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Zheng S.,University of Shanghai for Science and Technology | Zheng S.,Machinery Industrial Key Laboratory for Mechanical Strength and Reliability Evaluation of Auto Chassis Components | Liu J.,Machinery Industrial Key Laboratory for Mechanical Strength and Reliability Evaluation of Auto Chassis Components | Feng J.,University of Shanghai for Science and Technology | Feng J.,Machinery Industrial Key Laboratory for Mechanical Strength and Reliability Evaluation of Auto Chassis Components
Advanced Materials Research | Year: 2012

The development of Electric Vehicle is not only a replacement of power source, but a new process of reasonable design and development on the mechanical structure and power system. Considering the strained condition of the support structure when the Electric Vehicle is under the four typical working conditions: accelerating, braking, steering and vertical impact, the dynamic design method and finite element theory are adapted to analysis its strength and mode, while the orthogonal test method is used to analyze the influencing factors of its modes. Combining the size optimization, the weight of the power system's support structure has been reduced. This method, which has been adapted in the independent development of an Electric Vehicle, will provide a useful reference for the dynamical and lightweight design of similar mechanical structure. © (2012) Trans Tech Publications.


Zheng S.,University of Shanghai for Science and Technology | Zheng S.,Machinery Industrial Key Laboratory for Mechanical Strength and Reliability Evaluation of Auto Chassis Components | Chen T.,University of Shanghai for Science and Technology | Chen T.,Machinery Industrial Key Laboratory for Mechanical Strength and Reliability Evaluation of Auto Chassis Components | And 4 more authors.
Proceedings - 19th ISSAT International Conference on Reliability and Quality in Design, RQD 2013 | Year: 2013

As an ideal solution to global energy issues and climatic change, the fuel cell vehicle (FCV) has aroused widespread attention in China and abroad. However, the complex structure of FCV and the weak foundation for manufacturing have hindered the improvement of reliability and the industrialization of FCV. This paper analyses the reliability and durability of FCV with data collected from road tests. Based on such analysis, this paper discusses the failure distribution rules and failure reasons for FCV. Meanwhile, reliability parameters such as MMTFF, MMBF are confirmed. It is also pointed out in this paper the general direction in which technological breakthrough should be made to further improve the reliability and durability of FCV.


Zheng S.,Machinery Industrial Key Laboratory for Mechanical Strength and Reliability Evaluation of Auto Chassis Components | Zheng S.,University of Shanghai for Science and Technology | Gu H.,University of Shanghai for Science and Technology | Feng J.,Machinery Industrial Key Laboratory for Mechanical Strength and Reliability Evaluation of Auto Chassis Components | And 3 more authors.
Qiche Gongcheng/Automotive Engineering | Year: 2012

Based on the basic idea of flexible multi-body system dynamics, a novel flexible body model for suspension bushing is put forward with consideration of the coupling of bushing stiffness in different directions. The deformations of bushing are calculated and its mode shapes are obtained by using modal synthesis technique. Then modal neutral files are generated and input into ADAMS/Car to establish a rigid-flexible coupling dynamics model for four-link suspension, and simulations and real vehicle tests are conducted. The results show that the flexible body bushing model established is more accurate than the conventional one, and can more truly predict and analyze the performance of vehicle suspension at design stage.


Liu X.,University of Shanghai for Science and Technology | Liu X.,Shanghai University of Engineering Science | Zheng S.,University of Shanghai for Science and Technology | Zheng S.,Machinery Industrial Key Laboratory for Mechanical Strength and Reliability Evaluation of Auto Chassis Components | And 3 more authors.
Quality and Reliability Engineering International | Year: 2015

A fuel cell vehicle (FCV) is a type of alternative energy vehicle that could help resolve the energy crisis, mitigate environmental problems, and contribute to sustainable development. Developing an FCV with high reliability is an important goal for automobile factories and research institutions. Other key factors required by FCVs include mass production and customer approval. An FCV is a complex mechanism composed of many subsystems. During the development of the overall vehicle, steps should be taken to ensure that every subsystem is reliable. However, such development must also consider costs, which must be kept as low as possible. To ensure the reliability of FCV while operating under conditions that demand minimal cost, a genetic algorithm is employed to reallocate the reliability of the overall vehicle system. First, the growth factor of the reliability-feasibility of each subsystem is determined according to the complexity, importance, and technological level of the FCV subsystems. The FCV cost model is then established on the basis of such parameters as subsystem cost, reliability-feasibility growth factor, initial reliability, limit reliability, and so on. A genetic algorithm is then used to compute for the reliability of FCV subsystems. The rationality of reliability reallocation is verified according to the subsystem importance coefficient. This method considers the benefits for both enterprises and customers by applying principles of engineering and conducting a reliability study. Copyright © 2014 John Wiley & Sons, Ltd.


Zheng S.,University of Shanghai for Science and Technology | Zheng S.,Machinery Industrial Key Laboratory for Mechanical Strength and Reliability Evaluation of Auto Chassis Components | Li B.,University of Shanghai for Science and Technology | Feng J.,University of Shanghai for Science and Technology | And 2 more authors.
Jixie Qiangdu/Journal of Mechanical Strength | Year: 2013

Taking a car suspension spring as an object, the relationship between the indoor accelerated durability test and the durability mileage was studied to evaluate the spring's durability. After the combination of load spectrum from the strengthened Belgium road of the proving ground, the theory of low amplitude load strengthening was introduced in the process of the damage analysis. Considering the increase in fatigue strength due to the loads with strengthening effect below fatigue limit, the new S-N curve of the spring was obtained. Combining the statistical damage obtained from the new S-N curve with the indoor fatigue test under monotonic load, the equivalent relationship between indoor and outdoor tests was established. Through the comparison of damage estimates of outdoor durability load spectrum with traditional modified Miner's rule and low amplitude load strengthening theory, the contribution of the low amplitude load strengthening effort in the durability analysis of spring is verified. This study further broaden the scope of application of low amplitude load strengthening, and provide a technical reference for the durability evaluation of the auto parts.


Liu X.,University of Shanghai for Science and Technology | Liu X.,Shanghai University of Engineering Science | Zheng S.,University of Shanghai for Science and Technology | Zheng S.,Machinery Industrial Key Laboratory for Mechanical Strength and Reliability Evaluation of Auto Chassis Components | And 5 more authors.
Journal of Testing and Evaluation | Year: 2016

Electric vehicles are equipped with electric-drive wheel systems, so the development of matching hub reducers with proper durability is important. Based on the Shanghai standard road-driving cycle, this paper forecasts the load spectrum for key components of the hub-reducer system. After considering the material strengthening under low-amplitude loads, the reducer system running-in test specification is issued. This paper also develops an electric-drive system durability test specification on the basis of the Miner linear cumulative damage theory, and estimates the hub-reducer durability mileage. The bench test for durability shows that the first round of the prototype design satisfied the durability mileage required, and the bending-fatigue strength of the gear is sufficiently reliable, which gives possibilities for further lightweight designs. This method can be applied for the lightweight designing of other key automotive components. It also provides empirical evidence for developing automotive products that meet the standard road-driving-cycle conditions. © 2016 ASTM Int'l all rights reserved.


Zheng S.,University of Shanghai for Science and Technology | Zheng S.,Machinery Industrial Key Laboratory for Mechanical Strength and Reliability Evaluation of Auto Chassis Components | Ju F.,University of Shanghai for Science and Technology | Feng J.,University of Shanghai for Science and Technology | Feng J.,Machinery Industrial Key Laboratory for Mechanical Strength and Reliability Evaluation of Auto Chassis Components
Jixie Qiangdu/Journal of Mechanical Strength | Year: 2014

Based on the strengthening and damaging properties of the structure strength, a new fatigue life prediction model for components and parts under random load spectrum is put forward. 80% of the random loads are low amplitude loads which are below the fatigue limit. This model overcomes the deficiency of the traditional methods, of which only the effect of damage is considered for high amplitude loads. The structure strength increases first and then decreases with the number of low amplitude loads increasing. Based on this law, the dual effect of strengthening and damaging under low amplitude loads has been fully considered. This model reflects the fatigue process of random loading accurately. According to two instances of different vehicle parts, the predicted life by the new model is more precise and more simple. This new fatigue life prediction model provides theoretical and technical basis for vehicle parts lightweight design based on the full utilization to the structure strength within the service period.


Fang J.,University of Shanghai for Science and Technology | Zheng S.,University of Shanghai for Science and Technology | Zheng S.,Machinery Industrial Key Laboratory for Mechanical Strength and Reliability Evaluation of Auto Chassis Components | Chen T.,University of Shanghai for Science and Technology | Liang G.,University of Shanghai for Science and Technology
IEEE Transportation Electrification Conference and Expo, ITEC Asia-Pacific 2014 - Conference Proceedings | Year: 2014

Based on city driving cycles, this study analyzes the load distribution of the wheels-side electric drive (WSED) system for vehicles. The input load and speed are defined based on the output torque of motor, and its load characteristics are analyzed by employing gear counting method. The load distribution is determined by stratified sampling method, which follows a mixed Gaussian distribution. Moreover, the goodness-of-fit test and the extreme load extrapolation are performed to demonstrate the accuracy of the load distribution for the WSED system. The results can facilitate continued advancement in fatigue life prediction and reliability-based design for the WSED system. © 2014 IEEE.

Loading Machinery Industrial Key Laboratory for Mechanical Strength and Reliability Evaluation of Auto Chassis Components collaborators
Loading Machinery Industrial Key Laboratory for Mechanical Strength and Reliability Evaluation of Auto Chassis Components collaborators