機(jī)械式前置汽車變速器實(shí)驗(yàn)臺(tái)設(shè)計(jì)
機(jī)械式前置汽車變速器實(shí)驗(yàn)臺(tái)設(shè)計(jì),機(jī)械式,前置,汽車,變速器,實(shí)驗(yàn),試驗(yàn),設(shè)計(jì)
機(jī)械設(shè)計(jì)簡(jiǎn)介
設(shè)計(jì)過(guò)程
機(jī)器是機(jī)構(gòu)與其他零件的組合， 為了有益的用途而轉(zhuǎn)換，傳遞或利用能量，力或運(yùn)動(dòng)。實(shí)例有發(fā)動(dòng)機(jī)，渦輪，車輛，卷?yè)P(yáng)機(jī)，印刷機(jī)，洗衣機(jī)和電影攝影機(jī)。 許多適用于機(jī)器設(shè)計(jì)的原理和方法也適用于不是真正機(jī)器的制成品，從輪轂蓋和檔案櫥柜到儀表和核壓力容器。“機(jī)械設(shè)計(jì)”這一術(shù)語(yǔ)比“機(jī)器設(shè)計(jì)”更為廣義，它包括機(jī)器設(shè)計(jì)。而對(duì)于某些儀器，如用以確定熱，流動(dòng)線路和體積的熱力以及流體方面的問(wèn)題要單獨(dú)考慮。但是，在機(jī)械設(shè)計(jì)時(shí)要考慮運(yùn)動(dòng)和結(jié)構(gòu)方面的問(wèn)題以及保存和封裝的規(guī)定。在機(jī)械工程領(lǐng)域以及其他工程領(lǐng)域應(yīng)用機(jī)械設(shè)計(jì)，都需要諸如開關(guān)，凸輪，閥門，容器和攪拌器等機(jī)械裝置。
設(shè)計(jì)始于真正的或想象的需要?，F(xiàn)有的儀器可能需要在耐用性，效率，重量，速度或成本上加以改進(jìn)。 可能需要新的儀器來(lái)完成以前由人做的功能，如計(jì)算，裝配或保養(yǎng)。目標(biāo)全部或部分地確定后，設(shè)計(jì)的下一步就是構(gòu)思能夠完成所需功能的機(jī)構(gòu)及其布置。為此，徒手畫草圖價(jià)值極大，它不但作為一個(gè)人想法的記錄和其他人討論的輔助手段，而且尤其適于與自己的想法交流，作為創(chuàng)造性思路的興奮劑。還需要有關(guān)部件的廣泛知識(shí)，因?yàn)橐慌_(tái)新機(jī)器常常由熟知的各類零件重新安排或替換而成，也許改變了尺寸和材料。無(wú)論在構(gòu)思過(guò)程中還是之后，一個(gè)設(shè)計(jì)者都會(huì)進(jìn)行快速或粗略的計(jì)算或分析以確定一般尺寸和可行性。當(dāng)一些關(guān)于所需或可用空間量的想法確定后，可以按比例畫草圖。
當(dāng)幾個(gè)零件的大致形狀和幾個(gè)尺寸出來(lái)時(shí)，分析可以真正開始了。分析的目的在于使其具有令人滿意的或者優(yōu)越的性能，以及在最小重量下的安全性和耐用性和有競(jìng)爭(zhēng)力的成本。設(shè)計(jì)師將為每一個(gè)關(guān)鍵的承載截面尋找最佳的比例和尺寸，以及幾個(gè)零件強(qiáng)度的平衡。然后選擇材料和處理方法。這些重要的目標(biāo)只有通過(guò)基于機(jī)械原理的分析才可以得到，如關(guān)于反作用力和摩擦的最優(yōu)利用的靜力學(xué)原理；關(guān)于慣性，加速度和能量的動(dòng)力學(xué)原理；關(guān)于應(yīng)力和撓度的材料的彈性和強(qiáng)度原理；關(guān)于材料的物理行為原理；關(guān)于潤(rùn)滑和水力驅(qū)動(dòng)的流體力學(xué)原理。分析可以由構(gòu)思機(jī)械安排的同一個(gè)工程師來(lái)做，或者在大公司里由獨(dú)立的分析部門或研究組來(lái)做。分析的結(jié)果，可能需要新的安排和新的尺寸。不管是正式做的或非正式做的，設(shè)計(jì)是一個(gè)反復(fù)的和合作的過(guò)程，分析人員可以對(duì)所有階段起作用而不僅僅是他自己的階段。
最后，一項(xiàng)基于功能和可靠性的設(shè)計(jì)完成了，就可以制造樣機(jī)了。如果測(cè)試滿意，而且如果裝置要大量生產(chǎn)，就要對(duì)最初的設(shè)計(jì)進(jìn)行一定的修改以確保以較低的成本大量生產(chǎn)。在隨后幾年的制造和使用期間，設(shè)計(jì)有可能因構(gòu)思了新想法或者基于測(cè)試和經(jīng)驗(yàn)基礎(chǔ)上的進(jìn)一步分析所顯示的改變而改變。銷售吸引力，客戶滿意度和制造成本都與設(shè)計(jì)有關(guān)，設(shè)計(jì)能力與工程投資的成功密切相關(guān)。
一些設(shè)計(jì)準(zhǔn)則
在這一部分，有人建議運(yùn)用創(chuàng)造性的態(tài)度進(jìn)行的分析，這種分析可以引起重大改進(jìn)以及對(duì)備用產(chǎn)品的構(gòu)思和完善，也許產(chǎn)品功能更多，更經(jīng)濟(jì)，更耐用。創(chuàng)造階段無(wú)需是最初和獨(dú)立的階段。雖然分析人員可能并不負(fù)責(zé)整個(gè)設(shè)計(jì)，但是他不僅僅是能從數(shù)字上提出要他解決的問(wèn)題的正確答案，不僅僅是給出應(yīng)力值，尺寸或者工作限制。他可以提出更廣泛的見解，以便改進(jìn)規(guī)范或方案。由于在分析前或分析過(guò)程中，他會(huì)熟悉裝置及其工作條件，他就處于一個(gè)構(gòu)思備選方案的有利位置。最好他能提出建議改變形狀來(lái)消除力矩或應(yīng)力集中，而不是允許構(gòu)建具有大截面和過(guò)多動(dòng)態(tài)載荷的機(jī)構(gòu)。最好是他報(bào)廢他的細(xì)致的設(shè)計(jì)而不是后來(lái)看到的機(jī)械報(bào)廢。
為了激發(fā)創(chuàng)造性思維，建議設(shè)計(jì)人員和分析人員使用以下準(zhǔn)則。前6條準(zhǔn)則尤其適用于分析人員，雖然他可能涉及到所有這10項(xiàng)。
1. 創(chuàng)造性地利用所需的物理性能并控制不需要的。
2. 認(rèn)識(shí)實(shí)用載荷及其重要性。
3. 預(yù)選考慮沒有作用的載荷。
4. 發(fā)明更有利的加載條件。
5. 提供最小重量的最有利的應(yīng)力分布和剛性。
6. 用基本方程計(jì)算比例并使尺寸最優(yōu)化。
7. 選取材料以獲得性能組合。
8. 在備件和集成零件間仔細(xì)選擇。
9. 修改功能設(shè)計(jì)以適應(yīng)生產(chǎn)過(guò)程和降低成本。
10.考慮裝配中使部件精確定位和互不干擾。
北京理工大學(xué)學(xué)報(bào)，1998，Vol.7,No.2
汽車變速器性能實(shí)驗(yàn)臺(tái)自動(dòng)控制
閻清東 項(xiàng)昌樂(lè) 馮永存
（北京理工大學(xué)車輛工程學(xué)院，北京 100081）
摘要 目的 實(shí)現(xiàn)汽車變速器性能實(shí)驗(yàn)臺(tái)自動(dòng)控制。 方法 采用了潤(rùn)滑油油溫自動(dòng)恒溫控制技術(shù)，微機(jī)控制變速器自動(dòng)換檔，動(dòng)力電機(jī)無(wú)級(jí)調(diào)速，加載電渦流測(cè)功機(jī)變載，試驗(yàn)數(shù)據(jù)的自動(dòng)采集與實(shí)時(shí)處理技術(shù)。 結(jié)果 潤(rùn)滑油油溫控制在設(shè)定溫度℃；自動(dòng)換檔簡(jiǎn)單，可靠，準(zhǔn)確 ；無(wú)級(jí)調(diào)速調(diào)載快速準(zhǔn)確。加載轉(zhuǎn)矩偏差為r/min 。結(jié)論 將上述技術(shù)應(yīng)用于汽車變速器性能試驗(yàn)臺(tái)，利用該試驗(yàn)臺(tái)對(duì)某型變速器進(jìn)行了微機(jī)程控性能試驗(yàn)，效果良好。
關(guān)鍵詞 汽車變速器；性能試驗(yàn)；計(jì)算機(jī)輔助測(cè)試；自動(dòng)控制。
分類號(hào) U463.212 ；U467.12
為提高民族產(chǎn)品性能而對(duì)汽車各部件進(jìn)行試驗(yàn)和理論的復(fù)雜研究是發(fā)展民族汽車工業(yè)的重要途徑。齒輪箱是汽車變速器的一個(gè)關(guān)鍵部分，其特性會(huì)直接影響到變速器的性能。主要的性能參數(shù)是：變速器效率，潤(rùn)滑油，噪音等等。因此，對(duì)各性能進(jìn)行快速而精確的測(cè)試是很必要的。
在本文中，汽車變速器性能多功能試驗(yàn)臺(tái)應(yīng)用了自動(dòng)控制技術(shù)，實(shí)現(xiàn)了潤(rùn)滑油自動(dòng)恒溫控制，可編程自動(dòng)換檔，無(wú)級(jí)調(diào)速和負(fù)載調(diào)整，試驗(yàn)數(shù)據(jù)的自動(dòng)采集和處理，試驗(yàn)報(bào)告和測(cè)試曲線的自動(dòng)輸出，嚴(yán)格監(jiān)控了試驗(yàn)環(huán)境，精度和速度。
1. 自動(dòng)恒溫控制技術(shù)
性能測(cè)試中必須嚴(yán)格控制潤(rùn)滑油的溫度，在整個(gè)試驗(yàn)過(guò)程中油溫必須控制在設(shè)定溫度℃范圍內(nèi)。在本文中，采用了PID自動(dòng)控制技術(shù)混合冷熱機(jī)油來(lái)實(shí)現(xiàn)潤(rùn)滑油溫度恒定。該系統(tǒng)由潤(rùn)滑油強(qiáng)制循環(huán)系統(tǒng)和帶有反饋的PID電子控制系統(tǒng)組成。圖1是潤(rùn)滑油的強(qiáng)制循環(huán)系統(tǒng)圖，圖2是帶有反饋的PID電子控制系統(tǒng)圖。
圖1.潤(rùn)滑油強(qiáng)制循環(huán)系統(tǒng)
1－電機(jī) 2－機(jī)油泵 3－壓力氣壓表 4－溢流閥 5－滑閥 6－過(guò)濾器 7－輔助油箱
8－截流閥 9－冷卻裝置 10－電子加熱器和熱機(jī)油箱 11－三通電子驅(qū)動(dòng)閥 12－液壓油管 13－溫度傳感器 14－被測(cè)變速器
帶有反饋的PID自動(dòng)控制系統(tǒng)用于控制三通電子可調(diào)閥的驅(qū)動(dòng)電機(jī)。如果反饋溫度值低于設(shè)定溫度值，驅(qū)動(dòng)電機(jī)將順時(shí)針轉(zhuǎn)動(dòng)，熱機(jī)油流量增加，否則，驅(qū)動(dòng)電機(jī)將逆時(shí)針轉(zhuǎn)動(dòng)，冷機(jī)油流量增加。冷潤(rùn)滑油來(lái)自于冷卻裝置 ，熱潤(rùn)滑油來(lái)自裝有電子加熱器的熱潤(rùn)滑油油箱，溫度計(jì)用于監(jiān)測(cè)變速箱機(jī)油溫度為PID溫度控制器提供了基本的設(shè)定數(shù)。輔助溫度控制器用于控制熱潤(rùn)滑油箱中油溫保持在PID設(shè)定溫度的一定范圍內(nèi)。
圖2.PID自動(dòng)控制原理圖
1－PID溫度控制器 2－溫度計(jì) 3－輔助溫度控制器 4－電子加熱器 5－熱機(jī)油箱溫度傳感器 6－變速器油溫傳感器 7－反饋溫度傳感器 8－三通電子可調(diào)閥驅(qū)動(dòng)電機(jī)
2. 計(jì)算機(jī)控制系統(tǒng)
圖3是計(jì)算機(jī)自動(dòng)控制流程圖
系統(tǒng)功能如下：
1. 監(jiān)測(cè)性能參數(shù)；輸入轉(zhuǎn)速和扭矩，輸出轉(zhuǎn)速和扭矩，潤(rùn)滑油溫度，檔位。
2. 調(diào)整主可變頻率電機(jī)的轉(zhuǎn)速和電渦流電力測(cè)功機(jī)的負(fù)載。
圖3.計(jì)算機(jī)自動(dòng)控制流程圖
2.1換檔控制
換檔桿的運(yùn)動(dòng)是由用于換檔和位置控制的汽缸活塞曲柄機(jī)構(gòu)控制的，活塞行程是由電磁開關(guān)控制的。換檔過(guò)程完全是由單片機(jī)上的CPU控制的。圖4是換檔氣動(dòng)系統(tǒng)，圖5是換檔控制電路布置圖，CPU通過(guò)向單片機(jī)上的CPU發(fā)送換檔指令以閉合相應(yīng)的繼電器來(lái)控制電磁滑閥的動(dòng)作，同時(shí)不同的氣動(dòng)電路接通來(lái)實(shí)現(xiàn)不同的換檔和位置動(dòng)作。
圖4.氣動(dòng)換檔示意圖
1－油水分離器 2－儲(chǔ)氣筒 3－氣壓表 4，5，10，11－ 電磁滑閥 6－單向閥 7－換檔控制氣缸 8－電磁開關(guān) 9－位置控制氣缸
圖5.換檔控制電路示意圖
1，2，3，4－整體式繼電器 5，6，7，8－滑閥控制電磁鐵 9－主CPU 10－單片機(jī)上的CPU 11－位置開關(guān)
2.2 轉(zhuǎn)速和負(fù)載的控制
液晶示波器的頻率是1.832MHZ。第一級(jí)分離頻率的時(shí)間常數(shù)是2.頻率分離器的頻率是921.6KHZ，而后，系統(tǒng)控制軟件為下級(jí)頻率分離器設(shè)定連續(xù)的時(shí)間常數(shù)以獲得連續(xù)的電壓。時(shí)間常數(shù)和頻率之間的關(guān)系是：時(shí)間常數(shù)=921.6/頻率。
控制轉(zhuǎn)速和負(fù)載的自動(dòng)控制器帶有與計(jì)算機(jī)連接的電壓通道端口。再通過(guò)F/D（頻率/電壓）轉(zhuǎn)換器可以獲得控制電壓。輸入頻率，輸出電壓，驅(qū)動(dòng)電機(jī)轉(zhuǎn)速和測(cè)功機(jī)。磁化電流之間的相應(yīng)關(guān)系如下表：
表1. 對(duì)應(yīng)關(guān)系
輸入頻率/KHZ
輸出電壓/V
驅(qū)動(dòng)電機(jī)轉(zhuǎn)速/（r/min）
測(cè)功機(jī)磁化電流/A
0
0
0
0
5
5
6000
5
3.計(jì)算機(jī)數(shù)據(jù)實(shí)時(shí)采集和處理
3.1數(shù)據(jù)實(shí)時(shí)采集
傳感器的信號(hào)在傳送到計(jì)算機(jī)以前，被高精度的V/F（電壓/頻率）和I/F轉(zhuǎn)換器轉(zhuǎn)變成類似的線性頻率信號(hào)。通過(guò)8253時(shí)間計(jì)數(shù)器和相應(yīng)的計(jì)算，可以得出被測(cè)工程的可變值。對(duì)應(yīng)關(guān)系：A=CN，A是工程值，N是時(shí)間計(jì)數(shù)器的脈沖值，C為轉(zhuǎn)換器的校對(duì)系數(shù)。
3.2數(shù)據(jù)實(shí)時(shí)處理
從傳感器獲取的原始數(shù)據(jù)的基礎(chǔ)上，輸入功率，輸出功率，比例，效率會(huì)直接計(jì)算出來(lái)。同時(shí)，計(jì)算機(jī)屏幕上會(huì)顯示出效率曲線。
4. 實(shí)驗(yàn)臺(tái)的結(jié)構(gòu)
性能實(shí)驗(yàn)臺(tái)是一臺(tái)動(dòng)力開環(huán)測(cè)試臺(tái)，由機(jī)械框架，電控系統(tǒng)，計(jì)算機(jī)系統(tǒng)，潤(rùn)滑油自動(dòng)恒溫控制系統(tǒng)和可編程控制自動(dòng)換檔系統(tǒng)組成。圖6是實(shí)驗(yàn)臺(tái)的框架圖。動(dòng)力組是55KW的高轉(zhuǎn)速可變頻電機(jī)，可以實(shí)現(xiàn)0-6000r/min范圍內(nèi)的連續(xù)可變調(diào)速。因此，變速器輸入可以省去一臺(tái)調(diào)速器，在很大范圍內(nèi)降低了實(shí)驗(yàn)臺(tái)的噪音。負(fù)載組是一臺(tái)160KW的電渦流電力測(cè)功機(jī)，動(dòng)力可以單邊或雙邊輸入，以達(dá)到配有差速齒輪或無(wú)差速齒輪的變速器的要求。在變速器的輸出端采用了同步帶，可以簡(jiǎn)化實(shí)驗(yàn)臺(tái)的結(jié)構(gòu)和降低噪音。
圖6.實(shí)驗(yàn)臺(tái)框架結(jié)構(gòu)圖
1－55KW可變頻電機(jī) 2－輸入扭矩，轉(zhuǎn)速傳感器 3－被測(cè)變速器 4－輸出扭矩，轉(zhuǎn)速傳感器 5－同步帶 6－160KW電渦流電力測(cè)功機(jī) 7－潤(rùn)滑油泵工作臺(tái) 8－換檔機(jī)構(gòu)系統(tǒng)
5.試驗(yàn)舉例
在實(shí)驗(yàn)臺(tái)上對(duì)ALTO變速器進(jìn)行性能測(cè)試，通過(guò)原始數(shù)據(jù)處理，效率曲線如圖7所示。試驗(yàn)過(guò)程中，檢測(cè)參數(shù)被控制在實(shí)驗(yàn)臺(tái)許可范圍內(nèi)。試驗(yàn)數(shù)據(jù)如下圖：
圖7.效率曲線
輸入轉(zhuǎn)速：（（1000，2000，3000）5）r/min；
輸入扭矩：（（28，56）1）N·m；
潤(rùn)滑油溫度：（802）℃。
6.總結(jié)
1. 冷熱機(jī)油混合技術(shù)的采用，可以實(shí)現(xiàn)潤(rùn)滑油恒溫控制。
2. 可編程自動(dòng)換檔，可調(diào)轉(zhuǎn)速負(fù)載，和數(shù)據(jù)實(shí)時(shí)采集和處理技術(shù)的采用，變速器特性測(cè)試可以自動(dòng)完成。
3. 試驗(yàn)報(bào)告和測(cè)試結(jié)果曲線可以通過(guò)計(jì)算機(jī)顯示獲取。
參考文獻(xiàn)
Lu J F.傳感器端口通道和試驗(yàn)裝置電路（中文版）。北京 北京航空工業(yè)出版社，1994
（收錄于1997.11.26）
8
大 學(xué)
畢業(yè)設(shè)計(jì)任務(wù)書
學(xué) 院、系：
專 業(yè)：
機(jī)械設(shè)計(jì)制造及其自動(dòng)化
學(xué) 生 姓 名：
學(xué) 號(hào)：
設(shè) 計(jì) 題 目：
機(jī)械式汽車前置變速器實(shí)驗(yàn)臺(tái)
起 迄 日 期:
指 導(dǎo) 教 師:
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畢 業(yè) 設(shè) 計(jì) 任 務(wù) 書
1．畢業(yè)設(shè)計(jì)的任務(wù)和要求：
任務(wù)：設(shè)計(jì)機(jī)械式前置汽車變速器實(shí)驗(yàn)臺(tái)。
要求：設(shè)計(jì)零號(hào)圖紙（裝配圖）一張，部件圖三張（輸入傳動(dòng)、輸出傳動(dòng)、軸承座組件），零件圖三張（輸出軸、多楔帶輪、花鍵軸）。
設(shè)計(jì)說(shuō)明書一份。
刻錄光盤一張。
2．畢業(yè)設(shè)計(jì)的具體工作內(nèi)容：
原始數(shù)據(jù)：1）適用5T07汽車變速器。
2）輸入扭矩：85N.m。
3）輸入轉(zhuǎn)速：0~3000r/min。
4）反拖電機(jī)功率：3kw。
5）輸出扭矩：<1000N.m。
6）工件移動(dòng)距離：180~200mm。
技術(shù)要求：1）輸入軸跳動(dòng)<0.03mm。
2）輸出軸跳動(dòng)<0.02mm。
3）工件夾緊力≥150N。
4）工作效率：2~3min/件。
工作要求：1）學(xué)習(xí)AutoCAD軟件。
2）結(jié)構(gòu)設(shè)計(jì)合理。
3）撰寫設(shè)計(jì)說(shuō)明書。
4）翻譯英文資料一份。
畢 業(yè) 設(shè) 計(jì) 任 務(wù) 書
3．對(duì)畢業(yè)設(shè)計(jì)成果的要求：
設(shè)計(jì)零號(hào)圖紙（裝配圖）一張，部件圖三張（輸入傳動(dòng)、輸出傳動(dòng)、軸承座組件），零件圖三張（輸出軸、多楔帶輪、花鍵軸）。
設(shè)計(jì)說(shuō)明書一份。
刻錄光盤一張。
4．畢業(yè)設(shè)計(jì)工作進(jìn)度計(jì)劃：
起 迄 日 期
工 作 內(nèi) 容
2011年
3月 1 日 ~3月10日
3月11日 ~3月20日
3月21日 ~4月15日
4月16日 ~5月15日
5月16日 ~6月10日
6月10日~ 6月15日
查閱有關(guān)帶式輸送機(jī)自動(dòng)張緊裝置的資料，準(zhǔn)備開題；
完成開題報(bào)告；
機(jī)械式變速器實(shí)驗(yàn)臺(tái)設(shè)計(jì)的理論分析；
機(jī)械式變速器實(shí)驗(yàn)臺(tái)的總體和結(jié)構(gòu)設(shè)計(jì)；
完成畢業(yè)設(shè)計(jì)說(shuō)明書的撰寫，翻譯英文資料；
論文答辯
學(xué)生所在系審查意見：
系主任：
年 月 日
大學(xué) 屆本科畢業(yè)設(shè)計(jì)說(shuō)明書
機(jī)械式前置汽車變速器實(shí)驗(yàn)臺(tái)的設(shè)計(jì)
摘要
根據(jù)5T07汽車變速器性能試驗(yàn)的要求，提出了FF式機(jī)械式變速器試驗(yàn)臺(tái)的整體方案，介紹了各部分的結(jié)構(gòu)和工作原理，并給出了整個(gè)機(jī)械結(jié)構(gòu)系統(tǒng)的功能，說(shuō)明了試驗(yàn)臺(tái)的特點(diǎn)，使用情況，它集機(jī)械，變頻調(diào)速，傳感器等技術(shù)為一體，通過(guò)對(duì)機(jī)械式變速器的結(jié)構(gòu)原理以及相關(guān)測(cè)試診斷技術(shù)的分析，總結(jié)出機(jī)械式變速器臺(tái)架的試驗(yàn)方法，在此基礎(chǔ)上對(duì)試驗(yàn)臺(tái)的驅(qū)動(dòng)設(shè)備和負(fù)載設(shè)備進(jìn)行的選型和匹配，檢測(cè)臺(tái)主要由驅(qū)動(dòng)系統(tǒng)，負(fù)載系統(tǒng)，臺(tái)架系統(tǒng)，控制臺(tái)及一些附屬設(shè)備組成。臺(tái)架系統(tǒng)可以利用定位板實(shí)現(xiàn)變速器的夾緊定位，一臺(tái)交流異步電動(dòng)機(jī)以變頻方式調(diào)速實(shí)現(xiàn)模擬發(fā)動(dòng)機(jī)，采用磁粉制動(dòng)器作為負(fù)載裝置實(shí)現(xiàn)對(duì)路況的模擬，以滿足檢測(cè)的需要，監(jiān)控系統(tǒng)實(shí)現(xiàn)檢測(cè)模式的選擇，檢測(cè)過(guò)程的控制及顯示變速器運(yùn)行狀態(tài)等功能，附屬設(shè)備主要是提供變速器運(yùn)行所必需的及方便檢測(cè)工作的外部環(huán)境。該臺(tái)架系統(tǒng)實(shí)用性強(qiáng)，具有很高的推廣價(jià)值。
關(guān)鍵字： 機(jī)械式變速器，性能測(cè)試，實(shí)驗(yàn)裝置
Design of the Mechanical automobile transmission performance test stand
Abstract
Based on the requirement of the 5T07 transmission performance test stand, the article shows the overall layout the FF type automobile transmission test performance, both the function of Mechanical structure system and the Features，the use condition of the stand. It consists of the mechanical system, data Acquisition system, and sensor and so on. By the Analysis of the mechanical structure Principle and related test Technology, it is used to get the test method. The test stand includes driver equipment and load equipment, stands system, control system and auxiliary equipment. The stand uses positioning board to realize the clamping of the tested transmission, and an AC asynchronous motor to realize the Simulation of the drive engine, and use a magnetic braker to simulate the traffic condition. Monitoring System can realize the choice of the monitoring model, and the control of the monitoring processing, and the function to put out the test results. Auxiliary equipment is to offer the external environment during the test process. The test stand is of big Practicability, and has strong value.
Keyword: mechanical transmission, performance test, the test Equipments
畢業(yè)設(shè)計(jì)說(shuō)明書
機(jī)械式前置汽車變速器實(shí)驗(yàn)臺(tái)設(shè)計(jì)
高洪宇
0702014425
學(xué)生姓名： 學(xué)號(hào)：
學(xué) 院：
專 業(yè)： 機(jī)械設(shè)計(jì)制造及其自動(dòng)化
指導(dǎo)教師：
機(jī)械工程與自動(dòng)化學(xué)院
年 月
大 學(xué)
畢業(yè)設(shè)計(jì)說(shuō)明書評(píng)語(yǔ)
學(xué)院： 專業(yè)： 機(jī)械設(shè)計(jì)制造及其自動(dòng)化
姓名： 學(xué) 號(hào)：
題目： 機(jī)械式前置汽車變速器實(shí)驗(yàn)臺(tái)設(shè)計(jì)
指導(dǎo)教師評(píng)語(yǔ)：
同學(xué)在規(guī)定的時(shí)間內(nèi)完成了畢業(yè)設(shè)計(jì)任務(wù)書的要求。該同學(xué)所設(shè)計(jì)的機(jī)械式手動(dòng)變速器試驗(yàn)臺(tái)，設(shè)計(jì)方案合理，試驗(yàn)過(guò)程可行，數(shù)據(jù)符合實(shí)際設(shè)計(jì)情況。其中，反拖機(jī)構(gòu)的設(shè)計(jì)，結(jié)構(gòu)緊湊，具有一定創(chuàng)新性。
該同學(xué)在設(shè)計(jì)過(guò)程中勤于思考，對(duì)設(shè)計(jì)方案反復(fù)推敲，并與指導(dǎo)老師多次討論，力爭(zhēng)使設(shè)計(jì)更趨于合理，并獨(dú)立運(yùn)用CAD軟件完成了整個(gè)臺(tái)體的設(shè)計(jì)，表現(xiàn)出了較強(qiáng)的自學(xué)能力和扎實(shí)的設(shè)計(jì)基礎(chǔ)。
該同學(xué)在書寫設(shè)計(jì)說(shuō)明書的過(guò)程中，嚴(yán)格按照學(xué)校規(guī)定的說(shuō)明書格式書寫，說(shuō)明書整體結(jié)構(gòu)緊湊、書寫規(guī)范、文筆較流暢，翻譯也比較正確。
由于實(shí)踐經(jīng)驗(yàn)不足，在設(shè)計(jì)中還存在不足之處：如：結(jié)構(gòu)不太緊湊，這還有待于進(jìn)一步完善。
綜觀畢業(yè)設(shè)計(jì)整個(gè)過(guò)程，都說(shuō)明付曉強(qiáng)同學(xué)提交的答辯材料符合要求，可以提交答辯。
建議成績(jī)：
指導(dǎo)教師(簽字)： 年 月 日
大學(xué) 屆本科畢業(yè)設(shè)計(jì)說(shuō)明書
目 錄
1 緒論 1
1.1 汽車變速器試驗(yàn)臺(tái)簡(jiǎn)介 1
1.2 變速器的分類及特點(diǎn) 2
1.3 機(jī)械式變速器的基本要求 3
1.4 機(jī)械式變速器換檔規(guī)律 4
1.5 本文的主要內(nèi)容及其重點(diǎn) 4
2 變速器試驗(yàn)臺(tái)的結(jié)構(gòu)和工作原理 5
2.1 試驗(yàn)臺(tái)設(shè)計(jì)依據(jù) 6
2.2 試驗(yàn)工藝流程 7
2.3 實(shí)驗(yàn)臺(tái)工作原理和組成 7
2.4 臺(tái)體機(jī)械結(jié)構(gòu)形式 8
2.5 動(dòng)力設(shè)備的選擇 9
2.6 本章小結(jié) 9
3 電機(jī)的選擇 10
3.1 選擇電動(dòng)機(jī)類型和結(jié)構(gòu)形式 10
3.2 選擇電動(dòng)機(jī)的容量 10
3.3 確定電動(dòng)機(jī)的轉(zhuǎn)速 12
3.4 主電機(jī)轉(zhuǎn)速控制 13
3.5 本章小結(jié) 13
4 輸入部件的設(shè)計(jì) 14
4.1 輸入軸設(shè)計(jì)準(zhǔn)則 14
4.2 皮帶型號(hào)的選擇 15
4.3 皮帶的設(shè)計(jì) 17
4.4 帶輪型號(hào)的選擇 18
4.5 摩擦離合器型號(hào)的選擇 19
4.6 鍵的選擇計(jì)算 21
4.7 本章小結(jié) 21
5 輸出部件的設(shè)計(jì) 22
5.1 軸承類型的選擇 22
5.2 上傳輸軸的設(shè)計(jì) 23
5.3 左移動(dòng)滑臺(tái)驅(qū)動(dòng)液壓缸的選擇 27
5.4 輸入軸的設(shè)計(jì) 29
5.5 鍵的選擇計(jì)算和校核 30
5.6 聯(lián)軸器的選擇與校核 30
5.7 本章小結(jié) 32
6 其他零部件的設(shè)計(jì) 33
6.1 箱體及安裝滾筒的設(shè)計(jì) 33
6.2 導(dǎo)軌的設(shè)計(jì) 33
6.3 左，右輸出部分單片式離合器的選用 36
6.4 定位板的設(shè)計(jì) 37
6.5 傳感器的選擇 37
6.6 加載器的選擇 40
6.7 螺釘?shù)葏?shù) 40
6.8 本章小結(jié) 41
7 計(jì)算機(jī)數(shù)據(jù)采集分析系統(tǒng) 42
7.1 數(shù)據(jù)采集卡的選擇 42
7.2 試驗(yàn)臺(tái)控制系統(tǒng)主要部分及功能 44
7.3 試驗(yàn)臺(tái)測(cè)試系統(tǒng) 44
7.4 試驗(yàn)臺(tái)造型設(shè)計(jì) 45
7.4 本章小結(jié) 46
結(jié) 論 47
參考文獻(xiàn) 48
致 謝 49
第II頁(yè) 共Ⅱ頁(yè)
畢業(yè)設(shè)計(jì)中英文翻譯
高洪宇
0702014425
學(xué)生姓名： 學(xué)號(hào)：
學(xué) 院：
專 業(yè)： 機(jī)械設(shè)計(jì)制造及其自動(dòng)化
指導(dǎo)教師：
機(jī)械工程與自動(dòng)化學(xué)院
年 月
Introduction to Mechanical Design
The Design Process
A machine is a combination of mechanism and other components which transforms, transmits ,or utilizes energy, force ,or motion for a useful purpose .Examples are engines ,turbines ,vehicle ,hoists, printing presses, washing machines ,and movie cameras. Many of the principle and methods of design that apply to machines also apply to manufactured articles that are not true machines, from hub caps and filing cabinets to instruments and nuclear pressure vessels. The term “mechanical design” is used in a broader sense than “mechanical design” to include their design. For some apparatus, the thermal and fluid aspects that determine the requirements of heat, flow path, and volume are separately considered. However, the motion and structural aspects and the provisions for retention and enclosure are considerations in mechanical design. Applications occur in the field of mechanical engineering, and in other engineering fields as well, all of which require mechanical devices, such as switches, cams, valves, vessels, and mixers.
Designing starts with a need, real or imagined. Existing apparatus may need improvements in durability, efficiency, weight, speed, or cost. New apparatus may be needed to perform a function previously done by men, such as computation, assembly, or servicing. With the objective wholly or partly defined, the next step in design is the conception of mechanisms and their arrangements that will perform the needed functions. For this, freehand sketching is of great valve, not only as record of one’s thoughts and as an aid in discussion with others, but particularly for communication with one’s own mind, as a stimulant for creative ideas. Also, a broad knowledge of components is desirable ,because a new machine usually consists of a new arrangement or substitution of well-known types of components ,perhaps with changes in size and material .Either during or following this conceptual process, one will make quick or rough calculations or analyses to determine general size and feasibility. When some idea as to the amount of space that is needed or available has been obtained, to-scale layout drawing may be started.
When the general shape and a few dimensions of the several components become apparent, analysis can begin in earnest. The analysis will have as its objective satisfactory or superior performance, plus safety and durability with minimum weight, and a competitive cost. Optimum proportions and dimensions will be sought for each critically loaded section, together with a balance between the strengths of the several components. Materials and their treatment will be chosen. These important objectives can be attained only by analysis based upon the principles of mechanics, such as those of static’s for reactions forces and for the optimum utilization of friction; of dynamics for inertia, acceleration, and energy; of elasticity and strength of materials for stress and deflection; of physical behavior of materials; and of fluid mechanics for lubrication and hydrodynamic drives. The analyses may be made by the same engineer who conceived the arrangement of mechanisms, or, in a large company, they may be made by a separate analysis division or research group. As a result of the analyses, new arrangements and new dimensions may be required .Design is reiterative and cooperative process, whether done formally or informally, and the analyst can contribute to phases other than his own.
Finally, a design based upon function and reliability will be completed, and a prototype may be built. If its tests are satisfactory, and if the device is to be produced in quantity, the initial design will undergo certain modifications that enable it to be manufactured in quantity at a lower cost. During subsequent years of manufacture and service, the design is likely to undergo changes as new ideas are conceived or as further analyses based upon tests and experience indicate alterations . Sales appeal, customer satisfaction, and manufacturing cost are all related to design, and ability in design is intimately involved in the success of an engineering venture.
Some rule for design
In the section it is suggested that, applied with a creative attitude, analyses can lead to important improvements and to the conception and perfection of alternate, perhaps more functional, economical, and durable products. The creative phase need not be an initial and separate one. Although he may not be responsible for the whole design, an analyst can contribute more than the numerically correct answer to a problem that he is asked to solve- more than the values of stress, dimensions, or limitations of operation. He can take the broader view that the specifications or the arrangements may be improved. Since he will become familiar with device and its conditions of operation before or during hid analysis, he is in a good position to conceive of alternatives. It is better that he suggest a change in shape that will eliminate a moment or a stress concentration than to allow construction of a mechanism with heavy sections and excessive dynamic loads. It is better that he scrap his fine analysis, rather than that he later see the mechanism scrapped.
To stimulate creative thought, the following rules are suggested for the designer and analyst. The first six rules are particularly applicable for the analyst, although he may become involved with all ten rules.
1. Apply ingenuity to utilize desired physical properties and to control undesired ones.
2. Recognize functional loads and their significance.
3. Anticipate unintentional loads.
4. Devise more favorable loading conditions.
5. Provide for favorable stress distribution and stiffness with minimum weight.
6. Use basic equations to proportion and optimize dimensions.
7. Choose materials for a combination of properties.
8. Select carefully between stock and integral components.
9. Modify a functional design to fit the manufacturing process and reduce cost.
10. Provide for accurate location and noninterference of parts in assembly.
Journal of Beijing Institute of Technology, 1998, Vol.7, No.2
Automatic Control of Automobile Transmission Performance Test Stand
Abstract Aim to realize automatic control of automobile transmission performance test stand.
Methods The automatic control technique of the lubricant temperature, the program-controlled automatic shifting of the transmission, the continuous adjusting of revolution speed and load, data –acquisition and data real-time processing were adopted.
Results The lubricant temperature was controlled at the set temperature .The automatic shifting of the transmission is simple, reliable and accurate. The automatic adjusting of load and rotation speed is rapid and accurate, the torque divergence is, and the rotation speed divergence is.
Conclusion The four kinds of techniques are applied into the automobile transmission performance test stand successfully.
The profound study of test and theory about every part of automobile for improving the performances of national products is of very important meaning for developing the national automobile industry. Gear box is a key part of automobile transmission systems. Its properties have effects on the performance directly. The main performance parameters are: the transmission efficiency, the lubricant, the noise and so on. So it is necessary to do the performance test rapidly and accurately.
In this paper, automatic-control techniques are applied to the multifunction test stand of the automobile transmission performance. Lubricant automatic constant temperature control, program-controlled automatic shifting, infinitely variable adjusting rotation speed and load, automatic acquisition and processing of the test data, and automatic outputting test reports and curves are fulfilled. The test conditions, accuracy and speed are provided strictly.
1 AUTOMATIC CONSTANT TEMPERATURE CONTROL TECHNIQUE
The lubricant temperature should be controlled strictly under the performance test. In the whole process of the test, the temperature should be guaranteed at the set temperature. Otherwise, the test of the gear box performance would be affected.
In this paper, mixing cool oil and hot oil by PID automatic-control technique is used to realize the lubricant constant temperature. The system consists of the lubricant force-circulating system and the PID electric automatic-control with feedback system. Fig.1 shows the lubricant force-circulating system. Fig.2 illustrates the PID electric automatic-control with feedback system.
Fig. 1 lubricant force-circulating system
1-motor 2-oil pump 3-pressure manometer 4-discharge valve
5-slide valve 6-filter 7-auxiliary oil tank 8. Stop-valve 9-cooling apparatus 10-electric heater and hot oil tank 11.three-port electric-drive valve 12-hydraulic tube
The PID automatic control with feedback system is used to control the motor of the three-port electric-adjusting valve. If the feedback temperature valve is lower than the set temperature valve, the valve’s motor will rotate clockwise, and then the hot oil flow will rise. Otherwise, the valve’s motor will rotate counter-clockwise, and then the cool oil flow will rise. The cool lubricant comes from the cooling apparatus. The hot lubricant comes from the hot-lubricant tank with electric heaters. The temperature meter monitors the box’s oil temperature, and provides the basic set number for the PID temperature controller. The auxiliary temperature controller keeps the temperature of the oil in the hot lubricant tank in some range of the PID set temperature.
Fig.2 PID automatic-control principle diagram
1-PID temperature controller 2- temperature meter
3- Auxiliary temperature controller 4-electric heater
5-hot oil case temperature transducer 6- transmission oil temperature transducer
7-feedback temperature transducer 8- the motor of the three-port electric-adjusting valve
2. COMPUTER-CONTROL SYSTEM
Fig.3 illustrates the computer automatic control flow chat.
System functions are as follows:
1. Monitoring performance parameters: the input rotation speed and torque, the output rotation speed and torque, the lubricant temperature, the position of shifting.
2. Adjusting main variable frequency motor’s rotation speed and eddy current electro-dynamometer’s load.
3. Automatic selecting shift position.
Fig.3 Computer automatic control flow chart
2.1 Shifting Control
The cylinder position crank mechanism of shifting and positioning controls the shifter lever’s motion. Piston stroke is controlled by magnetic switches. Shifting steps are completed by
1-oil-water dividing filter 2-gas source 3- gas manometer
4, 5, 10, 11-magnetic slide valve 6-one-way valve
7-shifting cylinder 8- magnetic switch 9- positioning cylinder
Fig.4 shifting pneumatics system schematic diagram
1, 2, 3, 4-solid relay 5, 6, 7, 8-slide valve magnet 9- main computer
10-computer on slice 11-position switch
Fig.5 Shifting control electric circuit schematic diagram
the computer on slice. The shifting pneumatics system is shown as Fig.4 .The shifting control electric circuit demonstrating chart is shown as Fig.5. The computer sends shifting commands to the computer on slide for switching-on corresponding relay to control the magnetic slide valve. The different pneumatics circuits are switched on to realize different shifting and positioning motion.
2.2 Controlling of Rotation Speed and Load
The frequency of crystal oscillator is 1.8432MHz. The first grade dividing frequency time constant is 2. Then the frequency divider’s freq2uency is 921.6 kHz. Later, the system control software sets sequential time constant for next frequency divider to get sequential voltage. The relation between time constant and frequency is time constant=921.6frequency.
The automatic controllers of rotation speed and load have voltage access ports with computer. By F/V transducer control voltage is obtained. Corresponding relations among the input frequency, the output voltage, the motor rotation speed and the electrodynamometer magnetizing current are as follows:
Input frequency/kHz
Output voltage/V
Motor-rotation speed(r/min)
electrodynamometer magnetizing current/A
0
0
0
0
5
5
6000
5
3. COMPUTER DATA REAL-ACQUISITION AND PROCESSING
3.1 Data Real-Acquisition
The signals of transducers are changed into the same signal – the linear frequency signal by high precision V/F and I/F transducers before they transmitted to the computer. Then by 8253 time-counter and corresponding calculations, the valve of the tested engineering variable is obtained.
Corresponding relation is A=cN, A is the engineering valve, N is the number of pulses of time-counter, and c is the calibrated coefficient of transducer.
3.2 Data Real-Time Processing
On the basic of original data acquired from transducers, the input power, the output power, the ratio and the efficiency are calculated immediately. At the same time, the efficiency curves are showed on the computer screen.
4. THE CONSTRUCTION OF THE TEST STAND
This performance test stand is a power open-circuit test stand, and consists of the frame, the electric control system, the computer system, the lubricant automatic constant temperature system, and the program-controlled automatic shifting system. Fig.6 shows the frame of the test stand. The power set is a high rotation speed frequency-changing motor of 55KW, and able to realize infinitely variable speed adjusting from 0-6000r/min, thus, the transmission input doesn’t need a speeder, the noise of the test stand itself id lowered on a large scale .The loading set is an eddy current electrodynamometer of 160KW, the power could be input from one side or double sides, so as to meet the requirements of the transmission with a differential gear or without a differential gear. The synchronous belt is adopted at the transmission output side, thus, the construction id very simple and the noise is low.
1-55KW frequency changing motor 2-input torque, rotation speed transducer 3- tested transducer 4-output torque, rotation speed transducer 5- synchronous belt 6-160KW eddy current electrodynamometer 7-lubricant pump station 8-shifting mechanical system
Fig.6 The construction of the test stand frame
5. THE EXAMPLE OF THE TEST
The performance test of ALTO transmission is done on the test stand. By original data processing, the efficiency curves are shown as Fig.7
During the test process, monitor parameters are controlled in the range of the test stand, the data are as follows:
Fig.7 Efficiency curve
Input rotation speed :(( 1000, 2000, 3000)) r/min
Input torque ((28, 56)) Nm
Lubricant temperature (80)
6. CONCLUSIONS
(1) By the technique of mixing the cool and the hot oil, the transmission lubricant constant temperature control could be realized.
(2) By the technique of program-control automatic shifting, adjusting rotation speed and load, and data real-time acquisition and processing, the automobile transmission property test could be completed automatically.
(3) Computer gives test report and curves.
REFERENCE
1. Lu J F Transducer port and test apparatus circuit (in China). Beijing: Beijing institute of Aero-technics Publishing House, 1994
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