GB/T 47315-2026Road simulation rig test method for the structural durability of motor vehicles (English PDF)

3.1 Spindle-coupled test

A road simulation test that applies load to the vehicle via the spindle head.

7.1 Vehicle Preparation

7.1.1 Vehicle condition check

Based on the test demands, check and confirm the key parameters, critical parts, and components of the vehicle. Relevant records and results shall be filled in accordance with Table B.1 in Appendix B.

7.1.2 Parameter measurement and adjustment

7.1.2.1 Tire pressure measurement and adjustment

During the tire-coupled test, the tire pressure of the entire vehicle shall be measured and adjusted to match the condition at the time of road load spectrum acquisition and meet the technical conditions specified by the manufacturer. Relevant records and results shall be filled in accordance with Table B.2.

7.1.2.2 Wheel alignment parameter measurement and adjustment

In accordance with the manufacturer's wheel alignment specifications, measure and adjust the wheel alignment parameters. Relevant records and results shall be filled in accordance with Table B.3.

7.1.2.3 Mass parameter measurement

In accordance with the manufacturer's design requirements, determine the test load. The form and position of the counterweight should be consistent with the condition at the time of road load spectrum acquisition. The load error shall meet the requirements of Table 2.

In accordance with GB/T 12534, perform loading; in accordance with GB/T 12674, measure the overall vehicle mass parameters. Relevant records and results shall be filled in accordance with Table B.4.

7.2 Rig Preparation

7.2.1 System status confirmation

Confirm that the rig system is safe, reliable, and functionally normal.

7.2.2 On-site layout of rig system

In accordance with the wheel track and wheelbase parameters of the test vehicle, adjust the test rig to meet vehicle installation requirements.

During the spindle-coupled test, the wheel offset in the rig status shall be consistent with the wheel offset of the actual vehicle. Before vehicle installation, configure all parameters of the six-axis wheel force transducer. In the rig status, the coordinate system of the six-axis wheel force signal shall be consistent with the coordinate system of the six-axis wheel force signal during road load spectrum acquisition. Zero all channel signals and check the polarity of each channel.

7.2.3 Test vehicle installation

Install the test vehicle; all sensor connections shall be normal.

7.2.4 Cooling device arrangement

Arrange a cooling device to ensure that the temperature of components, for example, vibration dampers, remains within the normal operating range during the test.

7.2.5 Test system adjustment

Adjust the PID values of the spindle-coupled rig system/tire-coupled rig system, and it shall be ensured that the system is in the optimal state.

NOTE: PID adjustment is a system control mode, including proportional control, integral control and differential control.

7.3 Data Preparation

7.3.1 Data import

The data required for the rig test comes from the preliminary road load spectrum acquisition work. The road load spectrum acquisition scheme includes the determination of working conditions and road load signals.

Working conditions include, but are not limited to, the enhanced durability test conditions at the test site. The design of specific specifications is determined by the manufacturer or testing institution.

7.4.5 Generate drive file program

7.4.5.1 In accordance with the requirements of the manufacturer or testing institution, edit the sequence and number of loops of each drive file to generate the drive file program. In accordance with the method in GB/T 12678, determine the number of loops corresponding to the test conditions in the test field.

7.4.5.2 It is advisable to have test field durability mileage and user usage mileage corresponding to the rig test duration, and the correspondence shall comply with the provisions of the manufacturer's or testing institution's test specifications.

7.5 Test Run

7.5.1 Run the drive file program to start the structural durability test.

7.5.2 During the test, it is advisable to monitor the durability degradation of the chassis, vehicle body and its connecting parts. During the spindle-coupled test, the durability monitoring response signal should preferably include six-axis wheel force signal, etc.; during the tire-coupled test, the durability monitoring response signal should preferably include spindle head vertical acceleration signal and vehicle body vertical acceleration signal, etc.

7.5.3 Before the test run, upper and lower limits and allowable fluctuation ranges should be set for the rig sensor signal and durability monitoring response signal.

7.5.4 Run the cooling system to ensure that the temperature of temperature-sensitive components, for example, vibration dampers, is normal.

7.5.5 During the test run, it shall be ensured that the vehicle's load condition remains consistent with the load condition at the time of vehicle preparation.

7.5.6 If the durability monitoring response signal exceeds the allowable range due to changes in sample parts, etc., a new iteration shall be performed.

7.5.7 During the test, the test vehicle shall be inspected as required, faults shall be promptly identified and strictly recorded and handled in accordance with the requirements.

7.5.8 In accordance with different inspection objects, conduct item inspections. The table of test fault inspection items is shown in Table C.1 of Appendix C. The inspection objects mainly include structural components such as the vehicle suspension system, vehicle body, frame, and related accessories, etc.

7.6 Fault Detection, Diagnosis, and Handling

7.6.1 Fault detection

7.6.1.1 Regular inspections

Regular shutdown inspections shall be conducted, primarily inspecting the damage, degradation, loosening and misalignment of structural components.

It is advisable to stop the machine every 2 hours and inspect the test vehicle. The inspection interval can be adjusted in accordance with the intensity of the test conditions and the fault status of the test vehicle.

If the vehicle is equipped with adjustable suspension, for example, air springs, the vehicle body or frame height shall be periodically measured. If it exceeds the allowable range, adjustments shall be made.

7.6.1.2 Anomaly inspection

When any abnormal phenomena occur in the rig sensor signal, durability monitoring response signals, or vehicle conditions, immediately stop the machine for inspection.

7.6.1.3 Vehicle disassembly inspection

A vehicle disassembly inspection shall be performed after the rig test.

In accordance with the provisions of the test procedures, the frequency of vehicle disassembly inspection and the corresponding inspection content should be added during the test.

7.6.1.4 Fastener torque inspection in key positions

During or after the test, residual torque shall be measured and recorded. Relevant records and results shall be filled in accordance with Table B.5.

7.6.1.5 Inspection of other parameters

During or after the test, it is advisable to re-measure the dimensional parameters such as door, window, and hood clearances as measured before the test.

7.6.1.6 Functional and performance test

In accordance with the provisions of the test procedures, performance tests and functional inspections shall be performed on the whole vehicle during or after the rig test, which should include performance tests, for example, abnormal noises, as well as functional inspections, such as windshield wipers and window lifters, etc.

7.6.2 Fault diagnosis

In accordance with the methods described in QC/T 34, perform fault classification and fault mode judgment.

7.6.3 Fault handling

7.6.3.1 If a fault occurs on the test vehicle, it shall be immediately stopped for inspection. In principle, the fault shall be promptly eliminated. […]