汽车电器系统振动可靠性试验系统的研究与开发
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摘要
“汽车电器系统振动可靠性试验系统”是为开展汽车电器系统道路模拟试验而开发的试验室台架试验系统,是在试验室内借助试验设备较真实的模拟汽车电器在实际道路试验中的工况,对系统及部件的抗振性能进行考核,用于品质鉴定和设计指导,同时达到简化产品检验程序、节约试验成本的目的。
本试验系统是对整车电器系统的整体移植,要求电器系统处于正常工作状态下,并按路谱信号施加一定频率和加速度的振动激励,实现工况还原。以项目需求分析及电器系统整体布局为基础,构建了试验台夹具系统的初始结构模型,建立以结构重量、频率响应为优化设计目标的结构优化模型,通过拓扑优化、灵敏度分析、尺寸优化等方法获得了最佳的结构模型。采用LXI总线的模块化仪器构建了基于以太网的在线监控系统,根据信号特性合理选择仪器功能模块,进行硬件及软件设计,实现试验过程的数据采集、状态显示、数据记录和故障诊断报警。
最终完成系统的集成,形成一套适用于多车型电器系统振动可靠性试验系统。在试验过程中达到以自动化降低人工负荷,以设备保障试验数据的可靠性的目的,使汽车电器产品试验成为一个可控、可溯、可重复的过程。
The“System of Automotive Electric System Vibration Reliability Test”is one test system designed for the road simulation test for automotive electric system. It is that by using of test equipment indoors to simulate working condition of automotive electrics in actual road test, to assess anti-vibration performance of electric system and components, for quality identification and design guide, and reach the purpose of simplifying product test procedures and saving cost.
In this system, the automotive electric system as a whole transplant, required electric system in normal working condition, according to spectrum signal to exert vibration incentive with certain frequency and acceleration, achieving the working condition revert. Based on project need analysis and electric system overall layout, establish a structural optimization model with an optimization design target of structural weight and frequency response. Best structural model is obtained by the topology optimization, sensitivity analysis and size optimization. The Real-time monitoring is based on Ethernet by using LXI BUS modular instruments. Accomplish the hardware and software design according to characteristics of signals, to achieve data acquisition, status display, data processing, alarm and fault diagnosis in the process of monitoring.
Complete the system integration, which could be applied to different kinds of automobiles, for the purpose that using automation to reduce artificial load and to protect the reliability of test data by equipments. It makes testing of automotive electrical product to be a controllable, traceable and repeatable process.
本试验系统是对整车电器系统的整体移植,要求电器系统处于正常工作状态下,并按路谱信号施加一定频率和加速度的振动激励,实现工况还原。以项目需求分析及电器系统整体布局为基础,构建了试验台夹具系统的初始结构模型,建立以结构重量、频率响应为优化设计目标的结构优化模型,通过拓扑优化、灵敏度分析、尺寸优化等方法获得了最佳的结构模型。采用LXI总线的模块化仪器构建了基于以太网的在线监控系统,根据信号特性合理选择仪器功能模块,进行硬件及软件设计,实现试验过程的数据采集、状态显示、数据记录和故障诊断报警。
最终完成系统的集成,形成一套适用于多车型电器系统振动可靠性试验系统。在试验过程中达到以自动化降低人工负荷,以设备保障试验数据的可靠性的目的,使汽车电器产品试验成为一个可控、可溯、可重复的过程。
The“System of Automotive Electric System Vibration Reliability Test”is one test system designed for the road simulation test for automotive electric system. It is that by using of test equipment indoors to simulate working condition of automotive electrics in actual road test, to assess anti-vibration performance of electric system and components, for quality identification and design guide, and reach the purpose of simplifying product test procedures and saving cost.
In this system, the automotive electric system as a whole transplant, required electric system in normal working condition, according to spectrum signal to exert vibration incentive with certain frequency and acceleration, achieving the working condition revert. Based on project need analysis and electric system overall layout, establish a structural optimization model with an optimization design target of structural weight and frequency response. Best structural model is obtained by the topology optimization, sensitivity analysis and size optimization. The Real-time monitoring is based on Ethernet by using LXI BUS modular instruments. Accomplish the hardware and software design according to characteristics of signals, to achieve data acquisition, status display, data processing, alarm and fault diagnosis in the process of monitoring.
Complete the system integration, which could be applied to different kinds of automobiles, for the purpose that using automation to reduce artificial load and to protect the reliability of test data by equipments. It makes testing of automotive electrical product to be a controllable, traceable and repeatable process.
引文
[1]安相壁,唐天元.汽车试验工程[M].国防工业出版社:北京,2006.3.1-9.
[2]李光攀,过学迅,杨波,汪斌.汽车耐久可靠性试验方法[J].天津汽车. 2008.10:34-37.
[3]谭德荣,孟宪皆.汽车室内模拟试验综述[J].山东工程学院学报. 1998.3 ,12(1):57-60.
[4] French. M. An Introduction to Road Simulation Test[J]. Experimental Techniques. May/June. 2000:37-38.
[5]程永全.道路模拟试验系统的关键技术—远程参数控制技术[J].试验技术与试验机.2001.3:32-35.
[6]许素强,夏人伟.结构优化方法研究方法综述[J].航空学报.1995 ,16 (4) :385-396.
[7] GB/T10485—2007,汽车及挂车外部照明和信号装置基本环境试验.
[8] Griffiths D. Vehicle NVH Design Guide. Ford Motor Company, 1993.
[9]杜永昌,管迪华.汽车道路动态试验模拟控制系统的研究与开发[J].汽车技术. 1999.03:26-28.
[10]韩晓峰,董斌,陈剑.汽车电器可靠性试验台的路谱信号采集及其再现[J].噪声与振动控制. 2008,28(5):109-112.
[11]彭为,靳晓雄等.道路模拟试验中道路载荷谱的选择方法[J].上海工程技术大学学报.2004.3:15-18.
[12]罗鹏飞,张文明.随机信号处理[M].清华大学出版社:北京,2006.6.2-128.
[13]陈循,陶俊勇.可靠性强化试验与加速寿命试验综述[J].国防科技大学学报.2002.4:16-18.
[14] Miner线性累计损伤理论在汽车试验场可靠性试验强化系数研究中的应用[J].工程设计学报.2008.04:15-18.
[15]赵少汴.抗疲劳设计[M].机械工业出版社.1994.1:99-120.
[16]靳晓雄,张帆.时域波形再现技术在汽车道路模拟中的应用[J].中国机械工程学报,2006.04:18-22.
[17]傅志方.模态分析理论与应用[M] .上海交通大学出版社:上海.2000.4.1-15.
[18]郭荣平,段文颖等.随机振动试验夹具设计与研究[J].振动、测试与诊断,1997,17(1):50-53.
[19] Poncelet,Marin.Optimal design of fixtures for vibration testing of structures on electro-dynamic shaker.Twelfth International Congress on Sound andVibration.2005.3:1-8.
[20]鲍旭清.基于有限元法的某汽车电器可靠性试验台结构设计研究[D].合肥工业大学硕士学位论文.2009.4:37-50.
[21]何小阳.计算机监控原理及技术[M].重庆大学出版社:重庆,2003.1.1-12.
[22]秦红磊,路辉等.自动测试系统—硬件及软件技术[M].高等教育出版社:北京2007.10. 98-103.
[23] [法]L.F.Pau.故障诊断与性能监测[M].机械工业出版社:北京,1988.5.12-15.
[24]雷达.汽车电器系统振动可靠性试验台在线监测系统开发[D].合肥工业大学硕士学位论文.2009.4:15-20.
[25]任凤文.汽车电线束设计、制造及检验的探讨[J].汽车电器.1997.3:34-37.
[26]李明辉,刘连生.基于虚拟仪器的自动测试系统研究[J].电子测试.2008.3:21-23.
[27]李勇,张华宗.智能化汽车总成仪表寿命试验台[J].汽车技术.2002.2:9-11.
[28]马明建.数据采集与处理技术[M].西安交通大学出版社:西安,1998.9.251-253.
[29]齐同斌,李勇. LXI总线特点及其在自动测试系统中的应用研究[J].黑龙江科技信息.2008.5:26-28.
[30] Yu Wilson. LXI Instrument Development Platform Based on an Open Embedded Operating System [J]. Chinese Journal of Scientific Instrument. Vol.28 No.5 May 2007:788-791.
[31] Agilent 34980A Multifunction Switch/Measure Unit User’s Guide.
[32] Agilent 34411A Digital Multi-function Multimeter User’s Guide.
[33]雷国江等.应用DMM技术的多功能检定系统[J].自动化仪表. 2004.5,25(5):44-46.
[34]刘金宁,孟晨等.自动测试系统的通用测试接口设计与实现[J].仪表技术.2004.5:12-15.
[35]朱旖,杜建军.自动测试系统及其结构和标准[J].国外电子测量技术.2008.8:65-68.
[36]林继鹏,茹锋.虚拟仪器原理及应用[M].中国电力出版社:北京,2009.3.3-12.
[37]王建新,杨世凤. LabWindows/CVI测试技术及工程应用[M].化学工业出版社:北京,2006.8.10-25.
[38]刘守山,周晓军等.汽车驾驶室电路故障检测平台的设计与实现[J].汽车工程.2007.5:24-27.
[39]袁海英.模拟电路的可测性及故障诊断方法研究[J].电子测量及仪器学报.2006.10:15-19.
[40]虞和济.故障诊断的基本原理[M].冶金工业出版社.1989.9:54-69.
[41]马宏,王金波.误差理论与仪器精度[M].兵器工业出版社:北京,2007.2.171-199.
[2]李光攀,过学迅,杨波,汪斌.汽车耐久可靠性试验方法[J].天津汽车. 2008.10:34-37.
[3]谭德荣,孟宪皆.汽车室内模拟试验综述[J].山东工程学院学报. 1998.3 ,12(1):57-60.
[4] French. M. An Introduction to Road Simulation Test[J]. Experimental Techniques. May/June. 2000:37-38.
[5]程永全.道路模拟试验系统的关键技术—远程参数控制技术[J].试验技术与试验机.2001.3:32-35.
[6]许素强,夏人伟.结构优化方法研究方法综述[J].航空学报.1995 ,16 (4) :385-396.
[7] GB/T10485—2007,汽车及挂车外部照明和信号装置基本环境试验.
[8] Griffiths D. Vehicle NVH Design Guide. Ford Motor Company, 1993.
[9]杜永昌,管迪华.汽车道路动态试验模拟控制系统的研究与开发[J].汽车技术. 1999.03:26-28.
[10]韩晓峰,董斌,陈剑.汽车电器可靠性试验台的路谱信号采集及其再现[J].噪声与振动控制. 2008,28(5):109-112.
[11]彭为,靳晓雄等.道路模拟试验中道路载荷谱的选择方法[J].上海工程技术大学学报.2004.3:15-18.
[12]罗鹏飞,张文明.随机信号处理[M].清华大学出版社:北京,2006.6.2-128.
[13]陈循,陶俊勇.可靠性强化试验与加速寿命试验综述[J].国防科技大学学报.2002.4:16-18.
[14] Miner线性累计损伤理论在汽车试验场可靠性试验强化系数研究中的应用[J].工程设计学报.2008.04:15-18.
[15]赵少汴.抗疲劳设计[M].机械工业出版社.1994.1:99-120.
[16]靳晓雄,张帆.时域波形再现技术在汽车道路模拟中的应用[J].中国机械工程学报,2006.04:18-22.
[17]傅志方.模态分析理论与应用[M] .上海交通大学出版社:上海.2000.4.1-15.
[18]郭荣平,段文颖等.随机振动试验夹具设计与研究[J].振动、测试与诊断,1997,17(1):50-53.
[19] Poncelet,Marin.Optimal design of fixtures for vibration testing of structures on electro-dynamic shaker.Twelfth International Congress on Sound andVibration.2005.3:1-8.
[20]鲍旭清.基于有限元法的某汽车电器可靠性试验台结构设计研究[D].合肥工业大学硕士学位论文.2009.4:37-50.
[21]何小阳.计算机监控原理及技术[M].重庆大学出版社:重庆,2003.1.1-12.
[22]秦红磊,路辉等.自动测试系统—硬件及软件技术[M].高等教育出版社:北京2007.10. 98-103.
[23] [法]L.F.Pau.故障诊断与性能监测[M].机械工业出版社:北京,1988.5.12-15.
[24]雷达.汽车电器系统振动可靠性试验台在线监测系统开发[D].合肥工业大学硕士学位论文.2009.4:15-20.
[25]任凤文.汽车电线束设计、制造及检验的探讨[J].汽车电器.1997.3:34-37.
[26]李明辉,刘连生.基于虚拟仪器的自动测试系统研究[J].电子测试.2008.3:21-23.
[27]李勇,张华宗.智能化汽车总成仪表寿命试验台[J].汽车技术.2002.2:9-11.
[28]马明建.数据采集与处理技术[M].西安交通大学出版社:西安,1998.9.251-253.
[29]齐同斌,李勇. LXI总线特点及其在自动测试系统中的应用研究[J].黑龙江科技信息.2008.5:26-28.
[30] Yu Wilson. LXI Instrument Development Platform Based on an Open Embedded Operating System [J]. Chinese Journal of Scientific Instrument. Vol.28 No.5 May 2007:788-791.
[31] Agilent 34980A Multifunction Switch/Measure Unit User’s Guide.
[32] Agilent 34411A Digital Multi-function Multimeter User’s Guide.
[33]雷国江等.应用DMM技术的多功能检定系统[J].自动化仪表. 2004.5,25(5):44-46.
[34]刘金宁,孟晨等.自动测试系统的通用测试接口设计与实现[J].仪表技术.2004.5:12-15.
[35]朱旖,杜建军.自动测试系统及其结构和标准[J].国外电子测量技术.2008.8:65-68.
[36]林继鹏,茹锋.虚拟仪器原理及应用[M].中国电力出版社:北京,2009.3.3-12.
[37]王建新,杨世凤. LabWindows/CVI测试技术及工程应用[M].化学工业出版社:北京,2006.8.10-25.
[38]刘守山,周晓军等.汽车驾驶室电路故障检测平台的设计与实现[J].汽车工程.2007.5:24-27.
[39]袁海英.模拟电路的可测性及故障诊断方法研究[J].电子测量及仪器学报.2006.10:15-19.
[40]虞和济.故障诊断的基本原理[M].冶金工业出版社.1989.9:54-69.
[41]马宏,王金波.误差理论与仪器精度[M].兵器工业出版社:北京,2007.2.171-199.