矿用自卸汽车动力性、燃油经济性和平顺性虚拟试验技术研究
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摘要
本文结合企业合作项目“矿用自卸汽车虚拟试验技术研究”和江苏省教育厅自然科学基金项目“矿用自卸汽车动力性和经济性的虚拟试验研究”(06KJD440026),论述了矿用自卸汽车虚拟试验的研究内容,构建了虚拟试验功能框架,建立了机械传动和液力机械传动矿用自卸汽车动力传动系各总成模型、工况循环模型、整车控制模型,并将各模型封装成整车模型。面向用户使用环境,采用转速和转矩为控制参数的两参数换挡规律,以前向仿真和后向仿真相接合的仿真方法,开发矿用自卸汽车性能仿真软件。该软件能虚拟试验指定工况循环的车辆跟随性能、车辆动力性和燃油经济性,仿真车辆驱动链之间的工作,可对各部件功率流进行分析。对液力机械传动和机械传动两种类型的矿用自卸汽车进行动力性和燃油经济性的虚拟试验,并与实车试验结果进行了对比,虚拟试验结果和实车测试结果吻合较好。以燃油经济性为优化目标,用遗传算法优化变速箱各挡传动比。考虑车架弹性,建立了整车刚-弹耦合动力学模型,利用该模型进行平顺性虚拟试验,并与实车试验结果进行了对比,提取了车架关键位置的动应力曲线,为研究车架的疲劳寿命提供了条件。基于计算机仿真技术的矿用自卸汽车动力性、燃油经济性和平顺性虚拟试验,缩短了新产品开发周期,降低了开发成本。本文的研究成果已在国内矿用自卸汽车生产的骨干企业中应用,为矿用自卸汽车的设计提供了依据。
Power performance, fuel economy and ride comfort are the main performances of mining dump truck that should be analyzed and tested when all the new vehicles are developed. The traditional method is to create a physical prototype on which various testing equipments are installed to do prototype test. Only after the actual prototype testing, the power performance, fuel economy and ride comfort of vehicle can be assessed according to existing regulations and standards. The deficiencies of the design can be improved according to the test results, then further test can be done. So the new product development period is long and the cost of test is high. Based on the above issues, this dissertation studied the virtual test of power performance, fuel economy and ride comfort of mining dump truck. It also studied and established the power-train model of mine dump truck, developed a mine dump truck performance simulation software for user-oriented environment, and based on this software it constructed the power-train parameter optimization method for user-oriented environment.
Considering the frame elasticity, using the theory of elastomeric dynamics, established the rigid-elastic coupling dynamics model of the vehicle, using this model, not only the ride comfort of mine dump truck can be virtual tested but also the dynamic stress curve of the key location of frame can be extracted, this lays a foundation for the study of the fatigue life of frame.
In light of the major study contents mentioned above, this dissertation has done some specific works as follows:
First, through analyzing the research on virtual prototype technology, and the methods of virtual test of power performance, fuel economy and ride comfort of mining dump truck , building the platform for research on mining dump truck virtual test simulation based on virtual prototype technology.
Second, it studied and established the power-train model of mine dump truck, including engine model, subsidiary system power distribution model, clutch model, Torque-converter model, gear-box model, drive axle model, wheel model, traveling resistance mathematical model, drive cycle model and vehicle control model, etc, the vehicle model can be gotten by encapsulating all the models above. Using two parameters shift law, the control parameters of which are the rotate speed and the torque of the engine, based on the graphic user interface design environment, developed the mine dump truck performance simulation software for user-oriented environment. The software can virtual test power performance and fuel economy of mine dump truck, it can also virtual test follow performance of specified drive cycle, moreover it can simulate the work between drive chain of the vehicle and analyze the power distribution of every components.
Third, it did test on power performance and fuel economy of mine dump truck, the major test contents are as follows: consign engine manufacturer did engine performance test; did test on the position of the center of gravity and on sliding the results of which can be used to calculate the rolling resistance coefficient and the upwind drag coefficient; did the maximum speed test and the accelerated performance test; chose the direct block to do fuel consumption under one certain speed; joint and consigned the user of mine dump truck do the actual use of the fuel consumption test; did virtual test on power performance and fuel economy of mine dump truck, contrasted the results to the actual test results, this verifies the correctness of the power performance and fuel economy simulation model is correct. did virtual test on power performance and fuel economy of mine dump truck,which power-train model including torque-converter.
Fourth, it designed optimization method for user-oriented environment, the user could choose drive cycle to optimize the power-train parameter based on the working conditions of mine dump truck, the optimization targets is fuel economy and the optimization variables are the gear-box transmission ratio from Part I to VIII block which can be optimized using genetic algorithm (GA). Virtual test results prove that the final result of the optimization program is better than the original design. It also analyzed the parameter sensitivity the computation and analysis results show that the parameter sensitivity order of the power performance and fuel economy of mine dump truck from the biggest to the smallest is drive efficiency, rolling resistance coefficient and air resistance coefficient. Fifth, using a 3D modeling software the name of which is UG to establish the physical model of the frame and got its finite element model in ANSYS, create the elastomer neutral file of the frame and put the file into ADAMS. Established the 3D geometric models of the components on the frame, front axle, rear axle, crossbeam and A-frame and put these models into ADAMS. Established the ADAMS model of tyre, the front and rear suspension, the rigid-elastic coupling dynamics model of the vehicle can be established on the base of this. Using harmonic superposition method to generate C-class road model, established a triangular block-pulse input model according to the pulse input regulations in the vehicle ride comfort test method in GB/T5902-1986.
Sixth, it tested the ride comfort at the speed of 10km/h,20km/h,30km/h and 40km/h on the random road. Using the rigid-elastic coupling dynamics model of the vehicle, the acceleration on the fore-and-aft, right-and-left and vertical direction of the driver seat can be virtual tested on the C-class road. It tested the ride comfort on the step road at the speed of 10km/h and the ride comfort was also virtual tested on the triangular block pulse excitation road. The results of the virtual test and the actual test on the C-class road and the triangular block pulse excitation road show that the rigid-elastic coupling dynamics model of the vehicle in this paper is correct. It also did dynamics simulation on the C-class road and the triangular block pulse excitation road by the use of established rigid-elastic coupling dynamics model of mining dump truck, then the dynamic stress curve of the key location of frame can be extracted, this lays a foundation for the study of the fatigue life of frame.
Virtual test of power performance, fuel economy and ride comfort of mining dump truck which is based on computer simulation technology and the dynamic stress simulation curve of the frame on the basis of virtual test of ride comfort shorten the time and ruduce the cost of the developmen of new products. The research results of this paper have been applied in a cooperative enterprise production design, they provide a basis for mine dump truck design.
Power performance, fuel economy and ride comfort are the main performances of mining dump truck that should be analyzed and tested when all the new vehicles are developed. The traditional method is to create a physical prototype on which various testing equipments are installed to do prototype test. Only after the actual prototype testing, the power performance, fuel economy and ride comfort of vehicle can be assessed according to existing regulations and standards. The deficiencies of the design can be improved according to the test results, then further test can be done. So the new product development period is long and the cost of test is high. Based on the above issues, this dissertation studied the virtual test of power performance, fuel economy and ride comfort of mining dump truck. It also studied and established the power-train model of mine dump truck, developed a mine dump truck performance simulation software for user-oriented environment, and based on this software it constructed the power-train parameter optimization method for user-oriented environment.
Considering the frame elasticity, using the theory of elastomeric dynamics, established the rigid-elastic coupling dynamics model of the vehicle, using this model, not only the ride comfort of mine dump truck can be virtual tested but also the dynamic stress curve of the key location of frame can be extracted, this lays a foundation for the study of the fatigue life of frame.
In light of the major study contents mentioned above, this dissertation has done some specific works as follows:
First, through analyzing the research on virtual prototype technology, and the methods of virtual test of power performance, fuel economy and ride comfort of mining dump truck , building the platform for research on mining dump truck virtual test simulation based on virtual prototype technology.
Second, it studied and established the power-train model of mine dump truck, including engine model, subsidiary system power distribution model, clutch model, Torque-converter model, gear-box model, drive axle model, wheel model, traveling resistance mathematical model, drive cycle model and vehicle control model, etc, the vehicle model can be gotten by encapsulating all the models above. Using two parameters shift law, the control parameters of which are the rotate speed and the torque of the engine, based on the graphic user interface design environment, developed the mine dump truck performance simulation software for user-oriented environment. The software can virtual test power performance and fuel economy of mine dump truck, it can also virtual test follow performance of specified drive cycle, moreover it can simulate the work between drive chain of the vehicle and analyze the power distribution of every components.
Third, it did test on power performance and fuel economy of mine dump truck, the major test contents are as follows: consign engine manufacturer did engine performance test; did test on the position of the center of gravity and on sliding the results of which can be used to calculate the rolling resistance coefficient and the upwind drag coefficient; did the maximum speed test and the accelerated performance test; chose the direct block to do fuel consumption under one certain speed; joint and consigned the user of mine dump truck do the actual use of the fuel consumption test; did virtual test on power performance and fuel economy of mine dump truck, contrasted the results to the actual test results, this verifies the correctness of the power performance and fuel economy simulation model is correct. did virtual test on power performance and fuel economy of mine dump truck,which power-train model including torque-converter.
Fourth, it designed optimization method for user-oriented environment, the user could choose drive cycle to optimize the power-train parameter based on the working conditions of mine dump truck, the optimization targets is fuel economy and the optimization variables are the gear-box transmission ratio from Part I to VIII block which can be optimized using genetic algorithm (GA). Virtual test results prove that the final result of the optimization program is better than the original design. It also analyzed the parameter sensitivity the computation and analysis results show that the parameter sensitivity order of the power performance and fuel economy of mine dump truck from the biggest to the smallest is drive efficiency, rolling resistance coefficient and air resistance coefficient. Fifth, using a 3D modeling software the name of which is UG to establish the physical model of the frame and got its finite element model in ANSYS, create the elastomer neutral file of the frame and put the file into ADAMS. Established the 3D geometric models of the components on the frame, front axle, rear axle, crossbeam and A-frame and put these models into ADAMS. Established the ADAMS model of tyre, the front and rear suspension, the rigid-elastic coupling dynamics model of the vehicle can be established on the base of this. Using harmonic superposition method to generate C-class road model, established a triangular block-pulse input model according to the pulse input regulations in the vehicle ride comfort test method in GB/T5902-1986.
Sixth, it tested the ride comfort at the speed of 10km/h,20km/h,30km/h and 40km/h on the random road. Using the rigid-elastic coupling dynamics model of the vehicle, the acceleration on the fore-and-aft, right-and-left and vertical direction of the driver seat can be virtual tested on the C-class road. It tested the ride comfort on the step road at the speed of 10km/h and the ride comfort was also virtual tested on the triangular block pulse excitation road. The results of the virtual test and the actual test on the C-class road and the triangular block pulse excitation road show that the rigid-elastic coupling dynamics model of the vehicle in this paper is correct. It also did dynamics simulation on the C-class road and the triangular block pulse excitation road by the use of established rigid-elastic coupling dynamics model of mining dump truck, then the dynamic stress curve of the key location of frame can be extracted, this lays a foundation for the study of the fatigue life of frame.
Virtual test of power performance, fuel economy and ride comfort of mining dump truck which is based on computer simulation technology and the dynamic stress simulation curve of the frame on the basis of virtual test of ride comfort shorten the time and ruduce the cost of the developmen of new products. The research results of this paper have been applied in a cooperative enterprise production design, they provide a basis for mine dump truck design.
引文
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