Toinvestigatetheendurancequalityofanengineand/orcomponentpartsathighspeedoperation.Togeneratehighmileage/time-in-servicefailuremodesassociatedwithcylinderheadjointandgasketserviceto10yr/150,000milelifespan.Tosubjectthecylinderheadgasket(s)toheatinganddeepthermalcyclestoverifytheintegrityofthecylinderheadgasketsealandothersealingsurfaces.Tosubjecttheexhaustmanifold(s)toheatingandcoolingcyclestoverifythestructuraldurabilityoftheexhaustmanifolddesign.Toinvestigatethedurabilityandreliabilityofthecylinderheadgasketandenginesealingcomponents.OBSOLETEToverifytheintegrityofgasketsealsbysubjectingtheenginetoheatinganddeepcoolingcycles.OBSOLETEToevaluatethedurabilityofthebaseengine,engine-mountedcomponents,andFEADcomponentssubjectedtoenginefiringorderforces(vibrations)duringtransientengineoperationinneutral.Toevaluatethewearcharacteristicsoftheentireenginethroughoperationatmixedcoldandhotoperationconditionsandlighttomoderateloadswithdegradedengineoil(grannycycle).Todeterminetheenginebearinglinermaterialcharacteristicsunderacceleratedconditions.Toevaluatethesludgingcharacteristicsofallgasolineengines.Theengineisrunatworstcaseconditionsforsludgeformation.Toassessvalvetraindurabilityatlowenginespeedconditionswhichcorrespondtohighcamshaftstresslevelsatlowoilpressure.Todeterminetheabilityofthepistontoresistscuffincoldoperatingconditions.Toevaluatethepistonringandskirtfit.Toevaluatethepistonandpistonringforscuffunderextremeconditionscausedbylossofcoolantcirculation.Todeterminetheendurancequalitiesofthepistonandcylinderheadgasket(s)underseveretestconditions.TestClassificationSystemTestStructural/SystemTestStructuralFatigueStructuralFatigueStructuralFatigueStructuralFatigueThermalFatigueThermalFatigueThermalFatigueThermalFatigueThermalFatigueVibrationWearWearSludge/DepositKLTKLTKLTKLTKnockToleranceComponentsOnTest*AllALL,thisisanenginesystemtestBlocks,CylinderHeads,IntakeManifold,Lubrication,Valvetrain,Piston&Rod,Crankshaft,BearingsPiston&Rod,Crankshaft,CamdriveBlocks,CylinderHeads,Lubrication,Valvetrain,Piston&Rod,Crankshaft,BearingsPiston&Rod,CrankshaftCylinderHead(surface),CylinderHeadGasket,Block(deckface)CylinderHeads,IntakeManifolds,Camdrive,Lubrication,HeadGasket,Sealing,CoolingExhaustManifold,ExhaustManifoldHeatShieldCylinderHeadGasket,SealingLubrication,CamdriveAccessoryDrive,Int.Manifold,Exh.Manifold,Valvetrain,Camdrive,Lubrication,Ignition,Crank,Sealing,FuelCharging,EmissionControlsAll-thisisanenginesystemtest.Crankshaft,MainBearings,RodBearingsNOTREQUESTEDBYV-ENGINELubricationSystem,PCVSystem,PistonRingsCamshaftLobesPiston,PistonRings,CylinderBoresPiston,PistonRings,PistonPin,CylinderBoresPiston,PistonRings,PistonPin,CylinderBoresHeadGasket,Crankshaft,Piston&RodOBSOLETELoadRangeIdletoFullLoadIdle,20%,40%,60%,80%,WOTIdle,NoloadandFullloadFullloadIdleandFullloadFullloadNoLoadtoFullLoadNoLoadandFullLoadMotoredand