CA3107975A1 - Electric loading multifunctional test bench for power-dividing hydraulic-mechanical composite transmission system and application thereof - Google Patents

Electric loading multifunctional test bench for power-dividing hydraulic-mechanical composite transmission system and application thereof Download PDF

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Publication number
CA3107975A1
CA3107975A1 CA3107975A CA3107975A CA3107975A1 CA 3107975 A1 CA3107975 A1 CA 3107975A1 CA 3107975 A CA3107975 A CA 3107975A CA 3107975 A CA3107975 A CA 3107975A CA 3107975 A1 CA3107975 A1 CA 3107975A1
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transmission unit
hydraulic
mechanical
power
input side
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CA3107975C (en
Inventor
Lirong WAN
Hanzheng DAI
Qingliang Zeng
Zhiyuan SUN
Mingqian TIAN
Wenting Liu
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Shandong University of Science and Technology
Taishan University
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Shandong University of Science and Technology
Taishan University
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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01MTESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M13/00Testing of machine parts
    • G01M13/02Gearings; Transmission mechanisms
    • G01M13/022Power-transmitting couplings or clutches

Abstract

An electric loading multifunctional test bench for a power-dividing hydraulic-mechanical composite transmission system and a method thereof. The test bench comprises a mechanical part and a control part. The test bench can achieve performance test of the hydraulic drive unit of the hydraulic-mechanical composite transmission system. By simulating the actual driving conditions and operating conditions of a vehicle in an application scenario, the transmission performance of the hydraulic drive unit of the hydraulic-mechanical composite transmission system is tested, and one-stage and multi-stage hydraulic transmission unit performance test, the test of the proportion of mechanical and hydraulic power flow of the composite transmission system and the automatic optimization of the distribution ratio of the mechanical and hydraulic power flow can be achieved. According to the matched universal characteristic curve of an engine, the optimal combined distribution scheme of the mechanical and hydraulic power flow is finally achieved, and power performance optimization is provided for vehicles, using a hydraulic-mechanical composite transmission system, that will be put into production in the future.

Description

Description ELECTRIC LOADING MULTIFUNCTIONAL TEST BENCH FOR POWER-DIVIDING
HYDRAULIC-MECHANICAL COMPOSITE TRANSMISSION SYSTEM AND APPLICATION
THEREOF
I. Technical Field The present invention relates to an electric loading multifunctional test bench for power dividing hydraulic-mechanical composite transmission system and application thereof, which are suitable for acquisition of performance parameters of a hydraulic transmission unit and testing of the proportion of mechanical power flow and hydraulic power flow of a transmission system, and belong to the technical field of engineering machinery.
II. Background Art Engineering machinery, tractors and other working vehicles have characteristics of high transmission power, complex operating conditions and wide speed regulation range. With the development of the society and the continuous progress of technology, the requirements for transmission efficiency, shifting comfort and operation automation level of the transmission systems thereof become higher and higher. Hydraulic-mechanical continuously variable transmission (CVT) is a type of power dividing hydraulic-mechanical composite transmission that combines hydraulic power flow and mechanical power flow for power transmission. It can realize high-efficiency high-power transmission by means of mechanical transmission as well as realize variable transmission by means of hydraulic transmission, and exhibits good application prospects on high-power vehicles. The hydraulic-mechanical CVT combines the advantages of excellent stepless speed regulation performance of hydrostatic transmission and high steady-state efficiency of mechanical transmission, so as to obtain a variable speed transmission device with stepless speed change ability, high efficiency and favorable distribution of high-efficiency area. Therefore, designing and developing high-performance hydraulic-mechanical CVTs for hydraulic-mechanical composite transmission system is the key to the technical research and application of high-power vehicles.
A hydraulic-mechanical CVT comprises a mechanical transmission unit, a pump-motor hydraulic continuously variable transmission unit, a planetary gear mechanism for dividing or converging power, automatic speed changing electronic control device, and a driving system, etc. When the transmission ratio of the mechanical transmission mechanism is given, the transmission ratio of the hydraulic-mechanical composite transmission system can be changed steplessly within a certain range by adjusting the transmission ratio of the hydraulic continuously variable unit, so that the power is outputted through power dividing, stepless speed change and convergence, and thereby high-power high-efficiency continuously variable transmission is realized.
Therefore, such a power dividing hydraulic-mechanical composite transmission system integrates the advantages of high transmission efficiency of a pure mechanical transmission system and stepless speed change of a pure hydraulic transmission system. However, the overall efficiency of the transmission system is = 1 =
Date Recue/Date Received 2021-01-28 determined by the efficiency of the fractional hydraulic power flow and efficiency of the fractional mechanical power flow in composite transmission and their allocation ratio.
The transmission efficiency characteristics of the mechanical transmission unit are relatively stable, while the transmission efficiency of the hydrostatic transmission unit is lower than that of mechanical transmission. The hydraulic pump, hydraulic motor, control valves and connecting pipelines, etc., which constitute the hydrostatic transmission unit, have the problem of efficiency in the entire system unit; moreover, the volumetric efficiency and mechanical efficiency of the pump and motor, which affect the overall transmission efficiency of the unit, continuously change with the speed, consequently the transmission efficiency is instable. Therefore, on the premise of maintaining the stepless speed change capability of the hydraulic transmission unit, the efficiency peak of the hydraulic transmission unit shall be improved and the high efficiency area under common operating conditions shall be expanded, for the purpose of ensuring the transmission efficiency and service performance of the hydraulic-mechanical composite transmission system.
At present, in the design and development of hydraulic-mechanical CVTs, the performance test is usually carried out on a special test bench or device after the trial-production of products. The matching design scheme of the hydraulic transmission unit and mechanical transmission unit of the trial-products are often proved not the best through a series of tests, and even the trial-production of products has to be repeated, resulting in high cost and long cycle of product design and development and high consumption of manpower and material resources. Although the product design cycle and cost can be greatly reduced with the development of computer simulation and virtual prototyping technology, the inconsistency between the simulation conditions and the actual operating conditions also leads to uncertainties in product development.
III. Contents of the Invention Technical Problem: the object of the present invention is to provide an electric loading multifunctional test bench for power dividing hydraulic-mechanical composite transmission system and application thereof, in order to overcome the drawbacks in the prior art.
Technical Solution: the present invention provides an electric loading multifunctional test bench for power dividing hydraulic-mechanical composite transmission system, which comprises a mechanical part and a control part, wherein the mechanical part comprises:
a DC motor at the power input side of a hydraulic transmission unit, an electromagnetic clutch at the power input side of the hydraulic transmission unit, and a rotation speed torque sensor at the input side of the hydraulic transmission unit, which are connected sequentially at an input side, a tested hydraulic transmission unit, and a rotation speed torque sensor at the output side of the hydraulic transmission unit;
an AC variable frequency motor at the power input side of a mechanical transmission unit, an electromagnetic clutch at the power input side of the mechanical transmission unit, and a rotation speed torque sensor of the mechanical transmission unit, which are connected sequentially at the input side;
the rotation speed torque sensor at the output side of the hydraulic transmission unit and the rotation = 2 =
Date Recue/Date Received 2021-01-28 speed torque sensor of the mechanical transmission unit are respectively in a transmission connection with an input shaft of a convergence mechanism; an output shaft of the convergence mechanism is in a transmission connection with a rotation speed torque sensor at the output side and a DC motor at the output side sequentially;
the control part comprises:
an industrial control computer, a signal acquisition unit and a programmable logic controller (PLC), which are respectively connected with the industrial control computer;
the signal acquisition unit is connected with the tested hydraulic transmission unit via a pressure sensor and a flow sensor; the signal acquisition unit is further connected with the rotation speed torque sensor at the input side of the hydraulic transmission unit, the rotation speed torque sensor at the output side of the hydraulic transmission unit, the rotation speed torque sensor of the mechanical transmission unit, and the rotation speed torque sensor at the output side respectively;
the PLC is respectively connected with a D/A module at the input side of the PLC, a D/A module at the output side of the PLC, the electromagnetic clutch at the power input side of the hydraulic transmission unit, the electromagnetic clutch at the power input side of the mechanical transmission unit, and speed adjusting controller; wherein the D/A module at the input side of the PLC is respectively connected with the DC motor at the power input side of the hydraulic transmission unit and the AC variable frequency motor at the power input side of the mechanical transmission unit via a speed adjusting controller of the DC motor at the power input side of the hydraulic transmission unit and a frequency converter of the AC variable frequency motor at the power input side of the mechanical transmission unit; the D/A module at the output side of the PLC is connected with the DC motor at the output side via a speed adjusting controller of the DC motor at the output side; the speed adjusting controllers are respectively connected with the convergence mechanism and the tested hydraulic transmission unit.
Preferably, the DC motor at the power input side of the hydraulic transmission unit, the AC variable frequency motor at the power input side of the mechanical transmission unit, and the DC motor at the output side are all connected with a power supply source.
Preferably, the industrial control computer is further connected with an alarm unit, a display, and bench operating status indicator lights respectively.
Preferably, the DC motor at the power input side of the hydraulic transmission unit is connected with one end of the electromagnetic clutch at the power input side of the hydraulic transmission unit via a coupling, and the rotation speed torque sensor at the output side of the hydraulic transmission unit is in a transmission connection with a hydraulic transmission unit coupling shaft of the convergence mechanism.
Preferably, the AC variable frequency motor at the power input side of the mechanical transmission unit is connected with one end of the electromagnetic clutch at the power input side of the mechanical transmission unit via a coupling, and the other end of the electromagnetic clutch at the power input side of the mechanical transmission unit is in a transmission connection with a mechanical transmission unit coupling shaft of the convergence mechanism via a coupling.
= 3 =
Date Recue/Date Received 2021-01-28 Preferably, the convergence mechanism comprises: a planetary gear train that is composed of a gear ring of the planetary gear train, a planetary gear of the planetary gear train and a planet carrier of the planetary gear train; a fixed gear transmission unit that is composed of a gear A and a gear B, a clutch Li, a clutch L2, a clutch L3, a clutch L4, and actuator element of the speed adjusting controller; the hydraulic transmission unit coupling shaft, the mechanical transmission unit coupling shaft, and a convergence mechanism output shaft extend outwardly from the convergence mechanism. An advantage of the design lies in that different clutches in the convergence mechanism can be engaged to realize operating modes with different hydraulic power flow and mechanical power flow, and thereby performance test of the hydraulic transmission unit of the hydraulic-mechanical composite transmission system can be carried out under all operating conditions.
Preferably, the bench operating status indicator lights comprise a red light, a green light, and a yellow light. The function of the design is to enable the lights in different colors to indicate different operating statuses: the green light indicates a normal operating status; the yellow light indicates a normal shutdown status; the red light along with an audible alarm indicates an abnormal stop status.
The present invention further provides an application of the electric loading multifunctional test bench for power dividing hydraulic-mechanical composite transmission system, which comprises the following steps:
operating modes for controlling engagement status of four clutches in the convergence mechanism by means of speed adjusting controller:
(1) forward power convergence transmission mode of hydraulic transmission unit:
when the clutch L2 and the clutch L4 are engaged, the mechanical transmission unit coupling shaft is connected with the gear ring of the planetary gear train, the hydraulic transmission unit coupling shaft is always connected with a sun gear of the planetary gear train via the fixed gear transmission unit composed of the gear A and the gear B, and the convergence mechanism output shaft is connected with the planet carrier of the planetary gear train; at the moment, the rotation speed of the convergence mechanism output shaft increases as the rotation speed of the hydraulic transmission unit coupling shaft increases, forming forward convergence transmission in which the outputted rotation speed increases as the outputted rotation speed of the DC motor at the power input side of the hydraulic transmission unit increases;
(2) reversed power convergence transmission mode of hydraulic transmission unit:
when the clutch Li and the clutch L3 are engaged, the mechanical transmission unit coupling shaft is connected with the planet carrier of the planetary gear train, the hydraulic transmission unit coupling shaft is always connected with the sun gear of the planetary gear train via the fixed gear transmission unit composed of the gear A and the gear B, and the convergence mechanism output shaft is connected with the gear ring of the planetary gear train; at the moment, the rotation speed of the convergence mechanism output shaft decreases as the rotation speed of the hydraulic transmission unit coupling shaft increases, forming reversed convergence transmission in which the outputted rotation speed decreases as the outputted rotation speed of the DC
motor at the power input side of the hydraulic transmission unit increases;
= 4 =
Date Recue/Date Received 2021-01-28
(3) mono-power transmission mode of hydraulic transmission unit:
when the clutch Li and the clutch L2 are engaged, the transmission ratio of the planetary gear train is 1, the mechanical transmission unit coupling shaft doesn't transfer power, power is input from the hydraulic transmission unit coupling shaft, and power is outputted from the convergence mechanism output shaft;
and, under the two-stage control of the industrial control computer and the PLC, the DC motor and the AC variable frequency motor implement different operating modes:
(1) constant torque mode: in that mode, under the regulation and control of the control system and control program, the motor is adjusted according to the comparison between the feedback of measured value of torque and a given value; by means of automatic regulation through the frequency converter and the controller in a given control mode, the output torque of the motor is changed and maintained at a set value;
(2) constant rotation speed mode: in that mode, under the regulation and control of the control system and control program, the motor is adjusted according to the comparison between the feedback of measured value of rotation speed and a given value; by means of automatic regulation through the frequency converter and the controller in a given control mode, the output rotation speed of the motor is changed and maintained at a set value;
(3) constant power mode: in that mode, the motor is under the regulation and control of the control system and control program, and the output power of the motor is maintained at a given value;
thus, by means of two-stage control of the industrial control computer and PLC, the dynamic characteristics of the engine is simulated and a power source is provided for the bench, so that the test conditions for the tested hydraulic transmission unit are the closest to the actual service conditions, thereby the testing capability for the transmission system is improved and the testing range is extended.
Beneficial effects: compared with the prior art, the present invention has the following advantages:
1) The electric loading multifunctional test bench for power dividing hydraulic-mechanical composite transmission system provided by the present invention can accomplish performance test of the hydraulic transmission unit of a hydraulic-mechanical composite transmission system. It can test the transmission performance of the hydraulic transmission unit of the hydraulic-mechanical composite transmission system by simulating and applying the actual travel conditions and operating conditions of a vehicle, test the performance of the hydraulic transmission unit in one-stage or multi-stage hydraulic-mechanical composite transmission, test the proportions of mechanical power flow and hydraulic power flow in the composite transmission system, automatically optimize the allocation ratio of mechanical power flow to hydraulic power flow, finally find out an optimal combination and allocation scheme of mechanical power flow and hydraulic power flow according to the universal characteristic curve of the matched engine, and provide power performance optimization for the production of vehicles in which the hydraulic-mechanical composite transmission system is applied in the future.
= 5 =
Date Recue/Date Received 2021-01-28 2) The bench in the present invention can also provide a test platform for testing the performance of a hydrostatic transmission system and the performance of a complete transmission system.
3) The bench in the present invention employs a rotation speed closed-loop control system, which has high stability in rotation speed test; in addition, the bench has a reasonable structural design, is simple and reliable, operates safely and reliably, is cost-saving, and can realize a function of reverse power generation if it is provided with a DC motor, so as to achieve the purpose of saving energy.
IV. Description of Drawings FIG. 1 is a schematic structural diagram of the electric loading multifunctional test bench for power dividing hydraulic-mechanical composite transmission system in the present invention;
FIG. 2 is a schematic diagram of the transmission structure of the convergence mechanism in the present invention;
FIG. 3 shows the control principle of the electric loading multifunctional test bench for power dividing hydraulic-mechanical composite transmission system in the present invention.
In the figures: 1 - D/A module at input side of the PLC; 2 - programmable logic controller (PLC); 3 - bench operating status indicator light; 4 - display; 5 - alarm unit; 6 -industrial control computer; 7 - signal acquisition unit; 8 - flow sensor; 9 - pressure sensor; 10 - D/A
module at output side of the PLC; 11 - speed adjusting controller; 12 - speed adjusting controller of the DC motor at the output side; 13 - DC motor at the output side; 14 - rotation speed torque sensor at the output side; 15 -convergence mechanism; 16 - rotation speed torque sensor at the output side of the hydraulic transmission unit; 17 - tested hydraulic transmission unit; 18 - rotation speed torque sensor of the mechanical transmission unit; 19 - rotation speed torque sensor at the input side of the hydraulic transmission unit; 20 - electromagnetic clutch at the power input side of the mechanical transmission unit; 21 - electromagnetic clutch at the power input side of the hydraulic transmission unit; 22 - AC variable frequency motor at the power input side of the mechanical transmission unit;
23 - power supply source; 24 - DC motor at the power input side of the hydraulic transmission unit;
25 - speed adjusting controller of the DC motor at the power input side of the hydraulic transmission unit; 26 - frequency converter of the AC variable frequency motor at the power input side of the mechanical transmission unit;
151 - hydraulic transmission unit coupling shaft; 152 - gear A; 153 - clutch Li; 154 - clutch L2; 155 - gear ring of the planetary gear train; 156 - planetary gear of the planetary gear train; 157 - clutch L3; 158 - clutch L4; 159 - planet carrier of the planetary gear train; 160 -convergence mechanism output shaft; 161 - sun gear of the planetary gear train; 162 - gear B; 163 -gear shaft of the sun gear;
164 - mechanical transmission unit coupling shaft.
V. Embodiments Hereunder the present invention will be further detailed in examples with reference to the accompanying drawings, but the present invention is not limited to those examples.
Example 1:
= 6 =
Date Recue/Date Received 2021-01-28 As shown in Figs. 1-2, in this example, an electric loading multifunctional test bench for power dividing hydraulic-mechanical composite transmission system is provided, said bench mainly comprising two parts: a mechanical part and a control part:
the mechanical part comprises:
a DC motor 24 at the power input side of a hydraulic transmission unit, an electromagnetic clutch 21 at the power input side of the hydraulic transmission unit, and a rotation speed torque sensor 19 at the input side of the hydraulic transmission unit, which are connected sequentially at an input side, a tested hydraulic transmission unit 17, and a rotation speed torque sensor 16 at the output side of the hydraulic transmission unit;
an AC variable frequency motor 22 at the power input side of a mechanical transmission unit, an electromagnetic clutch 20 at the power input side of the mechanical transmission unit, and a rotation speed torque sensor 18 of the mechanical transmission unit, which are connected sequentially at the input side;
the rotation speed torque sensor 16 at the output side of the hydraulic transmission unit and the rotation speed torque sensor 18 of the mechanical transmission unit are respectively in a transmission connection with an input shaft of a convergence mechanism 15; an output shaft of the convergence mechanism 15 is in a transmission connection with a rotation speed torque sensor 14 at the output side and a DC motor 13 at the output side sequentially;
the control part comprises:
an industrial control computer 6, and a signal acquisition unit 7 and a programmable logic controller (PLC) 2, which are respectively connected with the industrial control computer 6;
the signal acquisition unit 7 is connected with the tested hydraulic transmission unit 17 via a pressure sensor 9 and a flow sensor 8; the signal acquisition unit 7 is further connected with the rotation speed torque sensor 19 at the input side of the hydraulic transmission unit, the rotation speed torque sensor 16 at the output side of the hydraulic transmission unit, the rotation speed torque sensor 18 of the mechanical transmission unit, and the rotation speed torque sensor 14 at the output side respectively;
the PLC 2 is respectively connected with a D/A module 1 at the input side of the PLC, a D/A
module 10 at the output side of the PLC, the electromagnetic clutch 21 at the power input side of the hydraulic transmission unit, the electromagnetic clutch 20 at the power input side of the mechanical transmission unit, and speed adjusting controller 11; wherein the D/A module 1 at the input side of the PLC is respectively connected with the DC motor 24 at the power input side of the hydraulic transmission unit and the AC variable frequency motor 22 at the power input side of the mechanical transmission unit via a speed adjusting controller 25 of the DC
motor at the power input side of the hydraulic transmission unit and a frequency converter 26 of the AC
variable frequency motor at the power input side of the mechanical transmission unit; the D/A
module 10 at the output side of the PLC is connected with the DC motor 13 at the output side via a speed adjusting controller 12 of the DC motor at the output side; the speed adjusting controller 11 is respectively connected with the convergence mechanism 15 and the tested hydraulic transmission unit 17.
= 7 =
Date Recue/Date Received 2021-01-28 The DC motor 24 at the power input side of the hydraulic transmission unit, the AC variable frequency motor 22 at the power input side of the mechanical transmission unit, and the DC motor 13 at the output side are all connected with a power supply source 23.
The DC motor 24 at the power input side of the hydraulic transmission unit is connected with one end of the electromagnetic clutch 21 at the power input side of the hydraulic transmission unit via a coupling, one end of the rotation speed torque sensor 19 at the input side of the hydraulic transmission unit is connected with the electromagnetic clutch 21 at the power input side of the hydraulic transmission unit, the other end of the rotation speed torque sensor 19 at the input side of the hydraulic transmission unit is connected with the input shaft of the tested hydraulic transmission unit 17, the output shaft of the tested hydraulic transmission unit 17 is connected with one end of the rotation speed torque sensor 16 at the output side of the hydraulic transmission unit, the other end of the rotation speed torque sensor 16 at the output side of the hydraulic transmission unit is connected with an hydraulic transmission unit coupling shaft of the convergence mechanism 15, and the pressure sensor 9 and the flow sensor 8 are connected with the tested hydraulic transmission unit 17; in the electrical control connection part, the output side of speed adjusting controller 25 of the DC motor at the power input side of the hydraulic transmission unit is in an electric control connection with the DC motor 24 at the power input side of the hydraulic transmission unit, the input side of the speed adjusting controller 25 of the DC motor at the power input side of the hydraulic transmission unit is in an electric control connection with the output side of a D/A module 1 at the input side of the PLC, and the input side of the D/A module 1 at the input side of the PLC is in an electric control connection with the programmable logic controller (PLC) 2, the electromagnetic clutch 21 at the power input side of the hydraulic transmission unit is connected with the programmable logic controller (PLC) 2, the rotation speed torque sensor 19 at the input side of the hydraulic transmission unit, the pressure sensor 9, the flow sensor 8, and the rotation speed torque sensor 16 at the output side of the hydraulic transmission unit are connected with the signal acquisition unit 7, and the speed adjusting controller 11 is connected with the tested hydraulic transmission unit 17.
The AC variable frequency motor 22 at the power input side of the mechanical transmission unit is connected with one end of the electromagnetic clutch 20 at the power input side of the mechanical transmission unit via a coupling, and the other end of the electromagnetic clutch 20 at the power input side of the mechanical transmission unit is connected with a mechanical transmission unit coupling shaft of the convergence mechanism 15 via a coupling; in the electrical control connection part, the frequency converter 26 of the AC variable frequency motor at the power input side of the mechanical transmission unit is in an electric control connection with the AC
variable frequency motor 22 at the input side, the input side of the frequency converter 26 of the AC variable frequency motor and the electromagnetic clutch 20 at the power input side of the mechanical transmission unit are in an electric control connection with the output side of the D/A module 1 at the input side of the PLC, and the rotation speed torque sensor 18 of the mechanical transmission unit is connected with the signal acquisition unit 7.
As shown in Fig. 2, a hydraulic transmission unit coupling shaft 151, a mechanical transmission unit coupling shaft 164, and a convergence mechanism output shaft 160 extend outwardly from the convergence mechanism 15; inside the convergence mechanism, a gear A 152 and a gear B 162 = 8 =
Date Recue/Date Received 2021-01-28 form a fixed gear transmission unit, a sun gear 161 of the planetary gear train, a gear ring 155 of the planetary gear train, a planetary gear 156 of the planetary gear train, and a planet carrier 159 of planetary gear train form a planetary gear train; the actuator elements of the speed adjusting controller include a clutch Li 153, a clutch L2 154, a clutch L3 157 and a clutch L4 158. The different clutches in the convergence mechanism can be engaged to realize different convergence modes of hydraulic power flow and mechanical power flow, and thereby performance test of the hydraulic transmission unit of the hydraulic-mechanical composite transmission system can be carried out under all operating conditions.
The industrial control computer 6 is further connected with an alarm unit 5, a display 4, and bench operating status indicator lights 3 respectively. The bench operating status indicator lights 3 comprise a red light, a green light, and a yellow light. The lights in different colors indicate different operating statues: the green light indicates a normal operating status; the yellow light indicates a normal shutdown status; the red light along with an audible alarm indicates an abnormal stop status.
Example 2:
As shown in Fig. 3, an operating method of an electric loading multifunctional test bench for power dividing hydraulic-mechanical composite transmission system that employs the bench provided in the technical solution of example 1, comprising the following operating steps:
operating modes for controlling engagement status of the four clutches in the convergence mechanism 15 by means of the speed adjusting controllers 11:
(1) forward power convergence transmission mode of hydraulic transmission unit:
when the clutch L2 153 and the clutch L4 157 are engaged, the mechanical transmission unit coupling shaft 164 is connected with the gear ring 155 of the planetary gear train, the hydraulic transmission unit coupling shaft 151 is always connected with a sun gear 161 of the planetary gear train via the fixed gear transmission unit composed of the gear A 152 and the gear B 162, and the convergence mechanism output shaft 160 is connected with the planet carrier 159 of the planetary gear train; at the moment, the rotation speed of the convergence mechanism output shaft 160 increases as the rotation speed of the hydraulic transmission unit coupling shaft 151 increases, forming forward convergence transmission in which the outputted rotation speed increases as the outputted rotation speed of the hydraulic motor of the hydraulic transmission unit increases;
(2) reversed power convergence transmission mode of hydraulic transmission unit:
when the clutch Li 154 and the clutch L3 158 are engaged, the mechanical transmission unit coupling shaft 164 is connected with the planet carrier 159 of the planetary gear train, the hydraulic transmission unit coupling shaft 151 is always connected with the sun gear 161 of the planetary gear train via the fixed gear transmission unit composed of the gear A 152 and the gear B 162, and the convergence mechanism output shaft 160 is connected with the gear ring 155 of the planetary gear train; at the moment, the rotation speed of the convergence mechanism output shaft 160 decreases as the rotation speed of the hydraulic transmission unit coupling shaft 151 increases, forming reversed convergence transmission in which the outputted rotation speed decreases as the outputted rotation speed of the hydraulic motor of the hydraulic transmission unit increases;
= 9 =
Date Recue/Date Received 2021-01-28 (3) mono-power transmission mode of hydraulic transmission unit:
when the clutch Li 154 and the clutch L2 153 are engaged, the transmission ratio of the planetary gear train is 1, the mechanical transmission unit coupling shaft 164 doesn't transfer power, power is input from the hydraulic transmission unit coupling shaft 151, and power is outputted from the convergence mechanism output shaft 160.
At the power input side, the hydraulic transmission part employs the DC motor 24 at the power input side of the hydraulic transmission unit as a power source, the mechanical transmission part employs the AC variable frequency motor 22 at the power input side of the mechanical transmission unit as a power source, so that the speed ratio at the input side between the hydraulic transmission part and the mechanical transmission part can be adjusted freely, thereby the speed ratio can be automatically calibrated and compared, and an optimal proportion allocation range for the performance test of the hydraulic transmission unit in the entire composite transmission system can be determined; moreover, a control program can be worked out according to the universal characteristic curve of the selected matched engine, a power source can be provided for the bench by simulating the power characteristics of the engine under two-stage control of the industrial control computer 6 and the programmable logic controller (PLC) 2, so that the operating conditions of the tested hydraulic transmission unit in the test should be as close to the actual operating conditions as possible, thereby the testing capability for the transmission system is improved and the testing range is extended; according to the transmission characteristics of the hydraulic-mechanical composite transmission system, the hydraulic transmission unit may have a phenomenon of power backflow and circulation. In view of that phenomenon, the hydraulic transmission part employs a DC motor as the power source. Thus the DC motor can realize a power generation function in case of power backflow, and the generated electric power can be fed back to the power supply source, achieving an energy saving feature; engine exhaust emission is avoided under indoor test conditions of the bench, and thereby an environmental protection feature is achieved.
The device for simulating load at the power output side employs a DC motor 13 for loading at the output side to simulate the load resistance under working conditions of the vehicle. Under the two-stage control of the industrial control computer 6 and the programmable logic controller (PLC) 2, the resultant DC motor loading system has two operating states, i.e., a power generation state and an electric driving state. The generated electric energy is fed back to the power supply source, so that an energy saving feature is achieved. Moreover, the control system employs a two-stage control scheme with the industrial control computer and the programmable logic controller (PLC) to simulate the variations of power demand in the power transmission system of the vehicle, thereby the testing capability for the transmission system is improved and the application range is extended.
Under the two-stage control of the industrial control computer 6 and the PLC
2, the DC motor and the AC motor implement different operating modes:
(1) constant torque mode: in that mode, under the regulation and control of the control system and control program, the motor is adjusted according to the comparison between the feedback of measured value of torque and a given value; by means of automatic regulation through the frequency converter and the controller in a given control mode, the output torque of the motor = 10 =
Date Recue/Date Received 2021-01-28 is changed and maintained at a set value;
(2) constant rotation speed mode: in that mode, under the regulation and control of the control system and control program, the motor is adjusted according to the comparison between the feedback of measured value of rotation speed and a given value; by means of automatic regulation through the frequency converter and the controller in a given control mode, the output rotation speed of the motor is changed and maintained at a set value;
(3) constant power mode: in that mode, the motor is under the regulation and control of the control system and control program, and the output power of the motor is maintained at a given value.
The motors of the hydraulic transmission unit and the mechanical transmission unit at the input side may be set in a constant rotation speed mode, and the loading motor at the output side may be set in a constant torque mode, a constant rotation speed mode, or a constant power mode to simulate the actual operating conditions; the convergence mechanism may be set in a forward power convergence transmission mode of the hydraulic transmission unit according to the requirement of the experiment for performance test of the hydraulic transmission unit during forward power convergence transmission; the convergence mechanism may be set in a reversed power convergence transmission mode of the hydraulic transmission unit for performance test of the hydraulic transmission unit during reversed power convergence transmission; when the convergence mechanism switches between the above two operating modes, the performance of the hydraulic transmission unit of a multi-stage hydraulic-mechanical composite transmission system can be tested. When the convergence mechanism is set in a mono-power transmission mode of the hydraulic transmission unit, the performance of a pure hydraulic transmission system can be tested.
The bench operating status indicator lights comprise a red indicator light, a green indicator light, and a yellow indicator light. Their indications are as follows: the green indicator light indicates a normal operating status; the yellow indicator light indicates a normal shutdown status; the red indicator light along with an audible alarm indicates an abnormal stop status.
The computer displays text and provides audible indications while the alarm unit provides the alarm and the indicator lights provide indications, until the all clear button is pressed.
Dynamic loading can be realized by means of a control program to simulate the actual operating conditions and specified cyclic operating conditions of the hydraulic-mechanical composite transmission system; according to different test schemes, the control system and the control program can set the rotation speeds and torques of the motors at the input side and the output side to different set values, and employ closed-loop control, which can fully meet the requirements for performance test of the hydraulic transmission unit of the hydraulic-mechanical composite transmission system and test of the ratio of mechanical transmission power flow to hydraulic transmission power flow in the entire transmission system; during the test, the operator may debug the control program according to the actual requirements and then simply press a Start button, so as to realize whole process control and performance test; the measured values and result of analysis in the test can be displayed, processed, stored, and printed in real time by means of the industrial control computer and the display. Compared with conventional benches, the bench provided by the present invention can perform performance test of the hydraulic transmission unit of a hydraulic-mechanical composite transmission system simply and reliably, and can save test time = 11 =
Date Recue/Date Received 2021-01-28 and cost greatly.
= 12 =
Date Recue/Date Received 2021-01-28

Claims (8)

Claims
1. An electric loading multifunctional test bench for power dividing hydraulic-mechanical composite transmission system, comprising a mechanical part and a control part, wherein the mechanical part comprises:
a DC motor at the power input side of a hydraulic transmission unit, an electromagnetic clutch at the power input side of the hydraulic transmission unit, and a rotation speed torque sensor at the input side of the hydraulic transmission unit, which are connected sequentially at an input side, a tested hydraulic transmission unit, and a rotation speed torque sensor at the output side of the hydraulic transmission unit;
an AC variable frequency motor at the power input side of a mechanical transmission unit, an electromagnetic clutch at the power input side of the mechanical transmission unit, and a rotation speed torque sensor of the mechanical transmission unit, which are connected sequentially at the input side;
the rotation speed torque sensor at the output side of the hydraulic transmission unit and the rotation speed torque sensor of the mechanical transmission unit are respectively in a transmission connection with an input shaft of a convergence mechanism; an output shaft of the convergence mechanism is in a transmission connection with a rotation speed torque sensor at the output side and a DC motor at the output side sequentially;
the control part comprises:
an industrial control computer, and a signal acquisition unit and a programmable logic controller (PLC), which are respectively connected with the industrial control computer;
the signal acquisition unit is connected with the tested hydraulic transmission unit via a pressure sensor and a flow sensor; the signal acquisition unit is further connected with the rotation speed torque sensor at the input side of the hydraulic transmission unit, the rotation speed torque sensor at the output side of the hydraulic transmission unit, the rotation speed torque sensor of the mechanical transmission unit, and the rotation speed torque sensor at the output side respectively;
the PLC is respectively connected with a D/A module at the input side of the PLC, a D/A
module at the output side of the PLC, the electromagnetic clutch at the power input side of the hydraulic transmission unit, the electromagnetic clutch at the power input side of the mechanical transmission unit, and speed adjusting controllers; wherein the D/A
module at the input side of the PLC is respectively connected with the DC motor at the power input side of the hydraulic transmission unit and the AC variable frequency motor at the power input side of the mechanical transmission unit via a speed adjusting controller of the DC
motor at the power input side of the hydraulic transmission unit and a frequency converter of the AC variable frequency motor at the power input side of the mechanical transmission unit;
the D/A module at the output side of the PLC is connected with the DC motor at the output side via a speed adjusting controller of the DC motor at the output side; the speed adjusting controllers are respectively connected with the convergence mechanism and the tested hydraulic transmission unit.
2. The electric loading multifunctional test bench for power dividing hydraulic-mechanical composite transmission system according to claim 1, wherein the DC motor at the power input side of the hydraulic transmission unit, the AC variable frequency motor at the power input side of the mechanical transmission unit, and the DC motor at the output side are all connected to a power supply source.
3. The electric loading multifunctional test bench for power dividing hydraulic-mechanical composite transmission system according to claim 1, wherein the industrial control computer is further connected with an alarm unit, a display, and bench operating status indicator lights.
4. The electric loading multifunctional test bench for power dividing hydraulic-mechanical composite transmission system according to claim 1, wherein the DC motor at the power input side of the hydraulic transmission unit is connected with one end of the electromagnetic clutch at the power input side of the hydraulic transmission unit via a coupling, and the rotation speed torque sensor at the output side of the hydraulic transmission unit is in a transmission connection with a hydraulic transmission unit coupling shaft of the convergence mechanism.
5. The electric loading multifunctional test bench for power dividing hydraulic-mechanical composite transmission system according to claim 4, wherein the AC variable frequency motor at the power input side of the mechanical transmission unit is connected with one end of the electromagnetic clutch at the power input side of the mechanical transmission unit via a coupling, and the other end of the electromagnetic clutch at the power input side of the mechanical transmission unit is in a transmission connection with a mechanical transmission unit coupling shaft of the convergence mechanism.
6. The electric loading multifunctional test bench for power dividing hydraulic-mechanical composite transmission system according to claim 5, wherein the convergence mechanism comprises a planetary gear train that is composed of a gear ring of the planetary gear train, a planetary gear of the planetary gear train and a planet carrier of the planetary gear train, a fixed gear transmission unit that is composed of a gear A and a gear B, a clutch L1, a clutch L2, a clutch L3, a clutch L4, and actuator elements of the speed adjusting controllers; the hydraulic transmission unit coupling shaft, the mechanical transmission unit coupling shaft, and a convergence mechanism output shaft extend outwardly from the convergence mechanism.
7. The electric loading multifunctional test bench for power dividing hydraulic-mechanical composite transmission system according to claim 3, wherein the bench operating status indicator lights comprise a red light, a green light, and a yellow light.
8. An application of the electric loading multifunctional test bench for power dividing hydraulic-mechanical composite transmission system according to any one of claims 1-7, comprising the following steps:
operating modes for controlling engagement status of the four clutches in the convergence mechanism by means of the speed adjusting controllers:

(1) forward power convergence transmission mode of hydraulic transmission unit:
when the clutch L2 and the clutch L4 are engaged, the mechanical transmission unit coupling shaft is connected with the gear ring of the planetary gear train, the hydraulic transmission unit coupling shaft is always connected with a sun gear of the planetary gear train via the fixed gear transmission unit composed of the gear A and the gear B, and the convergence mechanism output shaft is connected with the planet carrier of the planetary gear train;
at the moment, the rotation speed of the convergence mechanism output shaft increases as the rotation speed of the hydraulic transmission unit coupling shaft increases, forming forward convergence transmission in which the outputted rotation speed increases as the outputted rotation speed of the DC motor at the power input side of the hydraulic transmission unit increases;
(2) reversed power convergence transmission mode of hydraulic transmission unit:
when the clutch L1 and the clutch L3 are engaged, the mechanical transmission unit coupling shaft is connected with the planet carrier of the planetary gear train, the hydraulic transmission unit coupling shaft is always connected with the sun gear of the planetary gear train via the fixed gear transmission unit composed of the gear A and the gear B, and the convergence mechanism output shaft is connected with the gear ring of the planetary gear train; at the moment, the rotation speed of the convergence mechanism output shaft decreases as the rotation speed of the hydraulic transmission unit coupling shaft increases, forming reversed convergence transmission in which the outputted rotation speed decreases as the outputted rotation speed of the DC motor at the power input side of the hydraulic transmission unit increases;
(3) mono-power transmission mode of hydraulic transmission unit:
when the clutch L1 and the clutch L2 are engaged, the transmission ratio of the planetary gear train is 1, the mechanical transmission unit coupling shaft doesn't transfer power, power is input from the hydraulic transmission unit coupling shaft, and power is outputted from the convergence mechanism output shaft;
and, under the two-stage control of the industrial control computer and the PLC, the DC motor and the AC variable frequency motor implement different operating modes:
(1) constant torque mode: in that mode, under the regulation and control of the control system and control program, the motor is adjusted according to the comparison between the feedback of measured value of torque and a given value; by means of automatic regulation through the frequency converter and the controller in a given control mode, the output torque of the motor is changed and maintained at a set value;
(2) constant rotation speed mode: in that mode, under the regulation and control of the control system and control program, the motor is adjusted according to the comparison between the feedback of measured value of rotation speed and a given value; by means of automatic regulation through the frequency converter and the controller in a given control mode, the output rotation speed of the motor is changed and maintained at a set value;
(3) constant power mode: in that mode, the motor is under the regulation and control of the control system and control program, and the output power of the motor is maintained at a given value;
thus, by means of two-stage control of the industrial control computer and PLC, the dynamic characteristics of the engine is simulated and a power source is provided for the bench, so that the test conditions for the tested hydraulic transmission unit are the closest to the actual service conditions, thereby the testing capability for the transmission system is improved and the testing range is extended.
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