CN112196842A - Hydraulic loading safety protection device and vehicle loading test system and method - Google Patents
Hydraulic loading safety protection device and vehicle loading test system and method Download PDFInfo
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- CN112196842A CN112196842A CN202011079063.2A CN202011079063A CN112196842A CN 112196842 A CN112196842 A CN 112196842A CN 202011079063 A CN202011079063 A CN 202011079063A CN 112196842 A CN112196842 A CN 112196842A
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- 238000012360 testing method Methods 0.000 title claims abstract description 67
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F15—FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
- F15B—SYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
- F15B1/00—Installations or systems with accumulators; Supply reservoir or sump assemblies
- F15B1/02—Installations or systems with accumulators
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F15—FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
- F15B—SYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
- F15B11/00—Servomotor systems without provision for follow-up action; Circuits therefor
- F15B11/02—Systems essentially incorporating special features for controlling the speed or actuating force of an output member
- F15B11/028—Systems essentially incorporating special features for controlling the speed or actuating force of an output member for controlling the actuating force
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F15—FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
- F15B—SYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
- F15B11/00—Servomotor systems without provision for follow-up action; Circuits therefor
- F15B11/08—Servomotor systems without provision for follow-up action; Circuits therefor with only one servomotor
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F15—FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
- F15B—SYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
- F15B13/00—Details of servomotor systems ; Valves for servomotor systems
- F15B13/02—Fluid distribution or supply devices characterised by their adaptation to the control of servomotors
- F15B13/04—Fluid distribution or supply devices characterised by their adaptation to the control of servomotors for use with a single servomotor
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F15—FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
- F15B—SYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
- F15B20/00—Safety arrangements for fluid actuator systems; Applications of safety devices in fluid actuator systems; Emergency measures for fluid actuator systems
- F15B20/004—Fluid pressure supply failure
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F15—FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
- F15B—SYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
- F15B20/00—Safety arrangements for fluid actuator systems; Applications of safety devices in fluid actuator systems; Emergency measures for fluid actuator systems
- F15B20/007—Overload
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F15—FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
- F15B—SYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
- F15B21/00—Common features of fluid actuator systems; Fluid-pressure actuator systems or details thereof, not covered by any other group of this subclass
- F15B21/02—Servomotor systems with programme control derived from a store or timing device; Control devices therefor
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M17/00—Testing of vehicles
- G01M17/007—Wheeled or endless-tracked vehicles
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- Fluid Mechanics (AREA)
- Mechanical Engineering (AREA)
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- Chemical & Material Sciences (AREA)
- Analytical Chemistry (AREA)
- General Physics & Mathematics (AREA)
- Testing Of Engines (AREA)
Abstract
本发明涉及一种液压加载安全保护装置及车辆加载测试系统、方法，其包括滤清器，滤清器一端与并联连接的第一液压保护回路、第二液压保护回路和第三液压保护回路串联；滤清器另一端为液压加载安全保护装置的第一连接端；安全保护控制器与第一液压保护回路、第二液压保护回路、第三液压保护回路中的可控性部件电连接。该车辆加载测试系统包括液压加载安全保护装置、测功机加载系统、液压加载系统、车用电机系统和CAN总线。加载安全保护控制器、液压加载系统控制器、车用电机系统控制器、测功机加载系统控制器通过CAN总线进行通信。本发明可应用于电动车辆台架水平的测试任务，可避免加载系统的过载或失效等故障导致的车辆加载测试系统失稳危险。
The invention relates to a hydraulic loading safety protection device and a vehicle loading testing system and method, comprising a filter, one end of the filter is connected in series with a first hydraulic protection circuit, a second hydraulic protection circuit and a third hydraulic protection circuit connected in parallel The other end of the filter is the first connection end of the hydraulic loading safety protection device; the safety protection controller is electrically connected with the controllable components in the first hydraulic protection circuit, the second hydraulic protection circuit and the third hydraulic protection circuit. The vehicle loading test system includes a hydraulic loading safety protection device, a dynamometer loading system, a hydraulic loading system, a vehicle motor system and a CAN bus. The loading safety protection controller, the hydraulic loading system controller, the vehicle motor system controller, and the dynamometer loading system controller communicate through the CAN bus. The invention can be applied to the test task of the electric vehicle bench level, and can avoid the risk of instability of the vehicle loading test system caused by failures such as overload or failure of the loading system.
Description
Technical Field
The invention relates to the technical field of electric automobile technology and bench test, in particular to a hydraulic loading safety protection device, a vehicle loading test system and a vehicle loading test method.
Background
Different from the traditional internal combustion engine vehicle with a single hydraulic braking system, the electric vehicle has two braking sources of motor braking and hydraulic braking at the same time, and the combined output of the motor braking and the hydraulic braking at wheels can be realized. Therefore, when the bench test is carried out on the electric automobile, the dynamometer loading can be carried out at the tail end of the wheel and the hydraulic friction loading can be carried out at the wheel edge brake disc. The electro-hydraulic composite loading mode can simulate road load on the bench test level and research the vehicle economy, dynamic performance and other problems on the whole vehicle level, and can test the performance of the hydraulic braking system under different vehicle running conditions by means of the bench test environment, such as emergency braking, anti-lock braking, regenerative braking and even vehicle operation stability conditions, so that test road test scenes and conditions are effectively simulated, and the development time and the integrated test cost of the whole vehicle system and the braking system are greatly reduced.
The existing loading test system for the vehicle bench test generally takes a single dynamometer (loading motor) loading mode as a main mode, and takes a centralized test bed for testing the performance of an internal combustion engine or a motor and a distributed test bed for testing the economy, comfort and safety of the whole vehicle as representatives, but the electro-hydraulic composite loading test system is not found in technical research, development and practical production.
Although the electro-hydraulic combined loading is a future development trend of the bench test technology of the electric vehicle, the problem which is difficult to solve still exists in the aspect of the safety of the bench test, particularly represented by overload and failure of a hydraulic loading system, once such a fault occurs in the test process, a transmission shaft is extremely easy to be locked or fly away, dynamic instability of a dynamometer and a vehicle-mounted power source (such as a vehicle-mounted motor) on mechanical dynamics is further caused, then a torque sharp increase or even a shaft breakage condition is generated, and personnel and property safety is seriously threatened. The existing electric vehicle bench test technology has the problem that the technology for testing the high efficiency and the safety is not overcome, so that innovative improvement work needs to be carried out on a hydraulic loading safety protection device and a vehicle loading test system.
Disclosure of Invention
Aiming at the defects and shortcomings of the bench test technology in the aspects of high efficiency and safety, the invention aims to provide a hydraulic loading safety protection device, a vehicle loading test system and a vehicle loading test method, which can be used for an electro-hydraulic composite loading test task of an electric vehicle, can overcome the loading fault problem caused by overload or failure of a hydraulic braking loading system through a safety protection design, and ensure the high efficiency and safety of the electric vehicle loading test.
In order to achieve the purpose, the invention adopts the following technical scheme: a hydraulically loaded safety protection device, comprising: the device comprises a first hydraulic protection circuit, a second hydraulic protection circuit, a third hydraulic protection circuit, a filter and a safety protection controller; one end of the filter is connected with the first hydraulic protection circuit, the second hydraulic protection circuit and the third hydraulic protection circuit which are connected in parallel in series and used for filtering and cleaning brake fluid; the other end of the filter is a first connecting end of the hydraulic loading safety protection device and is used for being connected with a hydraulic loading system; and the safety protection controller is electrically connected with the controllable components in the first hydraulic protection circuit, the second hydraulic protection circuit and the third hydraulic protection circuit and is used for the normal active control of the hydraulic loading safety protection device.
Further, first hydraulic protection return circuit includes first normally closed switch valve, the first end of first normally closed switch valve in proper order with the first end series connection of first energy storage ware, first oil pump and first check valve, first oil pump is connected with first pump oil motor, the second end of first normally closed switch valve with second, third hydraulic protection return circuit are parallelly connected, the second end of first check valve with the one end of filter is connected.
Further, the second hydraulic protection circuit comprises a second normally closed switch valve, a second oil pump, a second oil pumping motor, a second one-way valve, a first electric control overflow valve and a third one-way valve; the second oil pump is connected with the second oil pumping motor, and the first end of the second normally closed switch valve is connected with the first end of the second oil pump and the first end of the first electric control overflow valve respectively; the second end of the first electric control overflow valve is connected with one end of the filter after being connected with the third one-way valve in series; and the second end of the second normally-closed switch valve is connected with the second end of the first normally-closed switch valve and the third hydraulic protection circuit in parallel.
Further, the third hydraulic protection circuit comprises a third normally-open switch valve, a first end of the third normally-open switch valve is sequentially connected with a first reducing valve and a first end of a fourth one-way valve in series, and a second end of the fourth one-way valve is connected with one end of the filter; and the second end of the third normally-open switch valve is respectively connected with the second end of the second normally-closed switch valve and the second end of the first normally-closed switch valve in parallel to form a second connecting end of the hydraulic loading safety protection device.
A vehicle loading test system comprises the hydraulic loading safety protection device, a safety protection controller electrically connected with the hydraulic loading safety protection device, a hydraulic loading system controller electrically connected with the hydraulic loading system, a vehicle motor system, a hydraulic loading system controller electrically connected with the vehicle motor system, a dynamometer loading system controller electrically connected with the dynamometer loading system controller, and a CAN bus; the hydraulic loading safety protection device is connected with the hydraulic loading system through a first three-way oil pipe, a second three-way oil pipe and an oil return pipe to form a closed hydraulic loop, a first connecting end of the hydraulic loading safety protection device is connected with the hydraulic loading system through the oil return pipe, and a second connecting end of the hydraulic loading safety protection device is respectively connected with an oil outlet of a hydraulic adjusting unit and a brake caliper in the hydraulic loading system through the first three-way oil pipe and the second three-way oil pipe; the hydraulic loading system and the dynamometer loading system are both connected with the vehicle motor system, and the hydraulic loading system and the dynamometer loading system simultaneously apply hydraulic loading force and dynamometer loading force to the vehicle motor system; the safety protection controller, the hydraulic loading system controller, the vehicle motor system controller and the dynamometer loading system controller are connected and communicated through the CAN bus, so that electro-hydraulic composite loading control and loading safety protection control of vehicle loading test are realized.
A vehicle loading test method adopts the vehicle loading test system to carry out loading test on a vehicle, and comprises the following three stages:
1) the system is in an initial preparation state;
when not powered on, all the parts are in a standing state; when the hydraulic loading safety protection device is powered on and enters an initialization state, when a loading fault does not occur, the electric control command value of a safety protection device controller is zero, and meanwhile, the hydraulic loading system, the vehicle motor system, the dynamometer loading system and the CAN bus are sequentially powered on, enter an initialization standby state and prepare to perform a vehicle loading test task in a conventional working mode;
2) and (3) a normal working mode: after power-on, entering a loading test state in a conventional mode;
the vehicle motor executes a rotating speed or torque control command of a vehicle motor system controller, outputs rotating speed or torque through a transmission shaft, and simulates vehicle dynamics output when a vehicle runs under an actual working condition; the transmission shaft transmits the power output by the vehicle motor to the brake disc and the coupling flange assembly, so that the power is coupled with the hydraulic loading system and the dynamometer loading system to form the dynamic balance of the electro-hydraulic combined loading system;
the friction force on the brake disc is derived from the hydraulic loading action of a hydraulic loading system; pressure signals of the master cylinder pressure sensor and the wheel cylinder pressure sensor are transmitted to the hydraulic loading system controller to form closed-loop control of hydraulic pressure;
the loading torque on the coupling flange assembly is from a dynamometer loading system; the dynamometer loading system applies dynamometer loading force to the coupling flange assembly, and the two loading forces are coupled on the transmission shaft to realize electro-hydraulic composite loading effect on the vehicle motor system;
the hydraulic loading safety protection device in the conventional working mode keeps an initial state, the safety protection device controller receives state and instruction information of a vehicle loading test system sent by a vehicle motor system controller, a hydraulic loading system controller and a dynamometer loading system controller through a CAN bus, and the loading fault condition which possibly occurs at any time is monitored;
3) and (4) a safety protection mode: overload protection, boost protection, voltage stabilization protection and overload limit safety backup protection.
Further, during overload protection, specifically: when the hydraulic pressure in a brake cylinder of a brake in the hydraulic loading system is overhigh, a wheel cylinder pressure sensor transmits a pressure signal to a hydraulic loading system controller through a circuit, the hydraulic loading controller receives the hydraulic pressure signal and carries out loading safety evaluation on the composite loading system through a rotating speed or torque expected value and an actual value which are transmitted by a vehicle motor system controller and a dynamometer loading system controller through a CAN bus, and the overload danger of the hydraulic loading system which is or may be present is judged; the safety protection device controller receives an evaluation result and state information of the hydraulic loading system controller and system state and instruction information transmitted by the hydraulic loading system controller, the vehicle motor system controller and the dynamometer loading system controller through the CAN bus, and comprehensively judges that the loading safety protection is required at the moment; the safety protection device controller controls a first normally closed switch valve and a first pump oil motor of a first hydraulic protection loop, a first oil pump is driven, high-pressure brake fluid in a brake cylinder of a brake is subjected to rapid pressure reduction adjustment through a three-way oil pipe, overloaded brake fluid passes through the three-way oil pipe, the overload brake fluid passes through the first normally closed switch valve and the buffer action of an energy accumulator, the overload brake fluid passes through the first oil pump, the first one-way valve and a filter and enters a liquid accumulator through an oil return pipe, hydraulic adjustment in the brake cylinder of the brake is completed, and overload danger of a hydraulic loading system is avoided.
Further, during the pressurization protection, specifically: when hydraulic pressure in a brake cylinder of a brake in a hydraulic loading system suddenly drops to be lower than an expected pressure value, a wheel cylinder pressure sensor transmits a pressure signal to a hydraulic loading system controller through a circuit, the hydraulic loading controller receives the hydraulic pressure signal and carries out loading safety evaluation on a composite loading system through a rotating speed or torque expected value and an actual value which are transmitted by a vehicle motor system controller and a dynamometer loading system controller through a CAN bus, and the loading danger of the hydraulic loading force failure of the hydraulic loading system which currently appears or possibly appears is judged; the safety protection device controller receives an evaluation result and state information of the hydraulic loading system controller and system states and instruction information transmitted by the hydraulic loading system controller, the vehicle motor system controller and the dynamometer loading system controller through the CAN bus, and comprehensively judges that the loading safety protection is required at the moment; the safety protection device controller controls a second normally closed switch valve and a second oil pumping motor of a second hydraulic protection loop to drive a second oil pump, hydraulic pressure in a brake cylinder of the brake is quickly boosted and adjusted through a three-way oil pipe, brake fluid from a reservoir passes through an oil return pipe, passes through a filter, a second one-way valve, the second oil pump and the second normally closed switch valve, and then is injected into the brake cylinder through a first three-way oil pipe and a second three-way oil pipe to complete hydraulic pressure boosting and adjusting in the brake cylinder of the brake, and the driving danger of the compound loading system is avoided.
Further, during voltage stabilization protection, specifically: when hydraulic pressure in a brake cylinder of a brake in a hydraulic loading system is inconsistent with an expected pressure value, a wheel cylinder pressure sensor transmits a pressure signal to a hydraulic loading system controller through a circuit, the hydraulic loading controller receives the hydraulic pressure signal and carries out loading safety evaluation on a composite loading system through a rotating speed or torque expected value and an actual value transmitted by a vehicle motor system controller and a dynamometer loading system controller through a CAN bus, and the hydraulic loading force auxiliary pressure stabilization regulation requirement of the hydraulic loading system which possibly occurs at present is judged; the safety protection device controller receives an evaluation result and state information of the hydraulic loading system controller and system state and instruction information transmitted by the hydraulic loading system controller, the vehicle motor system controller and the dynamometer loading system controller through the CAN bus, and comprehensively judges that the loading safety protection is required at the moment; the safety protection device controller controls a second normally closed switch valve and a first electric control overflow valve of the second hydraulic protection loop, and a second oil pump motor and a second oil pump, so that the pressure boosting, pressure reducing and pressure maintaining of brake fluid pressure in the brake cylinder are adjusted, and the brake fluid in the brake cylinder and the reservoir is circulated and subjected to pressure stabilizing protection adjustment through the first three-way oil pipe, the second three-way oil pipe and the oil return pipe, so that the stability and the precision of a hydraulic loading effect are improved.
Further, during the overload limit safety backup protection, the method specifically comprises the following steps: the first pressure reducing valve in the third hydraulic circuit of the safety protection device is selected or adjusted before loading test work, when the composite loading system is overloaded and the safety protection controller or the first hydraulic protection circuit has electromechanical faults and cannot be normally and quickly reduced in pressure, high-pressure brake fluid in the brake cylinder can enter the reservoir through the three-way oil pipe via the third normally-opened switch valve, the first pressure reducing valve, the fourth one-way valve, the filter and the oil return pipe, brake fluid pressure reduction in the brake cylinder is completed, and a loading safety backup protection function is completed.
Due to the adoption of the technical scheme, the invention has the following advantages: 1. according to the hydraulic loading safety protection device, the first hydraulic protection circuit, the second hydraulic protection circuit and the third hydraulic protection circuit are arranged, so that overload protection, pressurization protection, voltage stabilization protection and extreme overload safety backup protection of a hydraulic loading system can be actively realized, the composite loading system of the electric vehicle can safely and reliably run, the efficiency and the safety of electro-hydraulic composite loading are improved, and the serious damage to personnel and property caused by the failure of the hydraulic loading system is avoided. 2. The vehicle loading test system with the hydraulic loading safety protection device can efficiently, safely and reliably realize the composite loading test task of the electric vehicle through the electro-hydraulic composite loading system and the hydraulic loading safety protection device, and can expand vehicle test projects and realize the accelerated development of the electric vehicle.
Drawings
Fig. 1 is a schematic structural diagram of a hydraulic loading safety protection device and a vehicle loading test system with the hydraulic loading safety protection device in one embodiment of the invention.
Reference numerals:
1, a hydraulic loading safety protection device; 2, a hydraulic loading system; 3, a motor system for the vehicle; 4, a dynamometer loading system; 5CAN bus; 100 a safety protection controller; 101 a first normally closed on-off valve; 102 an accumulator; 103 a first oil pumping motor; 104 a first oil pump; 105 a first one-way valve; 111 a second normally closed on-off valve; 112 a second oil pump; 113 a second oil pumping motor; 114 a second one-way valve; 115 a first electrically controlled spill valve; 116 a third one-way valve; 121 a third normally open switch valve; 122 a first pressure reducing valve; 123 fourth check valve; 130 a filter; 200 hydraulic loading system controller; 201 brake pedal; 202 braking the push rod; 203 brake booster; 204 master cylinder piston; 205 a master cylinder spring; 206 master cylinder body; 207 a reservoir; 208 a hydraulic pressure regulating unit; 209 oil outlet; 210 a brake caliper; 211 a brake piston; 212 brake cylinders; 213 brake disk; p1 master cylinder pressure sensor; a P2 wheel cylinder pressure sensor; s1 three-way oil pipe; s2 three-way oil pipe; s3 return pipe; 300 a vehicle motor system controller; 301 motor for vehicle; 302 motor output shaft for vehicle; 303 a motor rotating speed torque sensor for a vehicle; 304 a drive shaft; a 400 dynamometer machine loading system controller; 401 dynamometer motor; 402 a dynamometer output shaft; 403 dynamometer rotational speed torque sensor; 404 coupling flange assembly.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the drawings of the embodiments of the present invention. It is to be understood that the embodiments described are only a few embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the described embodiments of the invention, are within the scope of the invention.
In the description of the present invention, it should be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
In a first embodiment of the present invention, a hydraulic loading safety protection device 1 is provided, as shown in fig. 1, and in the present embodiment, the hydraulic loading safety protection device 1 includes a first hydraulic protection circuit, a second hydraulic protection circuit, a third hydraulic protection circuit, a filter 130, and a safety protection controller 100. One end of the filter 130 is connected in series with the first hydraulic protection circuit, the second hydraulic protection circuit and the third hydraulic protection circuit which are connected in parallel, and is used for filtering and cleaning brake fluid; the other end of the filter 130 is a first connection end of the hydraulic loading safety protection device 1, and is used for being connected with the hydraulic loading system 2. The safety protection controller 100 is electrically connected with controllable components (including an electric control switch valve, an electric control overflow valve and an oil pumping motor) in the first hydraulic protection circuit, the second hydraulic protection circuit and the third hydraulic protection circuit, and is used for normal active control of the hydraulic loading safety protection device. Wherein:
the first hydraulic protection circuit is used for performing emergency oil pumping to quickly reduce the pressure of the brake cylinder 212 in the hydraulic loading system 2 when the hydraulic loading is overloaded, so as to avoid locking. The first hydraulic protection circuit comprises a first normally closed switch valve 101, the first end of the first normally closed switch valve 101 is sequentially connected with the first end of the first energy accumulator 102, the first oil pump 104 and the first one-way valve 105 in series, the first oil pump 104 is connected with the first oil pumping motor 103, and the first oil pumping motor 103 is controlled to work by the first oil pump 104. A second end of the first normally closed switch valve 101 is connected in parallel with the second and third hydraulic protection circuits, and a second end of the first check valve 105 is connected with one end of a filter 130.
The second hydraulic protection loop is used for quickly and timely pressurizing the brake cylinder when the hydraulic loading system fails or the brake cylinder needs to stabilize the hydraulic pressure, so that the brake disc rotating at high speed is stabilized, the hydraulic pressure is stably loaded, and runaway is avoided. The second hydraulic protection circuit comprises a second normally closed switch valve 111, a second oil pump 112, a second oil pumping motor 113, a second check valve 114, a first electrically-controlled overflow valve 115 and a third check valve 116; the second oil pump 112 is connected to a second oil pumping motor 113, and the operation of the second oil pumping motor 113 is controlled. A first end of the second normally-closed switch valve 111 is respectively connected with a first end of the second oil pump 112 and a first end of the first electronic control overflow valve 115, and a second end of the second oil pump 112 is connected with one end of the filter 130 after being connected with the second normally-closed switch valve 111 in series; the second end of the first electrically controlled relief valve 115 is connected in series with the third check valve 116 and then connected to one end of the filter 130. The second end of the second normally-closed switch valve 111 is connected in parallel with the second end of the first normally-closed switch valve 101 and the third hydraulic protection circuit.
The third hydraulic protection loop is used for passively reducing pressure of the brake cylinder 212 in the hydraulic loading system 2 when the hydraulic loading system is extremely overloaded or the hydraulic loading safety protection device has electromechanical faults, so that safety protection backup is realized, and locking is avoided. The third hydraulic protection circuit comprises a third normally-open switch valve 121, a first end of the third normally-open switch valve 121 is sequentially connected with a first reducing valve 122 and a first end of a fourth check valve 123 in series, and a second end of the fourth check valve 123 is connected with one end of a filter 130. The second end of the third normally-open switch valve 121 is connected in parallel with the second end of the second normally-closed switch valve 111 and the second end of the first normally-closed switch valve 101, respectively, to form a second connection end of the hydraulic loading safety protection device 1.
In a second embodiment of the present invention, a vehicle loading test system with a hydraulic loading safety protection device is provided, as shown in fig. 1, the vehicle loading test system includes a hydraulic loading safety protection device 1 and a safety protection controller 100 electrically connected thereto, a hydraulic loading system 2 and a hydraulic loading system controller 200 electrically connected thereto, a vehicle motor system 3 and a hydraulic loading system controller 300 electrically connected thereto, a dynamometer loading system 4 and a dynamometer loading system controller 400 electrically connected thereto, and a CAN bus 5. The hydraulic loading safety protection device 1 is connected with the hydraulic loading system 2 through a first three-way oil pipe S1, a second three-way oil pipe S2 and an oil return pipe S3 to form a closed hydraulic loop, a first connecting end of the hydraulic loading safety protection device 1 is connected with the hydraulic loading system 2 through the oil return pipe S3, and a second connecting end of the hydraulic loading safety protection device 1 is connected with an oil outlet 209 of a hydraulic adjusting unit 208 in the hydraulic loading system 2 and a brake caliper 210 through the first three-way oil pipe S1 and the second three-way oil pipe S2 respectively. The hydraulic loading system 2 and the dynamometer loading system 4 are both connected with the vehicle motor system 3, and the hydraulic loading system 2 and the dynamometer loading system 4 simultaneously apply hydraulic loading force and dynamometer loading force to the vehicle motor system 3. The safety protection controller 100, the hydraulic loading system controller 200, the vehicle motor system controller 300 and the dynamometer loading system controller 400 are connected and communicated through the CAN bus 5, so that electro-hydraulic composite loading control and loading safety protection control of vehicle loading test are realized. The hydraulic loading system controller 200 provides a master cylinder pressure signal and a wheel cylinder pressure signal at the current moment for the safety protection device 1, the vehicle motor system controller 300 provides a torque and rotating speed signal at the current moment for the safety protection device 1, the dynamometer loading system controller 400 provides a torque and rotating speed signal at the current moment for the safety protection device 1, and after the safety protection device controller 100 analyzes signals from various sources and safety protection logic, if a loading fault is found, the loading safety protection function can be quickly and effectively realized.
In the above embodiment, the hydraulic loading system 2 includes the pedal assembly, the master cylinder assembly, the hydraulic pressure adjusting unit 208, the brake assembly, the oil pipe, the master cylinder pressure sensor P1, and the brake pressure sensor P2.
The pedal assembly comprises a brake pedal 201, a brake push rod 202 and a brake booster 203; the brake pedal 201 is connected to a brake push rod 202, and the brake push rod 202 is connected to one end of a brake booster 203.
The master cylinder assembly comprises a master cylinder body 206, a master cylinder piston 204, a master cylinder spring 205 and a reservoir 207, and is used for generating hydraulic pressure of the hydraulic loading system through manpower or assistance. The other end of the brake booster 203 is connected with one end of a master cylinder piston 204 positioned in a master cylinder body 206, and the other end of the master cylinder piston 204 is connected with a master cylinder spring 205; one end of the reservoir 207 is connected to the master cylinder block 206, and the other end of the reservoir 207 is connected to the first connection end of the hydraulic loading safety protection device 1 through the return pipe S3.
The hydraulic pressure adjusting unit 208 is used for realizing adjustment control of the hydraulic pressure loading level, and the hydraulic pressure adjusting unit 208 comprises the conventional ABS, ESC or EHB product; the hydraulic pressure adjusting unit 208 is connected to the master cylinder block 206, and a master cylinder pressure sensor P1 is provided on the connection line; an oil outlet 209 of the hydraulic adjusting unit 208 is connected with a second connecting end of the hydraulic loading safety protection device 1 through a second three-way oil pipe S2.
The brake assembly is used for friction loading of the hydraulic loading system 2 on the vehicle motor system 3 and comprises a brake disc 213, a brake caliper 210, a brake cylinder 212 and a brake piston 211; the brake caliper 210 is connected with an oil outlet 209 of a hydraulic pressure adjusting unit 208 in the hydraulic loading system 2 through a first three-way oil pipe S1, and a wheel cylinder pressure sensor P2 is arranged on the first three-way oil pipe S1; one end of the brake disc 213 is disposed in the caliper 210, and the brake cylinder 212 and the brake piston 211 are disposed in the caliper 210.
The hydraulic loading system controller 200 is electrically connected to the hydraulic pressure adjusting unit 208, the master cylinder pressure sensor P1, and the wheel cylinder pressure sensor P2, and is used to actively control the hydraulic loading system.
Preferably, the brake booster 203 is a vacuum booster or a vacuum booster driven by an electronic vacuum pump or a motor booster.
Preferably, the hydraulic pressure regulating unit 208 has four oil outlets 209 adaptable to four sets of hydraulic loading systems 2 and four sets of dynamometer loading systems 4.
Preferably, four sets of hydraulic loading safety protection devices 1 are matched with a four-wheel loading whole vehicle loading test system with a hydraulic loading system 2 and a dynamometer loading system 4.
In the above embodiments, the dynamometer loading system 4 includes a dynamometer motor 401, a dynamometer output shaft 402, a dynamometer rotational speed and torque sensor 403, and a coupling flange assembly 404. The dynamometer loading system controller 400 is electrically connected to the dynamometer rotational speed torque sensor 403 and the dynamometer motor 401 for actively controlling the dynamometer loading system. The dynamometer motor 401 is connected with one end of a dynamometer rotating speed torque sensor 403 through a dynamometer output shaft 402, and the other end of the dynamometer rotating speed torque sensor 403 is coaxially connected with a brake disc 213 in the hydraulic loading system 2 through a coupling flange assembly 404.
In the above embodiments, the vehicle motor system 3 includes the vehicle motor 301, the vehicle motor output shaft 302, the vehicle motor rotational speed and torque sensor 303, and the transmission shaft 304. The vehicle motor system controller 300 is electrically connected to the vehicle motor rotational speed torque sensor 303 and the vehicle motor 301, and is used for actively controlling the vehicle motor system. The vehicle motor 301 is connected to one end of a vehicle motor rotational speed torque sensor 303 through a vehicle motor output shaft 302, and the other end of the vehicle motor rotational speed torque sensor 303 is coaxially connected to the brake disc 213 through a transmission shaft 304.
Based on the loading test system, the invention also provides a vehicle loading test method, which comprises the following steps:
(1) the vehicle motor 301 executes a rotating speed or torque control command of the vehicle motor system controller 300, outputs rotating speed or torque through the transmission shaft 304, and simulates vehicle dynamics output when the vehicle runs under actual working conditions;
(2) the hydraulic braking loading force of the hydraulic loading system 2 acts on the brake disc 213, the dynamometer loading system 4 acts the dynamometer loading force on the coupling flange assembly 404, and the two loading forces are coupled on the transmission shaft 304 to realize the electro-hydraulic composite loading effect on the vehicle motor system.
(3) The safety protection controller 100 receives signals such as master cylinder pressure, wheel cylinder pressure, vehicle motor rotation speed/torque, dynamometer motor rotation speed/torque and the like, judges whether a hydraulic overload or failure and the like occur in the electro-hydraulic composite loading system, and immediately sends out a safety protection command to control an electromagnetic valve and an oil pump motor in the safety protection device if the safety protection controller judges that the failure occurs, so that the first hydraulic protection loop is controlled to actively reduce pressure, the second hydraulic protection loop is controlled to actively increase or stabilize pressure, or safety protection backup is realized through the third hydraulic protection loop under the extreme condition of electromechanical control failure, thereby avoiding serious danger of the vehicle loading test system and improving the electro-hydraulic composite loading effect.
The hydraulic loading safety protection device and the vehicle loading test system with the same are not limited to the single wheel loading test simulated in the embodiment of the attached drawing, and further comprise the composite loading condition of two coaxial wheels or two-shaft four wheels on the whole vehicle layer. The method specifically comprises the following steps:
1) initial readiness of the System
When not powered on, the hydraulic loading safety protection device 1, the hydraulic loading system 2, the vehicle motor system 3, the dynamometer loading system 4 and the CAN bus 5 are all in a standing state. Meanwhile, the first normally closed switch valve 101 in the first hydraulic protection circuit in the hydraulic loading safety protection device 1 is in an unpowered normally closed state, no high-pressure brake fluid exists in the accumulator 102, the first oil pump 104 and the first oil pumping motor 103 do not work, and the first check valve 105 is in a closed state; a second normally-closed switch valve 111 in the second hydraulic protection circuit is in an unpowered normally-closed state, a second oil pump 112 and a second oil pumping motor 113 are not operated, a second one-way valve 114 is in a closed state, a first electronic control overflow valve 115 is not powered, and a third one-way valve 116 is in a closed state; the third normally-open switch valve 121 in the third circuit is in an unpowered and normally-open state, the first pressure reducing valve 122 is in a normally-closed state, and the fourth check valve 123 is in a closed state. When the hydraulic loading safety protection device 1 is powered on and enters an initialization state, in order to save electric energy, when loading faults such as overload or failure of a hydraulic loading system do not occur, the electric control command values of the safety protection device controller are all zero, in other words, the initial states of the first, second and third hydraulic protection loops in the hydraulic loading safety protection device are consistent with the initial states when the hydraulic loading safety protection device is in a standing state. Meanwhile, the hydraulic loading system 2, the vehicle motor system 3, the dynamometer loading system 4 and the CAN bus 5 are sequentially electrified, and enter an initialization standby state to prepare for a vehicle loading test task in a conventional working mode.
2) Normal mode of operation
After power-on, the loading test state in the normal mode can be entered.
The vehicle-mounted motor system 3 simulates the vehicle dynamic state of a real vehicle when the real vehicle runs on a road, the vehicle-mounted motor system controller 300 simulates a real vehicle controller to send a torque or rotating speed command of a power output shaft of the vehicle, the vehicle-mounted motor 301 is responsible for executing the torque or rotating speed command and outputs the torque or rotating speed command to the transmission shaft 304 through the vehicle-mounted motor output shaft 302, and the vehicle-mounted motor system rotating speed torque sensor 303 transmits a collected torque/rotating speed signal to the vehicle-mounted motor system controller 300, so that closed-loop control of the torque or rotating speed is formed. The transmission shaft 304 transmits the power output by the vehicle motor 301 to the brake disc 213 and the coupling flange assembly 404, so as to be in power coupling with the hydraulic loading system 2 and the dynamometer loading system 4, and form the dynamic balance of the electro-hydraulic composite loading system.
The friction force on the brake disc 213 is derived from the hydraulic loading action of the hydraulic loading system 2. The driver pushes the brake push rod 202 by pressing the brake pedal 201, amplifies the pedal force under the boosting action of the brake booster 203, pushes the master cylinder piston 204 to move forward, and compresses the master cylinder spring 205 and the brake fluid in the master cylinder 206 to form a certain level of brake fluid pressure. The compressed brake fluid flows into the hydraulic pressure adjusting unit 208 through the oil pipe downstream of the master cylinder. The hydraulic pressure adjusting unit 208 receives a control command of the hydraulic loading system controller 200 to perform hydraulic pressure adjustment processing such as pressure increase/decrease/pressure holding on the brake fluid flowing through the hydraulic pressure adjusting unit 208. Then, the brake fluid flows out through the oil outlet 209 of the hydraulic pressure adjusting unit 208, and after passing through the three-way oil pipes S1 and S2, a part of the brake fluid flows to the hydraulic loading safety protection device 1 in the initial system preparation state, and the other part of the brake fluid flows into the brake cylinder 212 of the brake assembly, and the part of the brake fluid pushes the brake piston 211 to move forward and further pushes the brake caliper 210 to press the brake disc 213, so that friction force is generated, and the hydraulic loading effect of the hydraulic loading system 2 on the vehicle-mounted motor system 3 is realized. The pressure signals of the master cylinder pressure sensor P1 and the wheel cylinder pressure sensor P2 are transmitted to the hydraulic loading system controller 200 to finally form closed-loop control of the hydraulic pressure.
The loading torque on the coupling flange assembly 404 is derived from the dynamometer loading system 4. The dynamometer loading system controller 400 sends a torque or rotational speed command, the dynamometer motor 401 receives and executes the command, a desired rotational speed or torque is output at the dynamometer motor output shaft 402, the dynamometer rotational speed torque sensor 403 measures a rotational speed or torque signal and sends the rotational speed or torque signal to the dynamometer loading system controller 400, and closed-loop control of the rotational speed or torque is formed. The power output of the dynamometer output shaft is transmitted to the transmission shaft 304 through the coupling flange assembly 404, so that the loading effect of the dynamometer loading system 4 on the motor system 3 for the vehicle is formed.
The hydraulic loading safety protection device 1 in the normal working mode keeps the initial state, the safety protection device controller 100 receives the state and instruction information of the vehicle loading test system sent by the vehicle motor system controller 300, the hydraulic loading system controller 200 and the dynamometer loading system controller 400 through the CAN bus 5, and the loading fault condition which possibly occurs at any time is monitored at any time.
3) Security protection mode
3.1) overload protection
In the process of the electro-hydraulic combined loading test, the dynamometer loading motor 401 and the brake disc 213 of the hydraulic loading system simultaneously load the transmission shaft 304. For the hydraulic loading system 2, the situation that the hydraulic pressure exceeds the hydraulic loading strength expected to be set and the hydraulic pressure fluctuates often occurs, in addition, under the condition that the brake pedal mechanism and the hydraulic pressure adjusting unit which are responsible for providing the hydraulic pressure braking source in the hydraulic loading system have misoperation or electromechanical faults (such as short circuit, overheating, sudden circuit break and the like of an electromagnetic valve), the dangerous situation that the brake hydraulic pressure in the hydraulic cylinder rises rapidly can be caused, the locking danger of the compound loading system can be seriously caused by the overload situation of the hydraulic loading system, and even the serious mechanical dangers such as overload impact, breakage and the like of the transmission shaft can easily occur.
When the hydraulic pressure in the brake cylinder 212 of the brake in the hydraulic loading system 2 is too high, the wheel cylinder pressure sensor P2 transmits a pressure signal to the hydraulic loading system controller 200 through a circuit, the hydraulic loading controller 200 receives the hydraulic pressure signal and the expected value and the actual value of the rotating speed or the torque transmitted by the vehicle motor system controller 300 and the dynamometer loading system controller 400 through the CAN bus to perform loading safety evaluation on the composite loading system, and the current occurrence or possible occurrence of overload risk of the hydraulic loading system is judged. The safety protection device controller 100 receives the evaluation result of the hydraulic loading system controller, the state information of the hydraulic loading system 2 and the system state and instruction information transmitted by the other controllers 200, 300 and 400 through the CAN bus 5, and comprehensively judges that the loading safety protection is required at this time. The safety protection device controller 100 controls the first normally closed switch valve 101 and the first oil pumping motor 103 of the first hydraulic protection circuit to drive the first oil pump 104, fast pressure reduction and regulation are performed on high-pressure brake fluid in the brake cylinder 212 of the brake through the three-way oil pipe S2, the overloaded brake fluid enters the reservoir 207 through the three-way oil pipe S2 through the buffering effect of the first normally closed switch valve 101 and the accumulator 102, the first oil pump 104, the first one-way valve 105 and the filter 130 and through the oil return pipe S3, hydraulic regulation in the brake cylinder 212 of the brake is completed, and overload danger of a hydraulic loading system is avoided.
3.2) pressure boost protection
During the loading test, another fault condition relative to the overload fault of the hydraulic loading system 2 is a condition that the braking force of the hydraulic loading system 2 suddenly drops or disappears, and at this time, the composite loading system has a condition that the rotating speed of the transmission shaft 304 suddenly rises or the vehicle flies due to the sudden drop or disappearance of the hydraulic loading action strength in the composite loading system.
When the hydraulic pressure in the brake cylinder 212 of the brake in the hydraulic loading system 2 suddenly drops to be lower than the expected pressure value, the wheel cylinder pressure sensor P2 transmits a pressure signal to the hydraulic loading system controller 200 through a circuit, the hydraulic loading controller 200 receives the hydraulic pressure signal and the loading safety evaluation of the composite loading system is carried out by the rotating speed or torque expected value and actual value transmitted by the vehicle motor system controller 300 and the dynamometer loading system controller 400 through the CAN bus 5, and the loading risk of the hydraulic loading force failure of the hydraulic loading system which currently occurs or is possible to occur is judged. The safety protection device controller 100 receives the evaluation result of the hydraulic loading system controller, the state information of the hydraulic loading system, and the system state and instruction information transmitted by the other controllers 200, 300, and 400 through the CAN bus 5, and comprehensively determines that the loading safety protection is required at this time. The safety protection device controller 100 controls the second normally closed switch valve 111 and the second oil pumping motor 113 of the second hydraulic protection circuit to drive the second oil pump 112, quickly boosts and adjusts the hydraulic pressure in the brake cylinder 212 of the brake through the three-way oil pipe S2, the brake fluid from the reservoir 207 passes through the oil return pipe S3, passes through the filter 130, the second one-way valve 114, the second oil pump 112 and the second normally closed switch valve 111, and finally is injected into the brake cylinder through the three-way oil pipes S1 and S2, the hydraulic pressure boost adjustment in the brake cylinder is completed, and the flying risk of the combined loading system is avoided.
3.3) Voltage stabilization protection
In the loading test process, the hydraulic loading system 2 mainly adjusts the loading hydraulic pressure in the brake through the hydraulic adjusting unit, however, when the performance of the hydraulic adjusting unit 208 is degraded due to electromechanical failure, it is necessary to realize an auxiliary pressure stabilizing protection function through the hydraulic pressure adjusting function of the second hydraulic protection circuit of the safety protection device 1, so as to avoid serious failures such as strong mechanical shock and vibration of the compound loading system due to large loading force fluctuation of the compound loading system.
When the hydraulic pressure in the brake cylinder 212 of the brake in the hydraulic loading system 2 fluctuates greatly and upwards and is inconsistent with the expected pressure value, the wheel cylinder pressure sensor P2 transmits a pressure signal to the hydraulic loading system controller 200 through a circuit, the hydraulic loading controller 200 receives the hydraulic pressure signal and the loading safety evaluation of the composite loading system is carried out by the rotating speed or torque expected value and actual value transmitted by the vehicle motor system controller 300 and the dynamometer loading system controller 400 through the CAN bus 5, and the hydraulic loading force auxiliary pressure stabilizing regulation requirement of the hydraulic loading system 2 which possibly occurs at present is judged. The safety protection device controller 100 receives the evaluation result of the hydraulic loading system controller 2, the hydraulic loading system state information and the system state and instruction information transmitted by the other controllers 200, 300 and 400 through the CAN bus 5, and comprehensively judges that the loading safety protection is required at this time. The safety protection device controller 100 controls the second normally closed switch valve 111 and the first electrically controlled relief valve 115 of the second hydraulic protection circuit, the second oil pumping motor 113 and the second oil pump 112 to realize the regulation of the pressure increase, pressure reduction and pressure maintaining of the brake fluid in the brake cylinder, and the brake fluid in the brake cylinder and the reservoir is circulated and subjected to pressure stabilizing protection regulation through the oil pipes S1, S2 and S3, so that the stability and precision of the hydraulic loading action are improved.
3.4) overload limit safety backup protection
The severity of the overload of the hydraulic loading system 2 during the loading test poses a significant threat to the composite loading system and therefore further safety backup protection is necessary for the situation described above for the overload protection mode. When the safety protection device controller 100 fails or the first normally closed switch valve 101 or the first oil pumping motor 103 or the first oil pump 104 of the first circuit in the safety protection device 1 fails, the protection measures in the overload protection mode cannot effectively realize the safety protection effect on the combined loading system, and at this time, the third hydraulic protection circuit of the hydraulic loading safety protection device 1 performs the rapid pressure reduction effect on the brake fluid in the brake cylinder 212 through the preset pressure reduction valve 122, so that the loading safety backup protection function under the dangerous condition is realized.
When the overload condition occurs in the combined loading system and the safety protection controller 100 or the first hydraulic protection circuit fails to perform normal and rapid pressure reduction due to electromechanical failure, the high-pressure brake fluid in the brake cylinder 212 can enter the reservoir through the three-way oil pipes S1 and S2 via the third normally-open switch valve 121, the first pressure reducing valve 122, the fourth one-way valve 123, the filter 130 and the oil return pipe S3, so as to reduce the pressure of the brake fluid in the brake cylinder and complete the loading safety backup protection function.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. It will be readily apparent to those skilled in the art that various modifications to these embodiments may be made, and the generic principles described herein may be applied to other embodiments without the use of the inventive faculty. Therefore, the present invention is not limited to the above-mentioned embodiments, and those skilled in the art should make improvements and modifications within the scope of the present invention based on the disclosure of the present invention.
Claims (10)
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