CN206593847U - Gear box casing deformation test system - Google Patents

Abstract

The utility model discloses a transmission case deformation test system, which includes a test bench device and a measurement and control system. The test bench device includes a base, and an end connection bracket and an end support of a gearbox to be tested are installed according to the installation and positioning method of a real vehicle. seat; a fixed locking mechanism for locking the output shaft of the gearbox to be tested, a loader bracket and a torque loading device installed on the loader bracket, the output shaft of the torque loading device is the same as the input shaft of the gearbox to be tested Shaft connection; the measurement and control system includes a torque sensor installed on the output shaft of the torque loading device, a strain sensor pasted on the test point of the casing of the gearbox to be tested, a data acquisition system and a computer, a torque sensor and a strain gauge All sensors are connected to the computer through the data acquisition system. The utility model has the advantages of simple loading method, high control and response precision, good repeatability, etc., and can improve the efficiency and accuracy of the deformation test of the transmission case.

Description

Transmission shell deformation test system

technical field

The utility model relates to the technical field of auto parts detection, in particular to a deformation test system for a transmission case.

Background technique

As an important basic part of the transmission assembly, the gearbox housing is connected with the engine, suspension and other vehicle components, and assembles the gears, shafts, bearings, shift forks and other related parts in the gearbox into a whole, keeping the gears, The correct position between the shafts, and make them transmit power in a coordinated manner according to a certain transmission relationship. Each shaft of the transmission is supported on the box body through bearings. During the gear transmission process, the box body bears a large load, and at the same time it bears the inertial force and impact caused by the powertrain when the vehicle brakes or accelerates and produces a large Therefore, the strength, stiffness and fatigue performance of the box directly affect the reliability and life of the transmission, and then affect the performance of the vehicle. At present, there are few studies on the strength and stiffness of the gearbox case.

Utility model content

Aiming at the deficiencies of the above-mentioned prior art, the technical problem to be solved by the utility model is: how to provide a simple loading method, high control and response precision, and good repeatability, which is conducive to improving the efficiency and accuracy of the gearbox shell deformation test. Transmission shell deformation test system.

In order to solve the above technical problems, the utility model adopts the following technical solutions:

A gearbox casing deformation test system, characterized in that it includes a test bench device and a measurement and control system, the test bench device includes a base, an end connection bracket for fixing the input shaft end of the gearbox and a support for supporting the gearbox The terminal support seat at the output shaft end of the terminal, the gearbox to be tested is installed on the end connection bracket and the end support seat according to the actual vehicle installation and positioning method; the base is located on one side of the output shaft of the gearbox to be tested. A fixed locking mechanism that locks the output shaft of the gearbox to be tested, and the output shaft of the gearbox to be tested is fixedly connected to the fixed lock mechanism; the base is located at the base of the input shaft of the gearbox to be tested One side is provided with a loader bracket and a torque loading device installed on the loader bracket, the output shaft of the torque loading device is coaxially connected with the input shaft of the gearbox to be tested; the measurement and control system includes a The torque sensor on the output shaft of the torque loading device, the strain gauge sensor pasted on the to-be-measured point of the casing of the gearbox to be tested, the data acquisition system and the computer, the torque sensor and the strain gauge sensor are all passed The data acquisition system is connected to the computer; the computer is also connected to a loading controller for controlling the output torque of the torque loading device, and the loading controller is connected to the torque loading device.

Using the above system, the loading controller is controlled by a computer, and the torque loading device is mainly controlled to load the input shaft of the transmission to be tested with torque according to the set value. Since the fixed locking mechanism locks the output shaft of the transmission to be tested, the speed change There is relative torsional deformation between the input shaft and output shaft of the box, which changes the force at the bearing support of the shell, makes the torque act on the gearbox shell, and causes the deformation of the gearbox shell. The strain sensor on the body can detect the strain data of the casing, and input it into the computer through the data acquisition system, calculate the principal stress value, and complete the measurement of the deformation of the gearbox casing. The torque sensor is installed on the output shaft of the torque loading device, so that the data acquisition system and the computer can obtain the real-time torque output by the torque loading device, which can realize the closed-loop control of the torque loading device and improve the accuracy of torque output.

Further, the loader bracket is an elastic bracket with elasticity at the lower end.

In this way, when the torsional load is applied, the small torsional load of the torque loading device driven by the deformation of the sample can be reduced, and it has the functions of buffering and reset.

Further, the strain sensor is provided with a plurality of them, which are pasted respectively on the outer edge of the output shaft rear bearing hole of the gearbox to be tested, the outer edge of the intermediate shaft rear bearing hole, the position of the rear shell bearing where the load is applied, and the middle shell bearing. Location where the load is applied and outside the main box.

Since the above-mentioned positions are usually places where the gearbox is subjected to force during actual driving and where the finite element analysis stress is relatively large, more accurate measurement results can be obtained by installing strain sensors at these positions.

Further, the torque loading device is a hydraulic servo torsion actuator.

The hydraulic servo torsion actuator has the characteristics of high dynamic response precision, high load rigidity, and large control power. The use of hydraulic servo torsion actuators can achieve precise torque input, which is conducive to improving measurement accuracy.

In summary, the utility model has the advantages of simple loading method, high precision of control and response, good repeatability, etc., and can improve the efficiency and accuracy of the deformation test of the gearbox case.

Description of drawings

Fig. 1 is a schematic structural view of an embodiment of the utility model.

Figure 2 is the loading curve 1 when the gearbox is in the first gear position with a torque amplitude of 100Nm.

Figure 3 is the loading curve 2 when the gearbox is in the first gear position and the torque amplitude is 100Nm.

Figure 4 is the loading curve 1 when the gearbox is in the first gear position and the torque amplitude is 200Nm.

Figure 5 is the loading curve 2 when the gearbox is in the first gear position and the torque amplitude is 200Nm.

Figure 6 is the loading curve 1 when the gearbox is in the first gear position and the torque amplitude is 270Nm.

Figure 7 is the loading curve 2 when the gearbox is in the first gear position and the torque amplitude is 270Nm.

Figure 8 is the loading curve 1 when the gearbox is in the first gear position and the torque amplitude is 300Nm.

Figure 9 is the loading curve 2 when the gearbox is in the first gear position and the torque amplitude is 300Nm.

Figure 10 is the strain diagram of measuring point 1 under the load level of 200Nm when the gearbox is in the first gear position.

Figure 11 is the calculated stress diagram of measuring point 1 under the loading level of 200Nm when the gearbox is in the first gear position.

Figure 12 is the strain diagram of measuring point 2 under the load level of 200Nm when the gearbox is in the first gear position.

Figure 13 is the calculated stress diagram of measuring point 2 under the loading level of 200Nm when the gearbox is in the first gear position.

Figure 14 shows the principal stress values of measuring point 1 in three gears under the loading level of 300Nm.

Figure 15 shows the principal stress values of measuring point 2 in three gears under the loading level of 300Nm.

Figure 16 shows the principal stress values of measuring point 1 under steady-state conditions with different loading amplitudes when the gearbox is in the first gear position.

Figure 17 shows the principal stress values of measuring point 2 under steady-state conditions with different loading amplitudes when the gearbox is in the first gear position.

Figure 18 is a comparison diagram of principal stress difference at measuring point 1 under steady-state conditions with different loading amplitudes when the gearbox is in the first gear position.

Figure 19 is a comparison diagram of principal stress difference at measuring point 2 under steady-state conditions with different loading amplitudes when the gearbox is in the first gear position.

detailed description

Below in conjunction with accompanying drawing, the utility model is described in further detail.

During specific implementation: as shown in Figure 1, a kind of gearbox housing deformation test system includes a test bench device 1 and a measurement and control system 2, and the test bench device 1 includes a base 11 for fixing the input shaft of the gearbox The end connection bracket 12 at the end and the end support seat 13 for supporting the output shaft end of the gearbox, the end connection support 12 and the end support seat 13 are equipped with a gearbox to be tested 14 according to the actual vehicle installation positioning method; the base 11 One side of the output shaft of the gearbox to be tested 14 is provided with a fixed locking mechanism 15 for fixedly locking the output shaft of the gearbox to be tested, and the output shaft of the gearbox to be tested 14 is fixedly connected to the fixed On the locking mechanism 15; the base 11 is positioned at one side of the input shaft of the gearbox 14 to be tested and is provided with a loader bracket 16 and a torque loading device 17 installed on the loader bracket 16, the torque loading The output shaft of the device 17 is coaxially connected with the input shaft of the gearbox to be tested 14; the measurement and control system 2 includes a torque sensor 21 installed on the output shaft of the torque loading device 17, pasted on the gearbox to be tested. The strain gauge sensor 22 on the point to be measured of the housing of 14, the data acquisition system 23 and the computer 24, the torque sensor 21 and the strain gauge sensor 22 are all connected to the computer 24 by the data acquisition system 23; The computer 24 is also connected with a loading controller 25 for controlling the output torque of the torque loading device 17 , and the loading controller 25 is connected to the torque loading device 17 .

Using the above system, the loading controller is controlled by a computer, and the torque loading device is mainly controlled to load the input shaft of the transmission to be tested with torque according to the set value. Since the fixed locking mechanism locks the output shaft of the transmission to be tested, the speed change There is relative torsional deformation between the input shaft and output shaft of the box, which changes the force at the bearing support of the shell, makes the torque act on the gearbox shell, and causes the deformation of the gearbox shell. The strain sensor on the body can detect the strain data of the casing, and input it into the computer through the data acquisition system, calculate the principal stress value, and complete the measurement of the deformation of the gearbox casing. The torque sensor is installed on the output shaft of the torque loading device, so that the data acquisition system and the computer can obtain the real-time torque output by the torque loading device, which can realize the closed-loop control of the torque loading device and improve the accuracy of torque output.

In practice, the loader bracket 16 is an elastic bracket with elasticity at the lower end.

In this way, when the torsional load is applied, the small torsional load of the torque loading device driven by the deformation of the sample can be reduced, and it has the functions of buffering and reset.

During implementation, the strain gauge sensor 22 is provided with a plurality, which are pasted respectively on the outer edge of the output shaft rear bearing hole of the gearbox 14 to be tested, the outer edge of the intermediate shaft rear bearing hole, the place where the load is applied at the rear shell bearing position, the middle Shell bearing locations where loads are applied and outside the main case.

Since the above-mentioned positions are usually places where the gearbox is subjected to force during actual driving and where the finite element analysis stress is relatively large, more accurate measurement results can be obtained by installing strain sensors at these positions.

In practice, the torque loading device 17 is a hydraulic servo torsion actuator.

The hydraulic servo torsion actuator has the characteristics of high dynamic response precision, high load rigidity, and large control power. The use of hydraulic servo torsion actuators can achieve precise torque input, which is conducive to improving measurement accuracy.

During specific implementation, an angular displacement sensor is also arranged on the output shaft of the torque loading device 17 . In this way, the initial position of the transmission can be adjusted through the control of the angle to eliminate the intermittent, so as to facilitate the torque control and improve the accuracy of the measurement.

During the test, the following steps are adopted: A. First obtain the above-mentioned gearbox housing deformation test system, install the gearbox to be tested on the test bench device 1 according to the installation and positioning method of the actual vehicle, and hold the output shaft of the gearbox to be tested dead fixed;

B. Connect the input shaft of the gearbox to be tested with the output shaft of the torque loading device, and set a torque sensor and an angular displacement sensor between the two, which are used to detect the rotation angle of the output shaft of the torque loading device and apply it to the torque loading device. the torque of the input shaft of the gearbox;

C. Select the point to be measured where the casing is deformed on the casing of the gearbox to be tested, and attach the strain gauge or strain rosette to the selected point to be measured;

D. Obtain the detection signals of the torque sensor and the angular displacement sensor in real time through the computer, put the gearbox into the forward gear or the reverse gear, and use the closed-loop control method to control the torque loading device to load the input shaft of the gearbox to be tested. , first gradually increase the output torque of the torque loading device from zero to the torque setting value within the time t1, and keep it stable within the time t2, and then gradually decrease from the torque setting value to zero within the time t3;

E. Record the strain data of the strain gauge or rosette pasted on the point to be measured, and calculate the principal stress value of the point to be measured through the formula of stress-strain transformation.

Using the above method, put the gearbox into the forward or reverse gear, and load the input shaft of the gearbox through the torque loading device. Since the output shaft of the gearbox is fixed and locked, there is a relative friction between the input shaft and the output shaft of the gearbox. Torsional deformation, changing the stress at the bearing support of the housing, causing the torque to act on the gearbox housing, causing deformation of the gearbox housing, using strain gauges or strain rosettes to detect the strain data of the gearbox housing, through The stress-strain conversion formula can obtain accurate principal stress values. The closed-loop control method of the computer can ensure that the torque output by the torque loading device has high precision and is stable and reliable; the loading process of gradually increasing the torque from zero to the torque setting value and gradually decreasing from the torque setting value to zero can be achieved. The dynamic deformation process of the gearbox housing is tested; the static deformation process of the gearbox housing can be tested by keeping the torque at the torque setting value. In this way, the dynamic and static deformation process of the gearbox casing can be tested, which is close to the actual constraints of the gearbox, which is conducive to improving the reliability and accuracy of the test. By setting the angular displacement sensor, the initial position of the transmission can be adjusted through angle control, eliminating intermittent, so as to facilitate torque control and improve the accuracy of measurement.

Wherein, in the step D, the gearbox is put into the 1st gear, the 2nd gear and the reverse gear respectively, and the input shaft of the gearbox to be tested in different gears is loaded, and the torque is loaded within the same time t1 The output torque of the device gradually increases from zero to the same torque setting value, and remains stable within the same time t2, and then gradually decreases from the torque setting value to zero within the same time t3.

Since the speed ratio of the first gear, second gear and reverse gear of the gearbox is large, the output speed is low and the torque is large, so the torque, meshing force and housing force transmitted by the first gear, second gear and R gear are relatively large. Using the above-mentioned working condition loading method can simulate the situation that the gearbox housing is subjected to a large force during actual driving, which is conducive to improving the efficiency and accuracy of the test.

Wherein, in the step D, in the same gear position, multiple different torque setting values are used to load the input shaft of the gearbox to be tested, so as to ensure that t1, t2 and t3 in each loading process are correspondingly equal.

Using the above method, at different torque setting values, control t1, t2 and t3 are correspondingly equal, so that in the same time t1 and the same time t3, due to the difference in amplitude, the slope of the torque loading curve will occur In this way, the dynamic deformation process of the shell under different dynamic loading processes can be tested. By keeping different torque setting values stable within the same time t2, the deformation process of the gearbox casing under different static amplitude loading conditions can be tested. In this way, it is possible to test the deformation of the gearbox under steady-state loads of different amplitudes and dynamic loads of different slopes during the actual driving process, which can effectively improve the efficiency and accuracy of the test.

Embodiment: Since the speed ratio of the first gear, the second gear and the reverse gear of the gearbox are large, the output speed is low and the torque is large, so the torque and meshing force transmitted by the gears of the first gear, the second gear and the R gear, the force on the housing is relatively large , so mainly consider the force of the transmission assembly under the action of input torque in the 1st gear, 2nd gear and R gear.

The loading method of variable amplitude and variable slope is adopted, and the dynamic and static deformation test process of the gearbox is considered comprehensively. During the test, the torque is slowly loaded in each gear of the 1st gear, 2nd gear and R gear within 20s. to 100Nm, 200Nm, 270Nm and 300Nm, and keep it steady for 20s, then within 20s, slowly increase the torque from 100Nm, 200Nm, 270Nm and 300Nm respectively to 0Nm. When loading, the torque is gradually increased or decreased, and the dynamic deformation process of the gearbox housing can be tested. By stabilizing the amplitude for a period of time, the static deformation process of the gearbox casing can be tested. In the process of increasing or decreasing the torque, because the amplitude of the torque change is different within the equal 20s, the slope of the amplitude change is different. In this way, dynamic shell deformations can be measured during different dynamic loading processes. And stabilizing the torque at different amplitudes can measure the deformation process of the gearbox case under different static amplitude loading conditions. The torque loading is shown in Figure 2 to Figure 9. It can be seen from the loading curve that the torque loading is stable and can be well returned to zero, indicating that the test system has high loading accuracy and good repeatability.

When processing the actual data, first observe the change of each group of data, check whether the data is normal and whether the repeatability is good, and calculate the strain data of each measuring point through the stress-strain transformation formula to obtain the principal stress value of each measuring point. Calculate the difference of the steady-state data of 3 samples at each measuring point under each loading condition, and the difference of the steady-state data before and after loading to check whether the strain sensor is working properly and the repeatability of the test system .

The strain-stress conversion formula of the triaxial Y-shaped equiangular strain rosette is as follows:

Among them, ε _x and ε _y are the normal strains in the x-axis and y-axis directions respectively, ε ₃₀ , ε ₉₀ and ε ₁₅₀ are the normal strains in the directions of 30°, 90° and 150° respectively, and σ ₁ and σ ₂ are the measuring points Principal stress, τ _max is the maximum shear force at the measuring point, γ _xy is the shear strain, E is the modulus of elasticity, and ν is Poisson's ratio. The stress-strain calculation formula of the uniaxial strain gauge is as follows:

σ = Eε (7)

σ is the stress, ε is the strain, and E is the modulus of elasticity

Now take the transmission in the first gear position, the strain-stress variation of the three-axis Y-shaped equiangular strain rosette at measuring point 1, and the uniaxial strain gauge at measuring point 2 at a loading level of 200Nm as an example. The data processing results are shown in Figures 10 to 13 shown.

After the installation and debugging are completed, the test is carried out, and 3 strain samples are collected at 5 measuring points R, 1 and 2 respectively, and the principal stress values are calculated according to formulas (1)-(7). The test results are illustrated only by the strain curve of measuring point 2 under the first gear of 200Nm loading level. It can be seen from Figures 9 to 12 that when the test is loaded, the test data rises steadily, and when the torque is stable, the principal stress and strain of the measuring point remain basically unchanged. After unloading, the stress and strain values return to before the test, and the test data can be returned to zero. It shows that the gearbox casing deformation test system has good repeatability.

Taking measuring point 1 and measuring point 2 as examples, Figure 14 shows the principal stress values of measuring point 1 in three gears at a loading level of 300Nm; Figure 15 shows the principal stress values of measuring point 2 in three gears at a loading level of 300Nm ; Fig. 16 is the principal stress value of measuring point 1 under different loading amplitude steady-state conditions when the gearbox is in the first gear position; Fig. 17 is the measuring point 2 under different loading amplitude steady-state working conditions when the gearbox is in the first gear position Figure 18 is a comparison chart of the principal stress difference of measuring point 1 under different loading amplitude steady-state conditions when the gearbox is in the first gear position; Figure 19 is the measuring point 2 when the gearbox is in the first gear position Comparison chart of principal stress difference under different loading amplitude steady-state conditions.

It can be seen from Figures 14 and 15 that under the steady-state loading condition of 300Nm, the maximum stress values of the sample measuring point 1 and measuring point 2 of the first gear, second gear and R gear are all less than the tensile strength value of the box material, which meets the strength requirements.

It can be seen from Figures 16 and 17 that the stress values of measuring point 1 and measuring point 2 are different under different loading levels, and the principal stress value shows an increasing trend with the increase of loading level, and the principal stress value is the largest at 300Nm; from Figures 18 and 19, Under the same torque loading level, the stress difference of each measuring point is stable. As the torque loading level increases, the stress difference gradually increases, which is in line with the actual situation. The sample data has good repeatability. The stress difference of measuring point 2 Larger, indicating that the stress value of measuring point 2 is larger. Some of the initial stress values of S1 are different under different torque loading levels, mainly because the test interval is slightly shorter and the residual stress of the strain gauge is caused.

From the above analysis, it can be seen that the transmission housing deformation test system designed with hydraulic servo system has simple loading method, good repeatability, high precision and high dynamic response characteristics. The variable slope and variable amplitude loading methods are used to comprehensively consider the dynamic and static shell deformation process of the gearbox, which is close to the actual constraints of the gearbox. The test results show that under the same torque loading level, the stress difference of each measuring point is stable, and as the torque loading level increases, the stress difference increases gradually, which is in line with the actual situation.

The above descriptions are only preferred embodiments of the present utility model, and are not limited to the present utility model. Any modifications, equivalent replacements and improvements made within the spirit and principles of the present utility model shall be included in the Within the protection scope of the present utility model.

Claims (4)

1. The gearbox shell deformation test system is characterized by comprising a test bench device (1) and a measurement and control system (2), wherein the test bench device (1) comprises a base (11), an end connecting support (12) for fixing an input shaft end of a gearbox and a terminal supporting seat (13) for supporting an output shaft end of the gearbox, and the gearbox (14) to be tested is mounted on the end connecting support (12) and the terminal supporting seat (13) according to a real-vehicle mounting and positioning mode; a fixed locking mechanism (15) for fixedly locking an output shaft of the gearbox to be tested is arranged on one side, located on the output shaft of the gearbox to be tested (14), of the base (11), and the output shaft of the gearbox to be tested (14) is fixedly connected to the fixed locking mechanism (15); a loader support (16) and a torque loading device (17) installed on the loader support (16) are arranged on one side, located on an input shaft of the gearbox to be tested (14), of the base (11), and an output shaft of the torque loading device (17) is coaxially connected with the input shaft of the gearbox to be tested (14); the measurement and control system (2) comprises a torque sensor (21) arranged on an output shaft of the torque loading device (17), a strain gauge sensor (22) adhered to a point to be measured of a shell of a gearbox (14) to be measured, a data acquisition system (23) and a computer (24), wherein the torque sensor (21) and the strain gauge sensor (22) are connected to the computer (24) through the data acquisition system (23); the computer (24) is also connected with a loading controller (25) for controlling the output torque of the torque loading device (17), and the loading controller (25) is connected to the torque loading device (17).

2. The gearbox housing deformation testing system of claim 1, wherein the loader bracket (16) is an elastic bracket with elasticity at the lower end.

3. The gearbox housing deformation testing system of claim 1, wherein the strain gauge sensors (22) are respectively attached to the outer side edge of the output shaft rear bearing hole of the gearbox (14) to be tested, the outer side edge of the middle shaft rear bearing hole, the position of the rear shell bearing where a load is applied, the position of the middle shell bearing where a load is applied and the outer side of the main box.

4. The gearbox housing deformation testing system of claim 1, wherein the torque loading device (17) is a hydraulic servo torsion actuator.