CN204575324U - Hybrid gearbox off-line test device - Google Patents

Abstract

A hybrid transmission off-line detection device, comprising: a power detector connected to the EDU to be tested and a bench controller including an HCU circuit, PEB and PLC, wherein: the EDU to be tested is connected to the HCU circuit, and the EDU to be tested is connected to the HCU circuit. The bench controller is connected, the EDU to be tested is connected to the PEB, and the EDU to be tested is connected to the power detector; the utility model uses the motor loading method to test some basic performances of the transmission assembly to realize the actual working state of the simulated transmission. The utility model has the advantages of convenient operation and high degree of automation.

Description

Hybrid transmission end-of-line detection device

technical field

The utility model relates to a technology in the field of mechanical processing, in particular to an EOL (End of line, off-line) detection device and method of an EDU (Electronic Driving Unit, hybrid transmission), which is mainly used for the speed change of a hybrid car Development and testing of power battery + electric motor + transmission + PT (power transformer, auxiliary system) in the box.

Background technique

Most of the currently widely used loading test benches are designed for traditional mechanical transmissions. The test benches developed now need to be used for hybrid transmissions and meet the following test items: transmission system performance verification, gearbox structural strength verification, Clutch control strategy optimization, gearbox built-in motor control strategy optimization, gearbox cooling system verification.

The calibration platform adopts a mechanical open structure. The electric closed system can be constituted by the energy recovery device. When the transmission power of the test bench reaches the maximum, the energy recovery rate of the electric closed system is not less than 80%. The situation of balance occurs, so there will be a certain difference from the design of the traditional transmission test bench. .

Utility model content

The utility model aims at the above-mentioned deficiencies in the prior art, and proposes a hybrid transmission off-line detection device, which tests some basic performances of the transmission assembly by means of motor loading, and realizes simulating the actual working state of the transmission. The utility model is easy to operate and has a high degree of automation.

The utility model is achieved through the following technical solutions:

The utility model includes: a power detector connected to the EDU to be tested and an HCU circuit (Hybrid control unit, hybrid power control unit), PEB (Power electrical box, power electronic box) and PLC (Programmable logicarray, programmable logic array) The bench controller of the unit, wherein: the EDU to be tested is connected to the HCU circuit and outputs the fault information inside the transmission, the EDU to be tested is connected to the bench controller and transmits the transmission verification process control interactive data information, and the EDU to be tested is connected to the PEB And transmit the working status information of the internal motor of the transmission, the EDU to be tested is connected to the power detector and transmits the operating parameter information of the bench dynamometer.

The fault information includes but not limited to: fault information from the shift lever, clutch, oil pump and transmission.

The transmission verification process control interaction data information includes: gear information of the transmission, ISG (Integrated starter and generator, integrated starter motor), TM (Torque motor, torque motor) operation mode, speed, torque and temperature 1. The clutch information inside the transmission is transmitted to PLC (Programmable logic array, programmable logic array).

The working state information of the internal motor of the transmission includes but not limited to: temperature information, rotational speed information and torque information.

The working state information of the bench dynamometer includes but not limited to: speed information and torque information.

Described EDU to be tested comprises: synchronizer, oil pressure mechanism and motor mechanism, wherein: the signal acquisition end of synchronizer is connected with HCU circuit and output gear change command to control the gear change of EDU to be measured, the gear change of oil pressure mechanism The signal acquisition end is connected to the EDU to be tested and provides pressure to its control valve. The signal acquisition end of the motor mechanism is connected to the PEB and outputs working state adjustment instructions to control its speed change and torque loading.

The motor mechanism includes: ISG motor and TM motor.

Described bench controller comprises: control circuit and PLC, wherein: control circuit is connected with EDU to be tested by UDS agreement and receives the status information from EDU to be tested, and control circuit is connected with PEB by CAN protocol and transmits the EDU to be tested The working information of the motor mechanism, the PLC and the control circuit are connected through NI OPC and transmit the verification data required in the transmission verification process for interaction.

The state information includes but not limited to: ISG, TM motor information, transmission gear information, clutch information, oil pump motor information.

The working information of the motor mechanism includes: the rotational speed, torque, operation mode and temperature information of the stator, rotor and inverter of the TM motor and the ISG motor.

The verification data interaction includes: the EDU gear position requested by the PLC, the clutch, and the operation mode and speed and torque information required by the TM and ISG motors, as well as the speed and torque information of the bench dynamometer and the information related to the dynamometer. The speed, torque and working status information of the dynamometer are connected and transmitted.

The control circuit includes: PEB, HCU circuit and industrial computer, wherein: the HCU circuit is connected with the industrial computer and transmits the internal synchronizer and oil temperature and oil pressure information of the EDU to be tested, and the PEB is connected with the industrial computer and transmits the EDU to be tested The operating parameter information of the motor mechanism.

The power detector includes: an input dynamometer, an output dynamometer, and a dynamometer controller, wherein: the input dynamometer and the output dynamometer are respectively connected to the EDU to be tested and transmit the bench torque and rotational speed information , the input end of the dynamometer controller is connected with the bench controller to receive the information of the rotational speed and torque of the motor, and the output end is connected with the industrial computer of the control circuit to transmit the information of the rotational speed and torque of the dynamometer.

The information on the torque and rotational speed of the stand includes: input and real-time rotational speed and torque of the left and right output dynamometers.

The input dynamometer and the output dynamometer are provided with a main shaft motor for driving, and the input end of the main shaft motor is provided with an electromagnetic clutch, a torque sensor and a universal telescopic drive shaft, and the servo feed is adopted, and the maximum stroke is 60mm; the main shaft motor is a direct drive output mode, equipped with an overload protection clutch, a torque sensor and a universal telescopic drive shaft, and adopts servo feed and servo centering.

The bench controller is also provided with a cooling pipeline for testing the airtightness of the cooling pipeline.

Description of drawings

Fig. 1 is the structural representation of the utility model.

Fig. 2 is a basic block diagram of the NVH test in the embodiment.

Detailed ways

The following is a detailed description of the embodiments of the present utility model. This embodiment is implemented on the premise of the technical solution of the present utility model, and detailed implementation methods and specific operating procedures are provided, but the protection scope of the present utility model is not limited to the following the described embodiment.

Example 1

As shown in Figure 1, this embodiment includes: bench controller, EDU, and HCU, PEB, power detector and cooling pipeline connected to EDU respectively, wherein: EDU is connected with HCU and transmits each electromagnetic valve inside EDU The oil pump motor, clutch and gear position information, the EDU is connected to the PEB and transmits information such as the speed, torque, temperature, and working status of the ISG and TM motors, and the PEB and HCU are connected to the bench industrial computer to transmit all the status and data inside the EDU 1. The industrial computer is connected to the PLC to transmit all EDU information to the PLC, and the PLC controls all actions of the EDU through the industrial computer.

The input transmission system is composed of input motor, torque sensor, universal coupling, German MAYR safety clutch, main shaft box and input spline connection assembly, servo motor and servo slide table and other components.

The torque sensor is a non-contact torque sensor from HBM, with a range of 0-500 NM, a maximum speed of 20,000 rpm, and a torque measurement accuracy of ±0.2%. The output power of the motor is transmitted to the spline drive sleeve at the front end of the main shaft through the torque sensor, universal coupling and safety clutch. Servo motors use Siemens products.

The center of the output shaft has the function of servo adjustment, and the servo adjustment center distance transmission drives the calibration device. Siemens 1FK series synchronous servo motor, Siemens SINAMICS S120 drive system, and Siemens S7-300 series PLC are used as the control system. The position value is directly input from the industrial computer or the screen on the touch screen, and then the PLC controls the drive system to drive the servo motor to reach the target position.

The NVH detection of the transmission adopts the ROTAS noise and vibration detection system produced by DISCOM Company with a BKS03 acceleration sensor for spectrum analysis. The sensor is calibrated by an independent calibration unit. The NVH test is shown in Figure 2, where the reverse gear is not tested for the TM motor. When testing the first and second gears, the loading torque will be different, which will be further clarified in conjunction with equipment debugging. Through the NVH off-line inspection, abnormal vibrations of EDU gears, bearings, motors, and hydraulic systems caused by processing defects, wrong or missing installations, etc. are detected to ensure the quality of the EDU assembly off-line and provide a basis for repair and assembly status. retrospective basis.

The judgment criteria of NVH detection are shown in Table 1.

Test items Testing Standard vibration detection The vibration signal is within ±5% of the regression analysis value* noise detection Noise does not exceed *75dB

Table 1 NVH detection standard

High-voltage insulation testing, testing whether the insulation performance of EDU TM, ISG and high-voltage wire harness meets the requirements. EDU assembly insulation testing requires special equipment with high-voltage insulation testing. During testing, the EDU assembly to be measured cannot be connected to high voltage.

The testing equipment and testing conditions are shown in Table 2.

Table 2 High-voltage insulation testing equipment and testing conditions

There are two motors TM and ISG in the EDU. TM is more powerful than ISG, and the wire diameter of the high-voltage outlet is also larger. Each motor outlet is a three-phase line, and the two plugs connected to the PEB will have different colors. Because the plug on the PEB has a limited service life, a conversion plug will be used on the EOL to correspond to it.

The high-voltage test results of TM, ISG and high-voltage harness system >=5MΩ are qualified.

EOL detection of the low-voltage electrical system to confirm that the EDU low-voltage electrical system, including wiring harnesses, sensors, connectors, and actuators, is working normally. Detection conditions require low-voltage electrical system EOL detection communication diagram as shown in Figure 1.

When the low-voltage system is detected, the main control industrial computer of the bench sends instructions to the HCU through CAN, and the HCU controls the sensors and actuators, executes actions, and provides status feedback to the bench.

EDU low-voltage electrical system testing items and corresponding standards are shown in Table 3

Table 3 EDU low-voltage electrical system testing items and corresponding standards

This embodiment realizes the detection through the following operations:

Operation steps 1. Test preparation, specifically: hoist the EDU to be tested into the tray of the bench, press the start button to remove the high-voltage wire harness docking device from the bench, and connect the high-voltage wire harness on the EDU to be tested to the bench Docking, scan the barcode of the EDU to be tested, press the start button again, and the bench will automatically complete the docking of the EDU to be tested with the testing bench. The innovation of this step is that the docking of the EDU to be tested and the bench adopts a fully automatic method, including the docking of the cooling pipeline, the docking of the transmission device, the docking of the HCU, the PEB and the EDU to be tested, the docking of the parking mechanism and the feeding Refueling of the EDU to be tested. During the docking process, if the docking fails for any reason, the reason for the docking failure will be prompted on the interface of the industrial computer. If necessary, the user can also switch the gantry to manual mode to perform a single docking operation on the gantry, which is flexible and reliable.

Operation step 2, the detection process, specifically: press the verification open button, wait for 2 seconds and then press the start button, the bench will automatically start testing all the detection items of the EDU to be tested, and the time lasts for about 30 minutes. The innovation of this operation step is that during the test process, the PLC controls the start and end of all test items. When the EDU to be tested is tested, the required information of the EDU to be tested will pass through the communication between the industrial computer and the HCU and PEB. The communication is transmitted, and the EDU information in the HCU and PEB is fed back to the PLC. The PLC judges whether the state of the EDU to be tested meets the conditions required for the current test. If the conditions are not met, the PLC will not start any test until the test conditions are met. allowed state. During the test, the operating parameters and information of the ISG and TM motors of the EDU to be tested will be transmitted to the industrial computer in real time through the can card, and the industrial computer will then transmit the received information to the PLC in real time. The PLC monitors the ISG and TM motors throughout the process. The running state is within the controlled range. During the test, if the speed or torque of the ISG or TM motor exceeds its set value by 10 rpm/20 Nm, the PLC will immediately cut off the high-voltage power supply of the EDU to be tested to stop the ISG and TM The motor runs and stops the test to ensure the absolute safety and reliability of the test bench. All unexpected situations in the process will be displayed in the interface of the industrial computer in the form of an alarm. In special cases, users can also use the option of manually selecting test items to select test items, which is flexible and diverse.

Operation step 3, detection information processing, specifically: the industrial computer collects the relevant information of the TM and ISG motors sent by the PEB through the can acquisition card, and uses the UDS protocol to collect the gear position of the EDU to be tested sent by the HCU through the can acquisition card. Oil pump information and control them. At the same time, the industrial computer transmits this information to the PLC, because the PLC cannot read the various information inside the EDU by itself, so the PLC and the EDU must be connected in series through the bridge of the industrial computer, and at the same time, the PLC connects the test bench to the PLC. The information of the power machine is sent to the industrial computer, and the industrial computer summarizes and displays the information of HCU\PEB\PLC on the control interface, and reflects these data to the user in real time. During the test, all PEB and bench dynamometer information will be recorded in the form of TDMS file format, and saved with the EDU barcode as the file name, so that future problems can be traced. After the test, the bench will generate a report in EXCEL format so that the user can view the results of all tests.

Operation step 4. The test conclusion is obtained, specifically: during the test process, the control software will judge whether the test result is passed according to the set judgment basis. If any test result is unqualified, the test bench will suspend the test and When an alarm is issued, the user can choose to retest or simply remove the EDU from the bench. Regardless of whether the results are qualified or not, an EXCEL format file will be generated to record all test content and results, which is convenient for users to view and serve as a basis for future traceability.

Claims (8)

1. a hybrid gearbox off-line test device, it is characterized in that, comprise: the power detector be connected with EDU to be measured respectively and the stage controller comprising HCU circuit, PEB and PLC, wherein: EDU and HCU circuit to be measured is connected, EDU to be measured is connected with stage controller, EDU and PEB to be measured is connected, and EDU to be measured is connected with power detector.

2. hybrid gearbox off-line test device according to claim 1, it is characterized in that, described EDU to be measured comprises: synchronizer, oil sector and motor mechanism, wherein: the signals collecting end of synchronizer is connected with HCU circuit, the signals collecting end of oil sector is connected with EDU to be measured, and the signals collecting end of motor mechanism is connected with PEB.

3. hybrid gearbox off-line test device according to claim 2, it is characterized in that, described motor mechanism comprises: ISG motor and TM motor.

4. hybrid gearbox off-line test device according to claim 1, it is characterized in that, described stage controller comprises: control circuit and PLC, wherein: control circuit is connected with EDU to be measured, and control circuit is connected with PEB, and PLC is connected with control circuit.

5. hybrid gearbox off-line test device according to claim 1, it is characterized in that, described control circuit comprises: PLC, PEB, HCU circuit and industrial computer, wherein: PLC is connected with industrial computer, HCU circuit is connected with industrial computer, and PEB is connected with industrial computer.

6. hybrid gearbox off-line test device according to claim 1, it is characterized in that, described power detector comprises: input dynamometer machine, output dynamometer machine and Dynamometer Control device, wherein: input dynamometer machine is connected with EDU to be measured respectively with output dynamometer machine, the input end of Dynamometer Control device is connected with stage controller, and output terminal is connected with the industrial computer of control circuit.

7. hybrid gearbox off-line test device according to claim 6, it is characterized in that, described input dynamometer machine and export in dynamometer machine the spindle motor be provided with for driving, the input end of this spindle motor is provided with electromagnetic clutch, torque sensor and Universal telescopic transmission shaft.

8. the hybrid gearbox off-line test device according to claim 1 or 3, is characterized in that, described stage controller is provided with for detecting the bubble-tight cooling line of cooling line.