CN112213124A - Method for detecting overall output efficiency and performance of EPS-SAM subassembly - Google Patents
Method for detecting overall output efficiency and performance of EPS-SAM subassembly Download PDFInfo
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Abstract
The invention relates to a method for detecting the overall output efficiency and performance of an EPS-SAM subassembly, belonging to the technical field of testing of an electronic hydraulic power steering gear of an automobile. The invention directly measures and collects the position of an input shaft, an input/output torque value and a current value of an electronic hydraulic power steering gear-SAM sub-assembly under different vehicle speeds and steering speeds through a detection device, accurately calculates the system efficiency and the output performance of the sub-assembly through collected data, and calculates the curve symmetry and the torque difference value through an input torque-current power-assisted curve and an input torque-output torque curve which are drawn in real time; and obtaining the output efficiency of the sub-assembly according to an output efficiency drawing efficiency-input shaft rotating speed curve calculated by collecting data, thereby realizing the detection of the symmetry of the steering assistance and the system efficiency. The method provides scientific basis for accurately measuring the sizes of all indexes of the electronic power-assisted part of the electronic hydraulic power-assisted steering gear.
Description
Technical Field
The invention relates to a method for detecting the overall output efficiency and performance of an EPS-SAM subassembly, belonging to the technical field of testing of an electronic hydraulic power steering gear of an automobile.
Background
The steering system serving as one of two safety systems of an automobile chassis is a key functional component for realizing high-performance maneuverability and stability of an automobile, and the mechanical performance and the control quality of the steering system directly influence the automobile maneuvering stability grade and greatly influence the driving safety. With the progress and development of society and the continuous improvement of people's living standard, automobiles become an indispensable part in the life of most people, and the requirement of people on the comfort level of automobiles is also continuously improved. An advanced automobile steering system needs to solve the contradiction between the light feeling of low-speed steering and the stable feeling of high-speed steering, and simultaneously needs to meet the requirements of energy conservation, environmental protection, power assistance adjustable along with the speed and the like, so that the electronic hydraulic power-assisted steering system is developed. The electronic hydraulic power-assisted Steering System consists of an electronic power-assisted unit and a hydraulic power-assisted unit, wherein the SAM-Steering Assistance System electronic power-assisted unit, namely an SAM sub-assembly, consists of an angle torque sensor, a Powerpack (containing a power-assisted motor and a controller (ECU)) and a worm and gear speed reducing mechanism, the SAM sub-assembly is a power-assisted Steering electronic System which directly provides power Assistance by the power-assisted motor, and the controller (ECU) controls the power-assisted motor to output torque.
The SAM sub-assembly of the electronic hydraulic power-assisted steering device (EPS) is used as an electronic power-assisted unit of a steering system, so that the steering operation force on a steering wheel of an automobile can be reduced, the fuel economy of the automobile during steering is improved, the active safety of the automobile is improved, and meanwhile, the electronic power-assisted unit can be provided with different steering hand force characteristics, so that the steering system has different steering characteristics, is quickly matched with different automobile types, and shortens the development and production periods. The output performance of the SAM sub-assembly of the electronic hydraulic power steering gear is an important index for measuring the function of the steering gear, so that the accurate measurement and calculation of the output performance parameters of the SAM sub-assembly of the steering gear is extremely important.
The performance of the current SAM subassembly of the steering gear only tests the output performance of the power-assisted motor of the Powerpack, namely, the output of the power-assisted motor is controlled by a torque signal value which is input into a controller for simulation, a current-torque performance graph is drawn, the symmetry degree is calculated, and the output symmetry of the Powerpack is judged according to the symmetry degree. However, the performance test of the SAM sub-assembly does not examine the indexes of the overall output efficiency, the performance and the like of the SAM sub-assembly, and does not acquire the output torque value of the sensor of the SAM sub-assembly system as the performance test data index. In the mode, the actual input torque signal of the sensor and the actual input/output of the SAM sub assembly are not examined, and the transmission efficiency of the mechanical part is not superposed, so that index values such as the symmetry, the output efficiency, the maximum performance and the like of the overall output torque of the SAM sub assembly cannot be obtained, and the sizes of all indexes of the electronic power-assisted part of the electronic hydraulic power-assisted steering device cannot be accurately measured.
Disclosure of Invention
The invention aims to: the method for detecting the overall output efficiency and the performance of the EPS-SAM subassembly is characterized in that different input shaft rotating speed and output shaft loading torque values can be set under different test schemes through testing the input/output torque of the SAM subassembly, and the symmetry, the efficiency and the performance are calculated through acquired variable values, so that a theoretical basis is provided for accurately measuring the indexes of an electronic power assisting part of an electronic hydraulic power steering gear.
The technical scheme of the invention is as follows:
an EPS-SAM subassembly overall output efficiency, performance detection method; the method is characterized in that: it comprises the following steps:
1) clamping an SAM sub-assembly on a detection device, wherein the SAM sub-assembly comprises a torque/angle sensor, a Powerpack and a worm and gear mechanism; then manually plugging the controller, the sensor and the CAN communication line aerial plug; connecting it with a detection device; setting the rotation speed of 1000rpm, the vehicle speed of 0km/h, the rotation speed of 100/s, 200/s, 400/s, 600/s and 800/s of the input shaft and the loading torque value of 4.46Nm of the output shaft on the detection device, which are required by the test;
2) starting a left sliding table cylinder and a right sliding table cylinder of the detection device, and enabling input shaft joints and spline joints on the left sliding table cylinder and the right sliding table cylinder to be sleeved into the input end and the output end of the corresponding SAM sub-assembly and locked and fixed;
3) after the preparation is finished, setting the initial position of an input shaft of the SAM subassembly to be 0 degree, and simultaneously loading the torque value of 4.46Nm set in the step 1 on the output end of the SAM subassembly;
4) after the controller is electrified, the controller communicates with the controller through a CAN card of the detection device, and the vehicle rotating speed signal data required to be tested is fed in, so that the controller of the SAM subassembly enters a normal working state;
5) rotating the input shaft of the SAM subassembly at different angular speeds of 100-800 degrees/S from the position of 0 degree by adopting the required angular speed in the clockwise direction until the torque reaches the required measurement torque value, and returning the input shaft of the SAM subassembly to the position of 0 degree after the stable test of 10 seconds;
6) after the input shaft of the SAM subassembly returns to the 0-degree position; rotating the input shaft of the SAM subassembly at different angular speeds of 100-800 degrees/s in the counterclockwise direction until the torque reaches the required measured torque value; after the stable test is carried out for 10S, the input shaft of the SAM subassembly returns to the 0-degree position;
7) after the steps are completed, resetting the loaded torque value of the output end of the device to be 8.94Nm/13.4Nm/17.86Nm, carrying out the steps, and repeatedly carrying out the test;
8) when the detection device drives the input shaft of the SAM sub-assembly to rotate, a torque/angle sensor of the SAM sub-assembly outputs a torque value according to the deformation quantity of the torsion bar, an ECU (controller) of the SAM sub-assembly collects torque and angle signals output by the current torque/angle sensor, and a basic power-assisted parameter value is set according to a program in combination with a current vehicle rotating speed message to drive a motor of the SAM sub-assembly to output torque so as to provide power assistance; meanwhile, the CAN card collects the input/output torque value and the motor current value of the SAM sub-assembly in real time and records the rotation angle information of the input shaft;
9) the PC calculates SAM sub-total output performance and efficiency according to the information collected by the CAN card; then, drawing an efficiency-input shaft position curve and a performance-angular velocity curve under different loading torques according to the calculation result, and displaying the performance-angular velocity curve on a PC (personal computer) in real time;
10) the PC calculates the efficiency and the performance of the current SAM subassembly system according to the input shaft rotation angular velocity data collected by the CAN card, and draws an efficiency and performance curve graph, wherein the drawn efficiency and performance curve graph is displayed by the PC in real time; therefore, theoretical basis is provided for accurately measuring the sizes of all indexes of the electronic power assisting part of the electronic hydraulic power steering gear.
The invention has the beneficial effects that:
the invention directly measures and collects the position of an input shaft, an input/output torque value and a current value of an electronic hydraulic power steering gear-SAM subassembly under different vehicle speeds and steering speeds through a detection device, accurately calculates the system efficiency and the output performance of the subassembly through collected data, calculates the curve symmetry and the torsion difference value (the input torque difference value under a rated output target torque) through an input torque-current power-assisted curve and an input torque-output torque curve which are drawn in real time, and draws an efficiency-input shaft rotating speed curve according to the output efficiency calculated through the collected data to obtain the output efficiency of the subassembly, thereby realizing the detection of the symmetry of the steering power assistance and the system efficiency. The invention can accurately obtain the index values of the input/output torque value, the efficiency, the output maximum performance and the like of the electronic hydraulic power steering gear-SAM sub-assembly so as to detect the symmetry of the output torque of the SAM sub-assembly and calculate the efficiency and the maximum performance of the sub-assembly; therefore, scientific basis is provided for accurately measuring the sizes of all indexes of the electronic power assisting part of the electronic hydraulic power steering gear.
Drawings
FIG. 1 is a schematic diagram of a detection device of the present invention;
FIG. 2 is a schematic illustration of an input torque-current curve of the present invention at various vehicle speeds;
FIG. 3 is a schematic input torque-output torque diagram of the present invention at various vehicle speeds;
FIG. 4 is a graph of real-time efficiency for an output loading torque of 4.46Nm at 100 input shaft speed/s in accordance with the present invention;
FIG. 5 is a graph of real-time efficiency for an output loading torque of 4.46Nm at an input shaft speed of 200 °/s in accordance with the present invention;
FIG. 6 is a graph of real-time efficiency for an output loading torque of 4.46Nm at an input shaft speed of 400 °/s in accordance with the present invention;
FIG. 7 is a graph of real-time efficiency for an output loading torque of 4.46Nm at 600 input shaft speed/s in accordance with the present invention;
FIG. 8 is a graph of real-time efficiency for an output loading torque of 4.46Nm at an input shaft speed of 800 °/s in accordance with the present invention;
FIG. 9 is a graph of a real-time curve of efficiency for an output end loaded torque of 8.94Nm and an input shaft speed of 100 °/s in accordance with the present invention;
FIG. 10 is a graph of a real time curve of efficiency for an output end loaded torque of 8.94Nm at an input shaft speed of 200 °/s in accordance with the present invention;
FIG. 11 is a graph of a real-time curve of efficiency for an output loading torque of 8.94Nm at 400 input shaft speed/s in accordance with the present invention;
FIG. 12 is a graph of a real-time curve of efficiency for an output loading torque of 8.94Nm at 600 input shaft speed/s in accordance with the present invention;
FIG. 13 is a graph of a real-time curve of efficiency for an output end loaded torque of 8.94Nm at an input shaft speed of 800 °/s in accordance with the present invention;
FIG. 14 is a graph of a real-time curve of efficiency for an output end loaded torque of 13.4Nm and an input shaft speed of 100 °/s in accordance with the present invention;
FIG. 15 is a graph of a real time curve of efficiency for an output end loaded torque of 13.4Nm at an input shaft speed of 200 °/s in accordance with the present invention;
FIG. 16 is a graph of a real time curve of efficiency for an output end loaded torque of 13.4Nm at an input shaft speed of 400 °/s in accordance with the present invention;
FIG. 17 is a graph of a real time curve of efficiency for an output end loaded torque of 13.4Nm at an input shaft speed of 600 °/s in accordance with the present invention;
FIG. 18 is a graph of a real time curve of efficiency for an output end loaded torque of 13.4Nm at an input shaft speed of 800 °/s in accordance with the present invention;
FIG. 19 is a graph of a real time curve of efficiency for an output loaded torque of 17.86Nm and an input shaft speed of 100/s in accordance with the present invention;
FIG. 20 is a graph of a real time curve of efficiency for an output loading torque of 17.86Nm at 200 input shaft speed/s in accordance with the present invention;
FIG. 21 is a graph of a real time curve of efficiency for an output loaded torque of 17.86Nm at 400 input shaft speed/s in accordance with the present invention;
FIG. 22 is a graph of a real time curve of efficiency for an output loaded torque of 17.86Nm at 600 input shaft speed/s in accordance with the present invention;
FIG. 23 is a graph of a real time curve of efficiency for an output loaded torque of 17.86Nm at an input shaft speed of 800 °/s in accordance with the present invention;
FIG. 24 is a line graph of the maximum output performance of a SAM sub-assembly of the present invention.
Detailed Description
The method for detecting the overall output efficiency and the performance of the EPS-SAM subassembly comprises the following steps; firstly, setting the required rotation speed 1000rpm, the vehicle speed 0km/h, the input shaft rotation speed 100/s, 200/s, 400/s, 600/s and 800/s and the output shaft loading torque value 4.46Nm on a detection device; the detection device comprises a machine table, a PC (personal computer), a workpiece fixture, a sliding table cylinder and a servo motor, wherein the sliding table cylinder comprises a left sliding table cylinder and a right sliding table cylinder. A working panel of the machine table is symmetrically provided with sliding table cylinders through sliding rails, the sliding table cylinders are provided with servo motors (Beckhoff AX5206), a workpiece clamp is fixedly arranged on the working panel between the sliding table cylinders, a PC (PC control program: MFC) and a CAN card (control program: Beckhoff TwinCAT 2) are arranged above the workpiece clamp through the machine table, and the PC is connected with the CAN card; the servo motors are all provided with a torque sensor (HBM T5). The torque sensor is connected with the CAN card, the CAN card is used for collecting information of each node on the CAN bus, transmitting the information to the PC, transmitting commands and data of the PC to each node and finishing monitoring and management work of a user system part on the CAN bus.
The SAM sub-assembly is fixedly arranged on the detection device through a workpiece clamp; and starting the left sliding table cylinder and the right sliding table cylinder of the detection device to move forwards relatively, so that servo motor power shaft joints on the left sliding table cylinder and the right sliding table cylinder are sleeved into the input end and the output end of the corresponding SAM sub-assembly and are locked and fixed. After the Powerpack is electrified, the CAN card of the detection device is communicated with the ECU, and vehicle rotating speed signal data required to be tested are fed in, so that the controller of the SAM subassembly enters a normal working state; the SAM sub-assembly comprises a torque/angle sensor, a controller, a power-assisted motor, a worm gear mechanism, a manual plug-in controller, a sensor and a CAN communication line aerial plug-in connector; so that it is connected to the detection means. And (3) connecting a direct current stabilized power supply (SINCHIP SDC30-100-S) with the SAM sub-assembly through a current sensor (Hall SY-DFH11-KD599-M) to drive a booster motor of the SAM sub-assembly to work. The current sensor is connected with the CAN card and used for collecting the current value of an output bus of the direct current stabilized voltage power supply and uploading the current value to the CAN card.
The test operation comprises two parts;
1) testing input/output torque, symmetry and skew, hysteresis:
setting the initial position of the input shaft of the SAM subassembly to be 0 degree, rotating the input shaft of the SAM subassembly at an angular speed of 2 degrees/s +/-5 percent from the position of 0 degree by adopting a required angular speed after a servo motor is started, and returning the input shaft of the SAM subassembly to the position of 0 degree until the torque reaches 15Nm +/-2 percent.
After the input shaft of the SAM subassembly returns to the 0-degree position; rotating the input shaft of the SAM subassembly in a counterclockwise direction at an angular speed of 2/s +/-5% until the input shaft of the SAM subassembly returns to the 0-degree position after the torque reaches 15Nm +/-2%;
and repeating the steps at different vehicle speeds (0 km/h, 40km/h and 80 km/h), drawing an input torque-current curve and an input torque-output torque curve at different vehicle speeds on a PC (personal computer) after the test is finished, and calculating a torque difference value and a hysteresis value under the curve symmetry and the rated output target torque.
2) Efficiency of testing and maximum performance:
the initial position of the input shaft of the SAM subassembly is set to be 0 degree, and a set torque value is loaded on a servo motor at the output end of the SAM subassembly. After the servo motor is started, the input shaft of the SAM subassembly is rotated at different angular speeds of 100-800 degrees/S from the position of 0 degrees by adopting the required angular speed in the clockwise direction until the torque reaches the required measurement torque value, and the input shaft of the SAM subassembly returns to the position of 0 degrees after the stable test of 10 seconds.
After the input shaft of the SAM subassembly returns to the 0-degree position; rotating the input shaft of the SAM subassembly at different angular speeds of 100-800 degrees/s in the counterclockwise direction until the torque reaches the required measured torque value; after the stable test is carried out for 10S, the input shaft of the SAM subassembly returns to the 0-degree position;
different torques are loaded on the output end respectively 4.46Nm/8.94Nm/13.4Nm/17.86 Nm)
And repeating the steps, and drawing an efficiency-input shaft rotating speed curve corresponding to the loading torque of the output end and efficiency values of different input shaft rotating speeds on the PC after the test is finished.
When the detection device drives the SAM sub-assembly input shaft to rotate, a torque/angle sensor of the SAM sub-assembly outputs according to the deformation quantity of the torsion bar, a controller (ECU) of the SAM sub-assembly collects torque and angle signals output by a current torque/angle sensor, and simultaneously sets a basic assistance parameter value according to a program by combining a current vehicle rotating speed value to drive a motor of the SAM sub-assembly to output torque so as to provide assistance; meanwhile, the CAN card collects the input/output torque value and the current value of the power-assisted motor of the SAM subassembly in real time and records the rotation angle information of the input shaft of the servo motor;
the PC calculates the symmetry of the curve, the fluctuation of the left torque and the right torque and the hysteresis value according to the information collected by the CAN card; current-torque performance curves and input torque-output torque curves at different speeds are drawn, the PC calculates the output efficiency and output performance of the current SAM subassembly system according to the collected input shaft rotation speed data by the CAN card, and draws output efficiency and output performance curves, and the drawn output efficiency and output performance curves are displayed by the PC in real time; therefore, theoretical basis is provided for accurately measuring the sizes of all indexes of the electronic power assisting part of the electronic hydraulic power steering gear.
The method specifically comprises the following steps:
curve symmetry, skew, hysteresis values:
the set values required by the test are set on the detection device, including vehicle rotating speed messages (taking 0km/h, 40km/h and 80km/h as examples), input torque ranges under corresponding vehicle speeds, maximum torque difference values, maximum hysteresis values and curve target symmetry degrees, and the initial position of the input shaft of the SAM sub-assembly is set to be 0 degree. After the servo motor is started, the input shaft is rotated clockwise from the 0-degree position at a speed of 1 degree/S +/-5% until the torque reaches 15Nm +/-2%, and after the input shaft of the SAM subassembly returns to the 0-degree position, the input shaft is rotated counterclockwise at a speed of 1 degree/S +/-5% until the torque reaches 15Nm +/-2%. And the PC machine draws an input torque-current curve and an input torque-output torque curve at different vehicle speeds according to the torque values of the input end and the output end and the current value of the bus collected by the CAN card and calculates the curve symmetry, the torque difference value and the hysteresis value at the current vehicle speed (see figures 2 and 3).
The torque-current curve symmetry degree calculation process is as follows:
(calculating the symmetry of the curve by taking the return segment and the absolute value of the value)
Formula of curve symmetry:
input torque points are. + -. 1.5Nm,. + -. 2.5Nm,. + -. 3.5Nm,. + -. 4.5Nm,. + -. 5.5Nm
The corresponding current value of the input torque is shown in the following table
According to the formula, the symmetry of the input torque-current curve of 0km/h
And the symmetry degree of the 40km/h input torque-current curve is 99.48 percent and the symmetry degree of the 80km/h input torque-current curve is 99.44 percent through calculation in the same way.
The table of data acquisition and calculation output results in the test process is as follows:
the input torque-output torque curve symmetry degree calculation process is as follows:
(calculating the symmetry of the curve by taking the return section and the absolute value)
Formula of curve symmetry:
；
wherein
Input torque points are. + -. 1.5Nm,. + -. 2.5Nm,. + -. 3.5Nm,. + -. 4.5Nm,. + -. 5.5Nm
The input torque corresponds to the current value as shown in the following table:
according to the formula, the symmetry degree of the curve of the input torque-output torque of 0km/h
And similarly, the symmetry degree of the 40km/h input torque-output torque curve is 98.95 percent, and the symmetry degree of the 80km/h input torque-output torque curve is 98.84 percent.
Calculation of hysteresis value:
hysteresis torque = | input torque 1-input torque 2-
Under the corresponding vehicle speed, the corresponding input torque values of different output torques in one stroke during clockwise/anticlockwise rotation are as follows: (Absolute hysteresis)
The table of data acquisition and calculation output results in the test process is as follows:
according to the result, the symmetry, fluctuation and hysteresis value of the output torque of the electronic power-assisted part of the electronic hydraulic power-assisted steering gear under the conditions of the vehicle speeds of 0km/h, 40km/h and 80km/h can be accurately measured; the combination with the performance of the real vehicle means comfort, portability and stability of the hand feeling of the electro-hydraulic power-assisted steering when the left/right steering is carried out.
Efficiency:
the set values required for the test are set on the detection device, including a vehicle speed message (taking the vehicle speed of 0km/h and the rotating speed of 1000rpm as an example), the initial 0-degree position of the input shaft of the SAM subassembly, the rotating speeds of the input shaft of 100 degrees/s, 200 degrees/s, 400 degrees/s, 600 degrees/s and 800 degrees/s, and simultaneously, a set torque value of 4.46Nm/8.94Nm/13.4Nm/17.86Nm is loaded on a servo motor at the output end of the device.
And then starting the test bench to rotate the input shaft of the SAM subassembly at a set angular speed from the 0-degree position at an angular speed of 100 degrees/S in a clockwise direction until the torque reaches a required measurement torque value, and returning the input shaft of the SAM subassembly to the 0-degree position after the SAM subassembly is stably tested for 10 seconds. After the input shaft of the SAM subassembly returns to the position of 0 degree, the input shaft of the SAM subassembly is rotated at a set angular speed in the counterclockwise direction until the torque reaches a required measurement torque value; after the stable test is carried out for 10S, the input shaft of the SAM subassembly returns to the 0-degree position;
the above test was repeated again at angular velocities of 200 °/s, 400 °/s, 600 °/s, 800 °/s, respectively. And the PC calculates the sub-assembly efficiency at the current rotating speed according to the variable information value collected by the CAN card and draws a curve.
The CAN card collects variable information values and records the variable information values as follows
Input torque value Tin (Nm)
Output torque Tout (Nm)
Angular position of input shaft
Voltage U (V)
Current I (A)
Input shaft angular velocity w (°/s)
The efficiency calculation formula is as follows:
output power (W)
Input power (W)
Powerpack power (W)
Efficiency (%)
1) When the loading torque of the output end is 4.46Nm, the data (average value of input torque, output torque and current) collected in the test process and the calculated output result table are as follows:
when the input shaft is rotated clockwise at 100 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
When the input shaft is rotated counterclockwise at 100 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
The test procedure, real-time efficiency curve at 100 °/s input shaft speed (see fig. 4), is divided into clockwise and counterclockwise directions:
when the input shaft is rotated clockwise at 200 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
When the input shaft is rotated counterclockwise at 200 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
The test procedure, real-time efficiency curve at 200 °/s input shaft speed (see fig. 5), is divided into clockwise and counterclockwise directions:
when the input shaft is rotated clockwise at 400 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
When the input shaft is rotated counterclockwise at 400 deg./s, the SAM subassembly efficiency is calculated as follows:
efficiency (%)
The test procedure, a real-time efficiency curve at an input shaft speed of 400 °/s (see fig. 6), is divided into clockwise and counterclockwise directions:
when the input shaft is rotated clockwise at 600 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
When the input shaft is rotated counterclockwise at 600 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
The test procedure, the real-time efficiency curve at 600 °/s input shaft speed (see fig. 7), is divided into clockwise and counterclockwise directions:
when the input shaft is rotated clockwise at 800 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
When the input shaft is rotated counterclockwise at 800 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
The test procedure, real-time efficiency curve at 800 °/s input shaft speed (see fig. 8), is divided into clockwise and counterclockwise directions:
2) when the loading torque of the output end is 8.94Nm, the data (average value of input torque, output torque and current) collected in the test process and the calculated output result table are as follows:
when the input shaft is rotated clockwise at 100 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
When the input shaft is rotated counterclockwise at 100 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
The test procedure, a real-time curve of the efficiency at 100 °/s input shaft speed (see fig. 9), is divided into clockwise and counterclockwise directions:
when the input shaft is rotated clockwise at 200 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
When the input shaft is rotated counterclockwise at 200 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
The efficiency at 200 °/s input shaft speed was plotted in real time (see fig. 10) during the test as follows (in both clockwise and counterclockwise directions):
when the input shaft is rotated clockwise at 400 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
When the input shaft is rotated counterclockwise at 400 deg./s, the SAM subassembly efficiency is calculated as follows:
efficiency (%)
The test procedure, real-time efficiency curve at input shaft speed 400 °/s (see fig. 11), is divided into clockwise and counterclockwise directions:
when the input shaft is rotated clockwise at 600 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
When the input shaft is rotated counterclockwise at 600 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
The real-time efficiency curve for a 600 °/s input shaft speed during the test is as follows (see fig. 12), divided into clockwise and counterclockwise directions:
when the input shaft is rotated clockwise at 800 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
When the input shaft is rotated counterclockwise at 800 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
The real-time efficiency curve at 800 °/s input shaft speed during the test is as follows (see fig. 13), divided into clockwise and counterclockwise directions:
3) when the loading torque of the output end is 13.4Nm, the data (average value of input torque, output torque and current) collected in the test process and the calculated output result table are as follows:
when the input shaft is rotated clockwise at 100 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
When the input shaft is rotated counterclockwise at 100 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
The test procedure, real-time efficiency curve at 100 °/s input shaft speed (see fig. 14), is divided into clockwise and counterclockwise directions:
when the input shaft is rotated clockwise at 200 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
When the input shaft is rotated counterclockwise at 200 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
The test procedure, real-time efficiency curve at 200 °/s input shaft speed (see fig. 15), is divided into clockwise and counterclockwise directions:
when the input shaft is rotated clockwise at 400 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
When the input shaft is rotated counterclockwise at 400 deg./s, the SAM subassembly efficiency is calculated as follows:
efficiency (%)
The test procedure, a real-time efficiency curve at 400 °/s input shaft speed (see fig. 16), is divided into clockwise and counterclockwise directions:
when the input shaft is rotated clockwise at 600 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
When the input shaft is rotated counterclockwise at 600 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
The test procedure, the real-time efficiency curve at 600 °/s input shaft speed (see fig. 17), is divided into clockwise and counterclockwise directions:
when the input shaft is rotated clockwise at 800 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
When the input shaft is rotated counterclockwise at 800 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
The test procedure, real-time efficiency curve at 800 °/s input shaft speed (see fig. 18), is divided into clockwise and counterclockwise directions:
4) when the loading torque of the output end is 17.86Nm, the data (average value of input torque, output torque and current) collected in the test process and the calculated output result table are as follows:
when the input shaft is rotated clockwise at 100 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
When the input shaft is rotated counterclockwise at 100 °/s, the SAM subassembly efficiency calculation process is as follows:
the test procedure, real-time efficiency curve at 100 °/s input shaft speed (see fig. 19), is divided into clockwise and counterclockwise directions:
when the input shaft is rotated clockwise at 200 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
When the input shaft is rotated counterclockwise at 200 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
The test procedure, real-time efficiency curve at 200 °/s input shaft speed (see fig. 20), is divided into clockwise and counterclockwise directions:
when the input shaft is rotated clockwise at 400 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
When the input shaft is rotated counterclockwise at 400 deg./s, the SAM subassembly efficiency is calculated as follows:
the test procedure, real-time efficiency curve at input shaft speed 400 °/s (see fig. 21), is divided into clockwise and counterclockwise directions:
when the input shaft is rotated clockwise at 600 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
When the input shaft is rotated counterclockwise at 600 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
The test procedure, a real-time efficiency curve at 600 °/s input shaft speed (see fig. 22), is divided into clockwise and counterclockwise directions:
when the input shaft is rotated clockwise at 800 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
When the input shaft is rotated counterclockwise at 800 °/s, the SAM subassembly efficiency calculation process is as follows:
efficiency (%)
The test procedure, real-time efficiency curve at 800 °/s input shaft speed (see fig. 23), is divided into clockwise and counterclockwise directions:
according to the result, the output efficiency of the electronic power-assisted part of the electronic hydraulic power-assisted steering device under the working conditions of different required output torques and different input shaft rotating speeds can be accurately measured, and great convenience can be brought to the optimization of motor type selection and mechanical structure design for meeting the design requirement of actually measured efficiency values in the development stage.
Maximum performance:
the set values required by the test are set on the detection device, including a vehicle rotating speed message (taking the vehicle speed of 0km/h and the rotating speed of 1000rpm as an example), the initial 0-degree position of the input shaft of the SAM sub-assembly, the rotating speed of the input shaft of 100 degrees/s, 200 degrees/s, 400 degrees/s, 600 degrees/s and 800 degrees/s, and meanwhile, a set torque value of 22.23Nm (1.3 times of the design theoretical output torque value) is loaded on a servo motor at the output end of the device.
And then starting the test bench to rotate the input shaft of the SAM subassembly at a set angular speed from the 0-degree position at an angular speed of 100 degrees/S in a clockwise direction until the torque reaches a required measurement torque value, and returning the input shaft of the SAM subassembly to the 0-degree position after the SAM subassembly is stably tested for 10 seconds. After the input shaft of the SAM subassembly returns to the position of 0 degree, the input shaft of the SAM subassembly is rotated at a set angular speed in the counterclockwise direction until the torque reaches a required measurement torque value; after the stable test is carried out for 10S, the input shaft of the SAM subassembly returns to the 0-degree position;
the above test was repeated again at angular velocities of 200 °/s, 400 °/s, 600 °/s, 800 °/s, respectively. And the PC calculates the output performance of the sub-assembly at the current rotating speed according to the variable information value collected by the CAN card and draws a curve.
The table for collecting data (clockwise/counterclockwise input torque, average value of output torque) and calculating output results in the test process is as follows:
the calculation process of the maximum output performance of the SAM sub-assembly is as follows:
(the performance of the sub-assembly is 100% when the rotating speed of the input shaft is taken as 0 degree/s and the theoretical output torque is designed to be 17.87 Nm.)
Then at an input shaft speed of 100 deg./s,
the same calculations give performance values of 96%, 95%, 94%, 89% for input shaft speeds of 200 °/s, 400 °/s, 600 °/s, 800 °/s, respectively (see FIG. 24).
According to the result, the output performance of the electronic power-assisted part of the electronic hydraulic power-assisted steering gear under the condition of the maximum output torque at different input shaft rotating speeds is accurately measured.
Claims (1)
1. An EPS-SAM subassembly overall output efficiency, performance detection method; the method is characterized in that: it comprises the following steps:
1) clamping an SAM sub-assembly on a detection device, wherein the SAM sub-assembly comprises a torque/angle sensor, a Powerpack and a worm and gear mechanism; then manually plugging the controller, the sensor and the CAN communication line aerial plug; connecting it with a detection device; setting the rotation speed of 1000rpm, the vehicle speed of 0km/h, the rotation speed of 100/s, 200/s, 400/s, 600/s and 800/s of the input shaft and the loading torque value of 4.46Nm of the output shaft on the detection device, which are required by the test;
2) starting a left sliding table cylinder and a right sliding table cylinder of the detection device, and enabling input shaft joints and spline joints on the left sliding table cylinder and the right sliding table cylinder to be sleeved into the input end and the output end of the corresponding SAM sub-assembly and locked and fixed;
3) after the preparation is finished, setting the initial position of an input shaft of the SAM subassembly to be 0 degree, and simultaneously loading the torque value of 4.46Nm set in the step 1 on the output end of the SAM subassembly;
4) after the controller is electrified, the controller communicates with the controller through a CAN card of the detection device, and the vehicle rotating speed signal data required to be tested is fed in, so that the controller of the SAM subassembly enters a normal working state;
5) rotating the input shaft of the SAM subassembly at different angular speeds of 100-800 degrees/S from the position of 0 degree by adopting the required angular speed in the clockwise direction until the torque reaches the required measurement torque value, and returning the input shaft of the SAM subassembly to the position of 0 degree after the stable test of 10 seconds;
6) after the input shaft of the SAM subassembly returns to the 0-degree position; rotating the input shaft of the SAM subassembly at different angular speeds of 100-800 degrees/s in the counterclockwise direction until the torque reaches the required measured torque value; after the stable test is carried out for 10S, the input shaft of the SAM subassembly returns to the 0-degree position;
7) after the steps are completed, resetting the loaded torque value of the output end of the device to be 8.94Nm/13.4Nm/17.86Nm, carrying out the steps, and repeatedly carrying out the test;
8) when the detection device drives the input shaft of the SAM sub-assembly to rotate, a torque/angle sensor of the SAM sub-assembly outputs a torque value according to the deformation quantity of the torsion bar, an ECU (controller) of the SAM sub-assembly collects torque and angle signals output by the current torque/angle sensor, and a basic power-assisted parameter value is set according to a program in combination with a current vehicle rotating speed message to drive a motor of the SAM sub-assembly to output torque so as to provide power assistance; meanwhile, the CAN card collects the input/output torque value and the motor current value of the SAM sub-assembly in real time and records the rotation angle information of the input shaft;
9) the PC calculates SAM sub-total output performance and efficiency according to the information collected by the CAN card; then, drawing an efficiency-input shaft position curve and a performance-angular velocity curve under different loading torques according to the calculation result, and displaying the performance-angular velocity curve on a PC (personal computer) in real time;
10) the PC calculates the efficiency and the performance of the current SAM subassembly system according to the input shaft rotation angular velocity data collected by the CAN card, and draws an efficiency and performance curve graph, wherein the drawn efficiency and performance curve graph is displayed by the PC in real time; therefore, theoretical basis is provided for accurately measuring the sizes of all indexes of the electronic power assisting part of the electronic hydraulic power steering gear.
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Denomination of invention: A Method for Testing the Overall Output Efficiency and Performance of EPS SAM Sub assemblies Granted publication date: 20220215 Pledgee: China CITIC Bank Co.,Ltd. Jingzhou branch Pledgor: HUBEI HENGLONG AUTOMOTIVE SYSTEM GROUP Co.,Ltd. Registration number: Y2024980012596 |