Study On Virtual Test Of Power Performance, Fuel Economy And Ride Comfort Of Mining Dump Truck

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.