CN112067287A - Odd-gear input shaft torque fatigue test method and test system - Google Patents
Odd-gear input shaft torque fatigue test method and test system Download PDFInfo
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Abstract
The invention discloses an odd-gear input shaft torque fatigue test method and a test system, wherein the method comprises the following steps: determining the torque fatigue test parameters of the input shaft with odd gears according to the fatigue test requirements; inspecting and determining the test sample as a qualified product; grouping the qualified test samples according to different types of fatigue test results required to be obtained; installing a test sample in a test system; setting test parameters and debugging test programs according to fatigue test results required to be obtained; performing a first test sample torsional fatigue test; according to the test result and the test requirement of the previous test sample in the torsional fatigue test, the test sample is replaced after the test parameters are adjusted; and (4) counting and analyzing the test data to finally obtain the torsional fatigue test result. The system comprises a test control system, a hydraulic system and a test bench; the invention can directly carry out the torque fatigue test of the input shaft with odd gears, and has the advantages of short test preparation period, low test cost and good test evaluation effect.
Description
Technical Field
The invention belongs to the technical field of transmission input shaft fatigue tests, and particularly relates to an odd-gear input shaft torque fatigue test method and a test system.
Background
The odd-numbered input shaft is a key component in an automotive DCT (i.e., a dual clutch transmission). The DCT has two sets of clutches, one corresponding to odd gears and the other corresponding to even gears. The odd-numbered gear input shaft is connected with the corresponding clutch and is used for transmitting the torque of the engine to the odd-numbered gear of the transmission, so that the torque transmission of the DCT in the working process of the odd-numbered gears is realized.
The odd-numbered gear input shaft and the even-numbered gear input shaft are coaxially arranged, and the odd-numbered gear input shaft is arranged in an inner hole channel of the even-numbered gear input shaft under a general condition, so that the odd-numbered gear input shaft has the characteristic of slender structure; meanwhile, the odd-numbered gear input shaft needs to provide lubricating oil for the synchronizer and the plurality of odd-numbered gear wheels which are arranged on the odd-numbered gear input shaft, so that the odd-numbered gear input shaft has a long lubricating oil duct (about total length 3/4), and the odd-numbered gear input shaft also has the structural characteristic of thin wall.
In conclusion, the odd-gear input shaft has the structural characteristics of being slender and thin-walled, and is used for bearing the load working condition of torque, so that the problem of torque fatigue cracking exists, and the torque fatigue performance of the odd-gear input shaft needs to be evaluated in the product development process.
In the prior art, the torque fatigue performance evaluation of the input shaft with odd gears is realized by a DCT assembly fatigue life reliability test. At present, a technical scheme specially aiming at the torque fatigue performance evaluation of the input shaft with the odd gears is not provided, so that the torque fatigue performance evaluation result of the input shaft with the odd gears is not accurate enough and has insufficient reliability, the test preparation period of the fatigue life reliability test of the DCT assembly is long, and the test cost is high.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides the odd-gear input shaft torque fatigue test method and the odd-gear input shaft torque fatigue test system, which can directly perform the torque fatigue test aiming at the odd-gear input shaft, and have the advantages of short test preparation period, low test cost and excellent test evaluation effect. The technical scheme of the invention is as follows by combining the attached drawings of the specification:
the odd-gear input shaft torque fatigue test method comprises the following steps:
step S1: determining the torque fatigue test parameters of the input shaft of the odd gear according to the input torque of the transmission assembly and the torque fatigue test requirements of the input shaft of the odd gear;
step S2: inspecting and determining the test sample as a qualified product;
step S3: grouping the qualified test samples according to different types of fatigue test results required to be obtained;
step S4: installing a test sample in a test system, and ensuring the coaxiality among the torque actuator, the test sample and the torque sensor;
step S5: setting test parameters and debugging test programs according to different types of fatigue test results required to be obtained;
step S6: performing a first test sample torsional fatigue test;
step S7: according to the test result and the test requirement of the previous test sample in the torsional fatigue test, after the test parameters are adjusted, the test sample is replaced, and the test of the next test sample is carried out;
step S8: and (4) counting and analyzing the test data to finally obtain the torsional fatigue test result.
Further, in step S1, the odd-numbered stage input shaft torque fatigue test request includes: the minimum safety factor, confidence coefficient and survival rate of the torque fatigue of the input shaft with the odd number gear;
the odd-gear input shaft torque fatigue test parameters comprise: test torque, test frequency, cycle base, number of samples, load waveform and load ratio.
Further, in step S3, the different types of fatigue test results include: torque fatigue minimum safety factor, torque fatigue limit strength, fatigue life at a given torque and fatigue hazard location.
Further, in step S5, according to the different types of fatigue test results that need to be obtained, setting test parameters, debugging a test program, and testing and evaluating the "torque fatigue minimum safety factor" process are as follows:
given a maximum input torque of the transmission of M, the test parameters were set as follows: the test frequency was 30Hz, the cycle base N was 1X 107Secondly, the load waveform is sine wave, the load ratio R is 0.1, the number of test samples i is 10-20, and the test maximum torque M of the first test sample1max1.5M, the test minimum torque of the first test sample is M1min＝0.1M1max；
The procedure of the test is as follows: if the first test specimen has not experienced fatigue fracture after passing through the cycle base, the test maximum torque M of the next test specimen2maxIncrease by 0.1M, i.e. M2max＝M1max+0.1M, corresponding to the minimum torque M of the test for the next test specimen2min＝0.1M2max(ii) a If the first test sample is fatigue-broken, the test maximum torque M of the next test sample2maxDecrease by 0.1M, i.e. M2max＝M1max0.1M, corresponding to the minimum torque M of the test for the next test specimen2min＝0.1M2max。
Further, in step S5, according to the different types of fatigue test results obtained as required, the test parameters are set, the test program is debugged, and the process of testing and evaluating "fatigue life at specified torque" is as follows:
knowing the test torque M, the test parameters were set as follows: the test frequency is 30Hz, the load waveform is sine wave, the load ratio R is 0.1, the number of test samples i is 10-20, and the maximum test torque is MmaxTest minimum torque M ═ Mmin＝0.1M。
Odd number keeps off input shaft torque fatigue test system, test system includes: the test system comprises a test control system, a hydraulic system and a test bench;
the test bench consists of a torque loading bench, a middle supporting bench and a torque sensor bench which are sequentially arranged on the workbench 19;
in the torque loading rack, one end of an odd-numbered gear input shaft 9 is coaxially connected with a torque actuator 5 through a first spline loading flange 8, and an angle sensor 4 is arranged on the outer side of the torque actuator 5 so as to collect the torsion angle of the odd-numbered gear input shaft 9 under the loading of the torque actuator 5;
in the middle supporting rack, the middle part of an input shaft 9 with odd gears is arranged in a bearing mounting hole formed by butting a supporting lower base 10 and a supporting upper cover plate 16 through a second rolling bearing 17;
in the torque sensor rack, the other end of an odd-gear input shaft 9 is coaxially connected with a torque sensor 13 through a second spline loading flange 11;
the test control system comprises a display 1 and a processor 2, wherein the processor 2 is in signal connection with a hydraulic system 3, an angle sensor 4, a torque actuator 5 and a torque sensor 13 respectively, the processor 2 is used for setting test parameters and test programs, receiving signals fed back by the hydraulic system 3, the angle sensor 4 and the torque sensor 13 and further sending control signals to the hydraulic system 3 and the torque actuator 5 so as to control the work of the hydraulic system 3 and the torque actuator 5 serving as hydraulic oil sources;
the display 1 is in signal connection with the processor 2;
the hydraulic system 3 is connected with a torque actuator 5 in the test bench through a pipeline.
Furthermore, a plurality of bolt connecting holes are uniformly formed in the circumferential direction of the end face of the inner side of the torque actuator 5, and a first positioning inner hole 501 is formed in the circle center of the end face of the inner side of the torque actuator 5;
a positioning round table 701 is arranged at the circle center of one end face of the first bearing support flange 7, a bearing installation groove is arranged at the circle center of the other end face of the first bearing support flange 7, bolt connection holes are uniformly distributed in the circumferential direction of the end face of the first bearing support flange 7, the positioning round table 701 on the end face of the first bearing support flange 7 is installed in a matching mode with a first positioning inner hole 501 on the end face of the inner side of the torque actuator 5, coaxial positioning of the first bearing support flange 7 and the torque actuator 5 is achieved, and the first bearing support flange 7 and the torque actuator 5 are coaxially and fixedly installed through bolts;
the first rolling bearing 15 is coaxially installed in a bearing installation groove in the end face of the first bearing support flange 7, and one end of the input shaft 9 with odd number gear to be tested is installed in the first rolling bearing 15.
Furthermore, a semi-arc bearing installation groove is formed in the middle of the top of the lower supporting base 10, and bolt blind holes are formed in two sides of the semi-arc installation groove respectively;
a semi-arc bearing installation groove is formed in the middle of the bottom of the supporting upper cover plate 16, and bolt through holes are formed in two sides of the semi-arc installation groove respectively;
after the supporting upper cover plate 16 is vertically installed above the supporting lower base 10 in a butt joint mode, the supporting upper cover plate 16 and a semi-arc installation groove formed in the supporting lower base 10 are in butt joint to form a complete bearing installation hole, and the supporting upper cover plate 16 is fixedly connected with the supporting lower base 10 through bolts;
the second rolling bearing 17 is installed in a bearing installation hole formed by butting the support upper cover plate 16 and the support lower base 10, and the middle section of the input shaft 9 with odd number gear to be tested is installed in the second rolling bearing 17 in a supporting mode.
Furthermore, a plurality of bolt connecting holes are uniformly formed in the circumferential direction of the end face of the inner side of the torque sensor 13, and a second positioning inner hole 1301 is formed in the circle center position of the end face of the inner side of the torque sensor 13;
a positioning round table is arranged at the circle center of one end face of the second bearing support flange 12, a bearing installation groove is arranged at the circle center of the other end face of the second bearing support flange 12, bolt connection holes are uniformly distributed in the circumferential direction of the end face of the second bearing support flange 12, the positioning round table on the end face of the second bearing support flange 12 is matched with a second positioning inner hole 1301 on the end face of the inner side of the torque sensor 13, the coaxial positioning of the second bearing support flange 12 and the torque sensor 13 is realized, and the second bearing support flange 12 and the torque sensor 13 are coaxially and fixedly installed through bolts;
the third rolling bearing 18 is coaxially arranged in a bearing installation groove on the end face of the second bearing support flange 12, and the other end of the input shaft 9 with odd number gear to be tested is arranged in the third rolling bearing 18.
Further, the torque actuator 5 is supported and mounted on the workbench 19 through an actuator bracket 6;
the torque sensor 13 is supported and mounted on a worktable 19 through a torque sensor bracket 14.
Compared with the prior art, the invention has the beneficial effects that:
1. the method for testing the torque fatigue of the input shaft with the odd gears has a simple process, and compared with the complex process of a DCT assembly fatigue life reliability test, the method for testing the torque fatigue of the input shaft with the odd gears is easier to realize.
2. Compared with a DCT assembly fatigue life reliability test system, the structure of the odd-gear input shaft torque fatigue test system and the used parts are simpler and lower in cost.
3. According to the odd-gear input shaft torque fatigue test method and the test system, the odd-gear input shaft is directly adopted as a test object, so that the test sample is simple and low in cost, the cost is only hundreds to one thousand yuan because the odd-gear input shaft is independently tested, and the cost is over ten thousand yuan because the DCT assembly fatigue life reliability test method is adopted, the test sample is a DCT assembly, and the test sample cost is over ten thousand yuan.
4. The test preparation period of the test of the odd-gear input shaft torque fatigue test method is short, and the test sample is only the odd-gear input shaft, so that the sample processing period is short, and compared with a fatigue life reliability test of a DCT assembly, the test preparation period of the DCT assembly is long, and the test preparation period of part processing, assembly and the like is long.
5. According to the odd-gear input shaft torque fatigue test method and the test system, the test sample is only the odd-gear input shaft directly aiming at the odd-gear input shaft, and other parts and assemblies do not influence the test result, so that the test evaluation effect is excellent, and the torque fatigue limit or the torque fatigue safety coefficient of the odd-gear input shaft can be easily and accurately quantified and analyzed.
6. According to the odd-gear input shaft torque fatigue test method, due to the fact that dependence on a DCT assembly is reduced, multi-wheel optimization design and corresponding torque fatigue performance evaluation can be independently conducted on the odd-gear input shaft. Therefore, the optimized design of the input shaft with odd gears is more facilitated.
Drawings
FIG. 1 is a block flow diagram illustrating the steps of the odd-numbered gear input shaft torque fatigue test method according to the present invention;
FIG. 2 is a schematic structural diagram of the odd-numbered gear input shaft torque fatigue test system according to the invention;
FIG. 3 is an exploded view of a brake of a test bed in the odd-gear input shaft torque fatigue test system according to the invention;
FIG. 4 is a schematic structural diagram of a torque actuator and a mounting connector thereof in the odd-numbered gear input shaft torque fatigue test system according to the present invention;
FIG. 5a is a schematic structural view of an end face of a flange of a bearing support in the odd-numbered gear input shaft torque fatigue test system according to the present invention;
FIG. 5b is a schematic structural view of another end face of a flange of a bearing support in the odd-numbered gear input shaft torque fatigue test system according to the present invention;
FIG. 6 is a schematic structural view of a spline loading flange in the odd-numbered gear input shaft torque fatigue test system according to the present invention;
FIG. 7 is a schematic structural view of a support lower base in the odd-gear input shaft torque fatigue test system according to the present invention;
FIG. 8 is a schematic structural view of a supporting upper cover plate in the odd-numbered gear input shaft torque fatigue test system according to the present invention;
FIG. 9 is a schematic structural diagram of a torque sensor and a mounting connector thereof in the odd-numbered gear input shaft torque fatigue test system according to the present invention;
in the figure:
1-display, 2-processor, 3-hydraulic system,
4-angle sensor, 5-torque actuator, 6-actuator bracket,
7-a first bearing support flange, 8-a first spline loading flange, 9-an odd-gear input shaft,
10-supporting lower base, 11-second spline loading flange, 12-second bearing support flange,
13-torque sensor, 14-torque sensor holder, 15-first rolling bearing,
16-supporting upper cover plate, 17-second rolling bearing, 18-third rolling bearing,
19-a workbench;
501-a first positioning inner hole, 701-a positioning circular truncated cone and 1301-a second positioning inner hole.
Detailed Description
For clearly and completely describing the technical scheme and the specific working process thereof, the specific implementation mode of the invention is as follows by combining the attached drawings of the specification:
in the present invention, unless otherwise expressly stated or limited, the terms "mounted," "connected," "secured," and the like are to be construed broadly and can, for example, be fixedly connected, detachably connected, or integrally formed; can be mechanically or electrically connected; they may be directly connected or indirectly connected through intervening media, or they may be connected internally or in any other suitable relationship, unless expressly stated otherwise. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
In the present invention, unless otherwise expressly stated or limited, the first feature "on" or "under" the second feature may be directly contacting the first and second features or indirectly contacting the first and second features through an intermediate. Also, a first feature "on," "over," and "above" a second feature may be directly or diagonally above the second feature, or may simply indicate that the first feature is at a higher level than the second feature. A first feature being "under," "below," and "beneath" a second feature may be directly under or obliquely under the first feature, or may simply mean that the first feature is at a lesser elevation than the second feature.
In the description herein, references to the description of the term "one embodiment," "some embodiments," "an example," "a specific example," or "some examples," etc., mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above are not necessarily intended to refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, various embodiments or examples and features of different embodiments or examples described in this specification can be combined and combined by one skilled in the art without contradiction.
The first embodiment is as follows:
the embodiment discloses an odd-gear input shaft torque fatigue test method, as shown in fig. 1, the odd-gear input shaft torque fatigue test method specifically comprises the following steps:
step S1: determining the torque fatigue test parameters of the input shaft of the odd gear according to the input torque of the transmission assembly and the torque fatigue test requirements of the input shaft of the odd gear;
the odd-gear input shaft torque fatigue test requirements comprise: the minimum safety factor, confidence coefficient and survival rate of the torque fatigue of the input shaft with the odd number gear;
the odd-gear input shaft torque fatigue test parameters comprise: the method comprises the following steps of (1) testing torque M, testing frequency, cycle base N, sample number i, load waveform and load ratio R;
step S2: inspecting and determining the test sample as a qualified product;
carrying out dimension and material performance inspection on the odd-numbered gear input shaft as a test sample, and determining the odd-numbered gear input shaft as the test sample as a qualified product;
step S3: grouping the qualified test samples according to different types of fatigue test results required to be obtained;
the different types of fatigue test results include: the minimum safety factor of the torque fatigue, the ultimate strength of the torque fatigue, the fatigue life under the appointed torque and the fatigue dangerous position; namely:
selecting 10-20 test samples from qualified test samples as a first test sample group for testing and evaluating the minimum safety coefficient of torque fatigue;
selecting 10-20 test samples from the qualified test samples as a second test sample group for testing and evaluating the fatigue limit strength of the torque;
selecting 10-20 test samples from qualified test samples as a third test sample group for testing and evaluating the fatigue life under the specified torque;
selecting 10-20 test samples from the qualified test samples as a test sample group IV for testing and evaluating fatigue risk positions;
step S4: installing a test sample in a test system, and ensuring the coaxiality among the torque actuator, the test sample and the torque sensor;
the torque actuator is used for applying torque load to an odd-gear input shaft serving as a test sample;
the torque sensor is used for detecting an actual torque signal generated by an odd-gear input shaft as a test sample under the action of the torque actuator;
step S5: setting test parameters and debugging test programs according to different types of fatigue test results required to be obtained;
in step S5, according to different types of fatigue test results that need to be obtained, test parameters are set, and test procedures are debugged, taking test evaluation "torque fatigue minimum safety factor" and "fatigue life under specified torque" as examples:
the test parameters and test procedures for testing and evaluating the torque fatigue minimum safety factor are specifically as follows:
given a maximum input torque of the transmission of M, the test parameters were set as follows: test frequency of 30Hz, cycle baseN is 1X 107Secondly, the load waveform is sine wave, the load ratio R is 0.1, the number of test samples i is 10-20, and the test maximum torque M of the first test sample1max1.5M, the test minimum torque of the first test sample is M1min＝0.1M1max；
The procedure of the test is as follows: if the first test specimen has not experienced fatigue fracture after passing through the cycle base, the test maximum torque M of the next test specimen2maxIncrease by 0.1M, i.e. M2max＝M1max+0.1M, corresponding to the minimum torque M of the test for the next test specimen2min＝0.1M2max(ii) a If the first test sample is fatigue-broken, the test maximum torque M of the next test sample2maxDecrease by 0.1M, i.e. M2max＝M1max0.1M, corresponding to the minimum torque M of the test for the next test specimen2min＝0.1M2max；
The test parameters and test procedures for testing and evaluating the fatigue life under the designated torque are specifically as follows:
knowing the test torque M, the test parameters were set as follows: the test frequency is 30Hz, the load waveform is sine wave, the load ratio R is 0.1, the number of test samples i is 10-20, and the maximum test torque is MmaxTest minimum torque M ═ Mmin＝0.1M；
Step S6: performing a first test sample torsional fatigue test;
in step S6, according to the different types of fatigue test results that need to be obtained, performing a corresponding test on the first odd-numbered input shaft test sample in the corresponding test sample group according to the specific parameters and test procedures set in step S5, and obtaining test data for evaluating the corresponding type of fatigue test results;
step S7: according to the test result and the test requirement of the previous test sample in the torsional fatigue test, after the test parameters are adjusted, the test sample is replaced, and the test of the next test sample is carried out;
in step S7, in the test sample group for obtaining the same type of fatigue test result, according to the test result and the test requirement of the previous test sample in the torsion fatigue test, and according to the test procedure set in step S5, after adjusting the test parameters, replacing the test sample, performing the test of the next test sample, and performing 10-20 times of tests according to the number of the test samples in the set test sample group, thereby obtaining the corresponding test data;
step S8: counting and analyzing the test data to finally obtain a torsional fatigue test result;
according to the test sample grouping of the step S3, respectively counting and analyzing test data for obtaining the same type of fatigue test result to obtain the final torsion fatigue test result;
the torsional fatigue test results include: the minimum safety factor of the torque fatigue of the input shaft with odd gears, the ultimate strength of the torque fatigue, the fatigue life under the appointed torque and the fatigue dangerous position are obtained;
example two:
the second embodiment discloses an odd-numbered gear input shaft torque fatigue test system, and the odd-numbered gear input shaft torque fatigue test system in the second embodiment is used for realizing the odd-numbered gear input shaft torque fatigue test method in the first embodiment.
As shown in fig. 1 and 2, the odd-gear input shaft torque fatigue testing system comprises a test control system, a hydraulic system and a test bench;
the test control system includes: a display 1 and a processor 2; wherein:
the processor 2 is in signal connection with the hydraulic system 3 and an angle sensor 4, a torque actuator 5 and a torque sensor 13 in the test bed respectively;
the processor 2 is used for setting test parameters and test programs, receiving signals fed back by the hydraulic system 3 and the angle sensor 4 and the torque sensor 13 in the test bench, and further sending control signals to the hydraulic system 3 and the torque actuator 5 in the test bench after analysis and processing based on the set test parameters and test programs so as to control the hydraulic system 3 and the torque actuator 5 serving as hydraulic oil sources to work;
the display 1 is in signal connection with the processor 2 and is used for displaying test parameters set in the using process and other data information sent by the processor, and displaying corresponding test data to test operators for the test operators to carry out statistics and analysis.
Hydraulic system 3 and the 5 tube coupling of torque actuator in the test bench, hydraulic system 3 and 2 signal connection of treater, with hydraulic system 3's running state signal feedback to treater 2 to receive the control signal that treater 2 sent, realize exporting hydraulic energy to torque actuator 5, provide hydraulic oil source for torque actuator 5.
The test bed comprises: the torque loading platform, the middle supporting platform and the torque sensor platform are sequentially arranged on the workbench 19; wherein:
as shown in fig. 3, the torque loading stage includes: the device comprises an angle sensor 4, a torque actuator 5, an actuator bracket 6, a first bearing support flange 7, a first rolling bearing 15 and a first spline loading flange 8;
as shown in fig. 4, the torque actuator 5 is horizontally arranged and supported by the actuator support 6 to be installed on the workbench 19, a plurality of bolt connection holes are uniformly formed in the circumferential direction of the end surface of the inner side of the torque actuator 5, and a first positioning inner hole 501 is formed in the circle center position of the end surface of the inner side of the torque actuator 5;
as shown in fig. 5a and 5b, a positioning circular truncated cone 701 is arranged at the center of a circle of one end surface of the first bearing support flange 7, a bearing installation groove is arranged at the center of a circle of the other end of the first bearing support flange 7, bolt connection holes are uniformly distributed in the circumferential direction of the end surface of the first bearing support flange 7, the positioning circular truncated cone 701 on the end surface of the first bearing support flange 7 is matched with a first positioning inner hole 501 on the end surface of the inner side of the torque actuator 5 for installation, so that the coaxial positioning of the first bearing support flange 7 and the torque actuator 5 is realized, and the first bearing support flange 7 and the torque actuator 5 are coaxially and fixedly installed through bolts;
the first rolling bearing 15 is coaxially arranged in a bearing installation groove on the end face of the first bearing support flange 7, and one end of the input shaft 9 with odd number to be tested is arranged in the first rolling bearing 15;
the first bearing support flange 7 realizes the support of one shaft end of the input shaft 9 with odd number gear on one hand, and ensures the coaxiality of the input shaft 9 with odd number gear and the torque actuator 5 on the other hand;
as shown in fig. 5, a spline hole is formed in the center of the first spline loading flange 8, a plurality of bolt connection holes are uniformly formed in the circumferential direction of the end surface of the first spline loading flange 8, the spline hole of the first spline loading flange 8 is installed in a matching manner with an external spline at one end of the odd-numbered stage input shaft 9, and the first spline loading flange 8 is coaxially and fixedly connected with the first bearing support flange 7 through bolts, so that the test load applied by the torque actuator 5 is reliably transmitted to the odd-numbered stage input shaft 9;
the torque actuator 5 is connected with the processor 2 through control signals, and loads a test torque outwards after receiving a control instruction sent by the processor, and the transmission path of the test torque is as follows: the torque actuator 5 → the first bearing support flange 7 → the first spline loading flange 8 → the input shaft 9 with odd gears;
the angle sensor 4 is installed in the outside terminal surface central point of torque actuator 5, and angle sensor 4 is arranged in the torsion angle of odd-numbered shelves input shaft 9 under torque actuator 5's loading among the collection test process to send the torsion angle to treater 2, judge whether fatigue fracture takes place for odd-numbered shelves input shaft 9 as the test sample according to the torsion angle signal.
As shown in fig. 3, the intermediate support stage includes: a lower supporting base 10, an upper supporting cover plate 16 and a second rolling bearing 17;
the lower supporting base 10 is vertically and fixedly installed on the workbench 19, as shown in fig. 7, a semi-arc bearing installation groove is formed in the middle of the top of the lower supporting base 10, and bolt blind holes are formed in two sides of the semi-arc bearing installation groove respectively; as shown in fig. 8, a semi-arc bearing installation groove is formed in the middle of the bottom of the supporting upper cover plate 16, and bolt through holes are respectively formed in two sides of the semi-arc installation groove; after the supporting upper cover plate 16 is vertically installed above the supporting lower base 10 in a butt joint mode, the supporting upper cover plate 16 and a semi-arc installation groove formed in the supporting lower base 10 are in butt joint to form a complete bearing installation hole, and the supporting upper cover plate 16 is fixedly connected with the supporting lower base 10 through bolts; the second rolling bearing 17 is arranged in a bearing mounting hole formed by butting the upper supporting cover plate 16 and the lower supporting base 10, and the middle section of the input shaft 9 with odd number gear to be tested is supported and arranged in the second rolling bearing 17;
the middle support rack realizes reliable support of the middle part of the odd-numbered gear input shaft 9 on one hand, and is used for ensuring the coaxiality between the odd-numbered gear input shaft 9 to be tested and the torque loading rack at one end and the torque sensor rack at the other end respectively, namely ensuring the coaxiality between the odd-numbered gear input shaft 9 and the torque actuator 5 and the torque sensor 13.
As shown in fig. 3, the torque sensor stage includes: a second spline loading flange 11, a second bearing support flange 12, a torque sensor 13, a third rolling bearing 18 and a torque sensor support 14;
as shown in fig. 9, the torque sensor 13 is horizontally arranged and supported by the torque sensor support 14 to be mounted on the worktable 19, a plurality of bolt connection holes are uniformly formed in the circumferential direction of the inner side end surface of the torque sensor 13, and a second positioning inner hole 1301 is formed in the center of the circle of the inner side end surface of the torque sensor 13;
as shown in fig. 5a and 5b, the second bearing support flange 12 is identical in structure to the first bearing support flange 7, namely: a positioning circular truncated cone is arranged at the circle center of one end face of the second bearing support flange 12, a bearing installation groove is arranged at the circle center of the other end of the second bearing support flange 12, bolt connection holes are uniformly distributed in the circumferential direction of the end face of the second bearing support flange 12, the positioning circular truncated cone on the end face of the second bearing support flange 12 is installed in a matching mode with a second positioning inner hole 1301 on the end face of the inner side of the torque sensor 13, the coaxial positioning of the second bearing support flange 12 and the torque sensor 13 is achieved, and the second bearing support flange 12 and the torque sensor 13 are coaxially and fixedly installed through bolts;
the third rolling bearing 18 is coaxially arranged in a bearing installation groove on the end face of the second bearing support flange 12, and the other end of the input shaft 9 with odd number gear to be tested is arranged in the third rolling bearing 18;
the second bearing support flange 12 realizes the support of the other shaft end of the odd-numbered gear input shaft 9 on one hand, and ensures the coaxiality of the odd-numbered gear input shaft 9 and the torque sensor 13 on the other hand;
as shown in fig. 5, the second spline loading flange 11 has the same structure as the first spline loading flange 8, that is: a spline hole is formed in the circle center of the second spline loading flange 11, a plurality of bolt connecting holes are uniformly formed in the circumferential direction of the end face of the second spline loading flange 11, the spline hole of the second spline loading flange 11 is matched and mounted with the external spline at the other end of the odd-numbered stage input shaft 9, and the second spline loading flange 11 is coaxially and fixedly connected with the second bearing support flange 12 through bolts, so that the torque generated on the odd-numbered stage input shaft 9 is reliably transmitted to the torque sensor 13;
the torque sensor 13 is in signal connection with the processor 2, converts the detected torque load borne by the odd-numbered gear input shaft 9 into a corresponding electric signal, and feeds the electric signal back to the processor 2, the processor 2 corrects the torque load applied next according to the torque signal obtained by feedback, and in addition, whether the odd-numbered gear input shaft 9 serving as a test sample is in fatigue fracture or not is judged according to the torque information detected by the torque sensor 13.
Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention, and that variations, modifications, substitutions and alterations can be made to the above embodiments by those of ordinary skill in the art within the scope of the present invention.
The above-described embodiments of the present invention should not be construed as limiting the scope of the present invention. Any other corresponding changes and modifications made according to the technical idea of the present invention should be included in the protection scope of the claims of the present invention.
Claims (10)
1. The odd-gear input shaft torque fatigue test method is characterized by comprising the following steps:
the test method comprises the following steps:
step S1: determining the torque fatigue test parameters of the input shaft of the odd gear according to the input torque of the transmission assembly and the torque fatigue test requirements of the input shaft of the odd gear;
step S2: inspecting and determining the test sample as a qualified product;
step S3: grouping the qualified test samples according to different types of fatigue test results required to be obtained;
step S4: installing a test sample in a test system, and ensuring the coaxiality among the torque actuator, the test sample and the torque sensor;
step S5: setting test parameters and debugging test programs according to different types of fatigue test results required to be obtained;
step S6: performing a first test sample torsional fatigue test;
step S7: according to the test result and the test requirement of the previous test sample in the torsional fatigue test, after the test parameters are adjusted, the test sample is replaced, and the test of the next test sample is carried out;
step S8: and (4) counting and analyzing the test data to finally obtain the torsional fatigue test result.
2. The odd-numbered gear input shaft torque fatigue test method according to claim 1, characterized in that:
in step S1, the odd-numbered stage input shaft torque fatigue test requirement includes: the minimum safety factor, confidence coefficient and survival rate of the torque fatigue of the input shaft with the odd number gear;
the odd-gear input shaft torque fatigue test parameters comprise: test torque, test frequency, cycle base, number of samples, load waveform and load ratio.
3. The odd-numbered gear input shaft torque fatigue test method according to claim 1, characterized in that:
in step S3, the different types of fatigue test results include: torque fatigue minimum safety factor, torque fatigue limit strength, fatigue life at a given torque and fatigue hazard location.
4. The odd-numbered gear input shaft torque fatigue test method according to claim 1, characterized in that:
in step S5, according to different types of fatigue test results obtained as required, setting test parameters, debugging test procedures, and testing and evaluating the "minimum safety factor of torque fatigue" process as follows:
given a maximum input torque of the transmission of M, the test parameters were set as follows: the test frequency was 30Hz, the cycle base N was 1X 107Secondly, the load waveform is sine wave, the load ratio R is 0.1, the number of test samples i is 10-20, and the test maximum torque M of the first test sample1max1.5M, the test minimum torque of the first test sample is M1min＝0.1M1max；
The procedure of the test is as follows: if the first test specimen has not experienced fatigue fracture after passing through the cycle base, the test maximum torque M of the next test specimen2maxIncrease by 0.1M, i.e. M2max＝M1max+0.1M, corresponding to the minimum torque M of the test for the next test specimen2min＝0.1M2max(ii) a If the first test sample is fatigue-broken, the test maximum torque M of the next test sample2maxDecrease by 0.1M, i.e. M2max＝M1max0.1M, corresponding to the minimum torque M of the test for the next test specimen2min＝0.1M2max。
5. The odd-numbered gear input shaft torque fatigue test method according to claim 1, characterized in that:
in step S5, according to the different types of fatigue test results that need to be obtained, test parameters are set, test programs are debugged, and the process of testing and evaluating "fatigue life under specified torque" is as follows:
knowing the test torque M, the test parameters were set as follows: the test frequency is 30Hz, the load waveform is sine wave, the load ratio R is 0.1, the number of test samples i is 10-20, and the maximum test torque isMmaxTest minimum torque M ═ Mmin＝0.1M。
6. Odd number keeps off input shaft torque fatigue test system, its characterized in that:
the test system comprises: the test system comprises a test control system, a hydraulic system and a test bench;
the test bench consists of a torque loading bench, a middle supporting bench and a torque sensor bench which are sequentially arranged on a workbench (19);
in the torque loading rack, one end of an odd-numbered gear input shaft (9) is coaxially connected with a torque actuator (5) through a first spline loading flange (8), and an angle sensor (4) is installed on the outer side of the torque actuator (5) so as to collect the torsion angle of the odd-numbered gear input shaft (9) under the loading of the torque actuator (5);
in the middle supporting rack, the middle part of an input shaft (9) with odd gears is arranged in a bearing mounting hole formed by butting a supporting lower base (10) and a supporting upper cover plate (16) through a second rolling bearing (17);
in the torque sensor rack, the other end of an odd-gear input shaft (9) is coaxially connected with a torque sensor (13) through a second spline loading flange (11);
the test control system is composed of a display (1) and a processor (2), wherein the processor (2) is in signal connection with the hydraulic system (3), the angle sensor (4), the torque actuator (5) and the torque sensor (13) respectively, the processor (2) is used for setting test parameters and test programs, receiving signals fed back by the hydraulic system (3), the angle sensor (4) and the torque sensor (13), and further sending control signals to the hydraulic system (3) and the torque actuator (5) to control the hydraulic system (3) and the torque actuator (5) serving as a hydraulic oil source to work;
the display (1) is in signal connection with the processor (2);
and the hydraulic system (3) is connected with a torque actuator (5) in the test bench through a pipeline.
7. The odd-numbered stage input shaft torque fatigue testing system according to claim 6, characterized in that:
a plurality of bolt connecting holes are uniformly formed in the circumferential direction of the end face of the inner side of the torque actuator (5), and a first positioning inner hole (501) is formed in the circle center position of the end face of the inner side of the torque actuator (5);
a positioning round table (701) is arranged at the circle center of one end face of the first bearing support flange (7), a bearing installation groove is arranged at the circle center of the other end face of the first bearing support flange (7), bolt connection holes are uniformly distributed in the circumferential direction of the end face of the first bearing support flange (7), the positioning round table (701) on the end face of the first bearing support flange (7) is matched with a first positioning inner hole (501) on the end face of the inner side of the torque actuator (5) for installation, coaxial positioning of the first bearing support flange (7) and the torque actuator (5) is realized, and the first bearing support flange (7) and the torque actuator (5) are coaxially and fixedly installed through bolts;
the first rolling bearing (15) is coaxially arranged in a bearing installation groove in the end face of the first bearing support flange (7), and one end of the input shaft (9) with odd number gear to be tested is arranged in the first rolling bearing (15).
8. The odd-numbered stage input shaft torque fatigue testing system according to claim 6, characterized in that:
a semi-arc bearing installation groove is formed in the middle of the top of the lower supporting base (10), and bolt blind holes are formed in two sides of the semi-arc installation groove respectively;
a semi-arc bearing installation groove is formed in the middle of the bottom of the supporting upper cover plate (16), and bolt through holes are formed in two sides of the semi-arc installation groove respectively;
the supporting upper cover plate (16) is vertically installed above the supporting lower base (10) in a butt joint mode, the supporting upper cover plate (16) is in butt joint with a semi-arc-shaped installation groove formed in the supporting lower base (10) to form a complete bearing installation hole, and the supporting upper cover plate (16) is fixedly connected with the supporting lower base (10) through bolts;
the second rolling bearing (17) is arranged in a bearing mounting hole formed by butting the upper supporting cover plate (16) and the lower supporting base (10), and the middle section of the input shaft (9) with odd gears to be tested is supported and arranged in the second rolling bearing (17).
9. The odd-numbered stage input shaft torque fatigue testing system according to claim 6, characterized in that:
a plurality of bolt connecting holes are uniformly formed in the circumferential direction of the end face of the inner side of the torque sensor (13), and a second positioning inner hole (1301) is formed in the circle center position of the end face of the inner side of the torque sensor (13);
a positioning circular truncated cone is arranged at the circle center of one end face of the second bearing support flange (12), a bearing installation groove is arranged at the circle center of the other end face of the second bearing support flange (12), bolt connection holes are uniformly distributed in the circumferential direction of the end face of the second bearing support flange (12), the positioning circular truncated cone on the end face of the second bearing support flange (12) is installed in a matching manner with a second positioning inner hole (1301) on the end face of the inner side of the torque sensor (13), coaxial positioning of the second bearing support flange (12) and the torque sensor (13) is achieved, and the second bearing support flange (12) and the torque sensor (13) are coaxially and fixedly installed through bolts;
the third rolling bearing (18) is coaxially arranged in a bearing installation groove on the end face of the second bearing support flange (12), and the other end of the input shaft (9) with odd number gear to be tested is arranged in the third rolling bearing (18).
10. The odd-numbered stage input shaft torque fatigue testing system according to claim 6, characterized in that:
the torque actuator (5) is supported and installed on the workbench (19) through an actuator bracket (6);
the torque sensor (13) is supported and mounted on the workbench (19) through a torque sensor bracket (14).
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113310688A (en) * | 2021-05-06 | 2021-08-27 | 中国第一汽车股份有限公司 | Motor rotor shaft torsional fatigue test system |
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