Car Wheel Dynamic Cornering Fatigue Test Machine
10/08/2024
Project Introduction
Fatigue breakdown is the primary failure mode for car wheels and is directly related to passenger safety. The bending fatigue strength is a critical parameter for assessing this condition. In this case, a microprocessor-controlled car wheel bending fatigue automatic test system is employed for real-time monitoring, control, and display, ensuring stability of the bending moment throughout the test. The system monitors rotation numbers to determine if the wheel passes the test and issues an alarm for fatigue before a breakdown occurs.
Car wheels, crucial for safety and comfort, undergo stringent manufacturing processes, including casting, stamping, forming, welding, and anti-corrosion treatment. The forces acting on wheels during driving are complex, involving support, lateral bending moments, and driving forces, along with temperature and pressure changes due to rotation and friction. Therefore, ensuring the fatigue lifespan meets application and performance requirements is a fundamental aspect of wheel design and manufacturing.
System Requirements
Typically, wheel fatigue lifespan tests and inspections include two aspects: The wheel radial fatigue test, which primarily inspects the comprehensive strength of the entire wheel, and the wheel bending fatigue test, which examines the wheel spoke and weld strengths. The test machine is to understand the changes in torque and the displacement deformation of the wheel under different rotational speeds. The machine is equipped with a laser sensor to detect wheel displacement deformation, and a load cell is used to detect changes in torque. Additionally, proximity switches are installed to detect displacement limits, upper and lower height limits, safety doors, aluminum plate protection, and other safety measures. The displacement and torque graph is continuously displayed to show the operating conditions of the wheel.
- Range of the primary wheel shaft rotation speed test: 40 to 400 RPM
- Pressure load test range: 0 to 70 kN.
- 50,000 test cycles follow the standard IS 9436:2018
- Highly efficient, anti-vibration computing platform.
- Highly efficient, anti-vibration computing platform.
- Machine layout is reasonable, compact, and easy to maintain.
Project Implementation
- ACP-4020: Compact 4U Rackmount Chassis for Half-size SBC or ATX/MicroATX Motherboard
- AIMB-788: LGA1700 12th/13th/14th Gen. Intel® Core™ i9/i7/i5/i3 ATX Motherboard with DP/HDMI/VGA, DDR4, USB 3.2, M.2
- PCIE-1812: 250 kS/s, 16-bit, 8-ch, Simultaneous Sampling, Multifunction PCIE Card
System Description
The main function is controlled by a computer through a digital input/output (DI/DO) card and an analog-to-digital (A/D) card to operate servo motors, simulating the rotation of automotive wheels.
The PCIE-1812 simultaneous sampling multifunction data acquisition board, with a 250 kS/s sampling rate, 16-bit high resolution A/D input channels, 32-ch programmable DI/DO and 32-bit counter/ timer/ encoder channels can fully satisfy the wheel rotation speed and pressurized force measurement requirements.
In Advantech’s compact 4U rackmount IPC ACP-4020 chassis with AIMB-788, the 12th/13th/14 Gen. Intel® Core™ i motherboard was used in combination with the PCIE-1810 to perform rapid data acquisition. The ACP-4020’s hot-swap drive bay ensures fast data transition, while its compact size optimizes space. This setup enables instant display of collected data on the human-machine interface, facilitating analyses, recording, report generation, and more.
System Diagram
Conclusion
Ensuring the fatigue strength of car wheels is vital for passenger safety, as fatigue breakdown is a primary failure mode. A microprocessor-controlled test system monitors wheel rotation, using digital input/output and analog-to-digital cards to operate servo motors simulating wheel rotation. The PCIE-1812 data acquisition board with high sampling rate and resolution measures rotation speed and pressure accurately. Advantech’s 4U rackmount IPC ACP-4020 chassis, combined with the AIMB-788 motherboard, enables rapid data acquisition and real-time display, facilitating comprehensive analysis and reporting. This robust setup ensures wheels meet stringent safety and performance standards.
Related Products
Advantech
AIMB-788
