Claims:We Claim:

1. A road simulator system (100) for testing vehicles, the road simulator system (100) comprising:
a belt conveyor (30) having a plurality of links (20) of concave and convex carved shapes from a top side with different depth and height in size for each link thereof to create pothole shape and bump shape, the plurality of links (20) having a plurality of connecting members (15) configured at left and right sides near a bottom end thereof, each of the connecting members (15) having a hole (10) configured thereon;
a plurality of pins (40) passing through the holes (10) of the plurality of connecting members (15) for joining the plurality of links (20) together;
a plurality of drive wheels (50) attached on the belt conveyor (30), wherein each of the plurality of pins (40) passes through each of the plurality of drive wheels (50);
a rail track (60) arranged to run the belt conveyor (30) thereon, the rail track (60) having at least two spaced side members extending lengthwise to form an elongated oval shape of the rail track (60);
a supporting structure (70) arranged to mount the rail track (60) thereon, the supporting structure (70) having at least two frames spaced apart from each other; and
a drive mechanism (80) attached at one inside end of the belt conveyor (30) to run the belt conveyor (30) thereon, the drive mechanism (80) having,
• a drive gearbox assembly (74) having shaft (72) attached thereto,
• a motor (76) attached to the drive gearbox assembly (74) to run the drive gearbox assembly (74); and
• a drive sprocket (78) mounted on the mounted on the shaft (72)of the drive gearbox assembly (74), the drive sprocket (78) having teeth connected to the plurality ofpins (40);
wherein, the drive sprocket (78) receives energy from the drive gearbox assembly (74) in order to push the plurality of pins (40) in linear direction to run the belt conveyor (30) thereby achieving required speed, then the vehicle in driving condition is loaded on the belt conveyor (30) to match the speed of the belt conveyor (30) thereby achieving the stationery state for testing the vehicle.

2. The road simulator system (100) as claimed in claim 1, wherein the belt conveyor is metallic.

3. The road simulator system (100) as claimed in claim 1, wherein each five links of the plurality of links (20) create pothole shape and bump shape to test the vehicle.

4. The road simulator system (100) as claimed in claim 1, wherein the plurality of drive wheels () is double flanged cylindrical wheel made from steel.

5. The road simulator system (100) as claimed in claim 1, wherein the drive gearbox assembly includes variable speed gear box.

, Description:Field of the invention:

The present invention relates to field of testing vehicles inside the laboratory and more particularly, to a road simulator system for testing the vehicles.

Background of the invention:

Vehicle has to be rigorously tested during the research and development phase of the product design in order to ensure that the vehicle meets all the safety and functional requirements. Many times OEM’s (Original Equipment Manufacturer) employs skilled drivers to drive and test the vehicles in different road conditions to ensure that the vehicle design is capable of withstanding the load excitations from the road. But, taking the vehicle to road constitutes many complications and also the test results are based on the skill level of the driver.

In order to get the Real World Usage Pattern of the vehicle, many OEM’s tried to simulate the road conditions in the laboratory facility for testing the vehicles and different other components.

In a prior art, USPatent 3520180 entitled as ‘Road Simulator Facility’, discloses use of spring and other mechanisms to bring in simulation. However, this system did not give accurate results due to the variation in different parameters of the mechanism.

Also, most of the prior art technologies for simulating the road condition are based on four poster tests and other hydraulic or pneumatic means of testing.

Accordingly, there exists need to provide a simple and efficient road simulator system for testing the vehiclesthat overcomes the above mentioned drawbacks in the prior art.

Objects of the invention:

An object of the present invention is to provide a simple and effective road simulator system for testing vehicles.

Another object of the present invention is to give testing results that are accurate to the on road testing of the vehicle.

Summary of the invention:

Accordingly, the present invention providesa road simulator system for testing vehicles. The road simulator system comprises a belt conveyor having a plurality of links, a plurality of pins,a plurality of drive wheels, rail track, a supporting structure and a drive mechanism. The belt conveyor includesthe plurality of links of concave and convex carved shapes from a top side with different depth and height in size for each link thereof to create pothole shape and bump shape if five links put together.Each five links of the plurality of links create pothole shape and bump shape to test the vehicle.The plurality of links includes a plurality of connecting members configured at left and right sides near a bottom end thereof. Each of the connecting members includes a hole configured thereon. Theplurality of pins passes through the holes of the plurality of connecting members for joining the plurality of links together. The plurality of drive wheels are attached on the belt conveyor such that each of the plurality of pins passes through each of the plurality of drive wheels.The rail track is arranged to run the belt conveyor thereon. The rail track includes at least two spaced side members extending lengthwise to form an elongated oval shape of the rail track. The supporting structure is arranged to mount the rail track thereon. The supporting structure includesat least two frames spaced apart from each other.

The drive mechanism is attached at one inside end of the belt conveyor to run the belt conveyor thereon.The drive mechanism includes a drive gearbox assembly, a motor and a drive sprocket. The drive gearbox assembly includes variable speed gear box. A shaft isattached to the drive gearbox assembly. The motor is attached to the drive gearbox assembly to run the drive gearbox assembly. The drive sprocketis mounted on the shaft of the drive gearbox assembly. The drive sprocket includes teeth that are connected to the plurality of pins. The drive sprocket receives energy from the drive gearbox assembly. Then, the drive sprocket pushes the plurality of pins in linear direction to run the belt conveyor. Once, required speed isachieved by the belt conveyor, the vehicle in driving condition is loaded on the belt conveyor. The vehicle matches the speed of the belt conveyor to achieve the stationery state for testing the vehicle.

Brief description of the drawings:

The objects and advantages of the present invention will become apparent when the disclosure is read in conjunction with the following figures, wherein

Figure 1 shows a perspective view of a road simulator system, in accordance with the present invention;

Figure 2 shows a side view of the road simulator system, in accordance with the present invention;

Figure 3 shows a plurality of links of a belt conveyor of the road simulator system, in accordance with the present invention;

Figure 4 shows an internal construction with pin and rack of the road simulator system, in accordance with the present invention; and

Figure 5 shows adrive mechanismof the road simulator system, in accordance with the present invention.

Detailed description of the embodiments:

The foregoing objects of the present invention are accomplished and the problems and shortcomings associated with the prior art, techniques and approaches are overcome by the present invention as described below in the preferred embodiments.

The present invention provides invention a road simulator system for testing vehicles. The road simulator system is simple in construction and effective in working. The road simulator system provides testing results that are accurate to the on road testing of the vehicle.

The present invention is illustrated with reference to the accompanying drawings, throughout which reference numbers indicate corresponding parts in the various figures. These reference numbers are shown in bracket in the following description.

Referring to figures 1to5, a road simulator system (100) for testing vehicles, in accordance with the present invention is shown. The road simulator system (100) comprises a belt conveyor (30) having a plurality of links (20), a plurality of pins (40), a plurality of drive wheels (50), a rail track (60), a supporting structure (70) and a drive mechanism (80).

The belt conveyor (30) is metallic. Specifically, the belt conveyor (30) is made up of Steel. The belt conveyor (30) includes the plurality of links (20) ofconcave and convex carved shapes from a top side with different depth and height in size for each link thereof to create pothole shape and bump shape if five links put together.In an embodiment, the shape of the plurality of links (20) is similar to the shape of Belgium pavement tracks and other test trackslike short wave pitch and long wave pitch. Each five links of the plurality of links (20) create pothole shape and bump shapeto represent Belgium pavement tracks for testing the vehicle. The plurality of links (20) includes a plurality of connecting members (15) (refer figure 3) configured at left and right sides (not numbered) near a bottom end (not numbered) thereof. Each of the connecting members (15) includes a hole (10) configured thereon.

The plurality of pins (40) pass through the holes (10) of the plurality of connecting members (15) for joining the plurality of links (20) together. In an embodiment, the plurality of pins (40) is made of Steel.

The plurality of drive wheels (50) are attached on the belt conveyor (30) such that each of the plurality of pins (40) passes through each of the plurality of drive wheels (50). In an embodiment, the plurality of drive wheels (50) is double flanged cylindrical wheel made from steel. The shape of the plurality of drive wheels (50) is similar to the wheel used in EOT (Electric Overhead Traveling) crane.

The rail track (60) is arranged to run the belt conveyor (30) thereon. The rail track (60) includes at least two spaced side members (not numbered) extending lengthwise to form an elongated oval shape of the rail track (60).

The supporting structure (70) is arranged to mount the rail track (60) thereon. The supporting structure (70) includes at least two frames (not numbered) spaced apart from each other.

The drive mechanism (80) is attached at one inside end (not numbered) of the belt conveyor (30) to run the belt conveyor (30) thereon. The drive mechanism (80) includes a drive gearbox assembly (74), a motor (76) and a drive sprocket (78)(refer figure 5). The drive gearbox assembly includes variable speed gear box. A shaft (72) is attached to the drive gearbox assembly (74). The motor (76) is attached to the drive gearbox assembly (74) to run the drive gearbox assembly (74). The drive sprocket (78) is mounted on the shaft (72) of the drive gearbox assembly (74). The drive sprocket (78) includes teeth (not numbered) that are connected to the plurality of pins (40). In an alternative embodiment, the drive mechanism (80) can include a traction motor.

The drive mechanism (80) drives the belt conveyor (30) that runs on the rail track (60). When the motor (76) is switched on, the drive sprocket (78) receives energy from the drive gearbox assembly (74). Then, the drive sprocket (78) pushes the plurality of pins (40) in linear direction to run the belt conveyor (30). Once, required speed (20 km/hour to 35 km/hour depends on type of the vehicle to be tested) is achieved by the belt conveyor (30), the vehicle (not shown) in driving condition is loaded on the belt conveyor (30). The vehicle matches the speed of the belt conveyor (30) to achieve the stationery state for testing the vehicle.

The road simulator system (100) providesa stationery view of the running vehicle during the Accelerated Durability test (ADT) cycles like Belgium Pave Track, long wave pitch, short wave pitch and frequency patch. The road simulator system (100) helps to understand the behavior of vehicle during the ADT. The vehicle can be monitored through various checks to improve the vehicle performance with durability requirement.

Advantages of the invention:

1. Area required for vehicle testing track can be eliminated and could be utilized that area for any other purpose.
2. Fuel consumption during testing can be minimized once engine part is validated.
3. If the vehicle is driven by robotics, then dedicated test drivers are not required. Hence, man power cost can be eliminated.
4. If length of the belt conveyor (30) increased, multiple vehicles can be validated at a time on the same test track i.e. the road simulator system (100).
5. No need of computer programming for excitation like 4 post-test.
6. Monitoring of the parameters of dynamic vehicle condition becomes easy due to stationery state of the vehicle; hence improvement can be done significantly.
7. Testing service can be offered to other OEMs.
8. Different test track can be produced on surface of the plurality of the links (20). For Example- if the geographic mapping of any area on any planet made available, then same path can be created on the links of this conveyor and vehicle can be design and validated on the earth.

The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, and to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention.