Multi-Axis Simulation Test for Two-Wheeler Carrier Structure of a Commercial Vehicle using Accelerated Road Load Data

Paper #:
  • 2017-01-0218

  • 2017-03-28
In the present scenario, delivering the right product at the right time is very crucial in automotive sector to grab the competitive advantage.In recent days, most of the commercial vehicle OEM’s started producing fully build solution products such as oil tanker, mining tipper and two-wheeler carrier based on the market requirements.During the development phase, all automotive components undergo stringent validation protocol in proving ground as well as in lab test which consumes most of the product development time. This project focuses on developing accelerated durability test for two-wheeler carrier structure of a heavy commercial vehicle.Two-wheeler carriers are commercial vehicles used to carry scooters and bikes in multiple decks over a long distance. The structure on which the scooters mounted will undergo variable amplitude fatigue loading.Any new design of two-wheeler carrier structure needs to be validated prior to production release. So, we acquired acceleration data from head to toe of a proto vehicle in the typical routes of a customer at different loading conditions. The roads were classified as good and bad road based on axle acceleration values. The measured acceleration data was compressed using proper scale and damage retention factors. The Spectrum and transmissibility of acceleration signals at frame and deck were thoroughly studied. Hotspots in the scooter carrier structure were strain gauged and compared the damage retention in compressed data against the road load data.Good correlation was obtained between acceleration and strain based editing of road load data. Test setup was designed to have same transmissibility and boundary conditions as in vehicle.One of the rear decks was fitted with mock-up structure of two-wheeler, and multi-axis simulation test with proper proportion of good and bad roads was completed in a shorter span of time.
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