CN112268568A - Engine sensor testing tool, testing system and testing method - Google Patents
Engine sensor testing tool, testing system and testing method Download PDFInfo
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- CN112268568A CN112268568A CN202011099544.XA CN202011099544A CN112268568A CN 112268568 A CN112268568 A CN 112268568A CN 202011099544 A CN202011099544 A CN 202011099544A CN 112268568 A CN112268568 A CN 112268568A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D5/00—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable
- G01D5/12—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means
- G01D5/14—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means influencing the magnitude of a current or voltage
- G01D5/142—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means influencing the magnitude of a current or voltage using Hall-effect devices
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D18/00—Testing or calibrating apparatus or arrangements provided for in groups G01D1/00 - G01D15/00
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D5/00—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable
- G01D5/12—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means
- G01D5/244—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means influencing characteristics of pulses or pulse trains; generating pulses or pulse trains
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D5/00—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable
- G01D5/12—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means
- G01D5/244—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means influencing characteristics of pulses or pulse trains; generating pulses or pulse trains
- G01D5/24457—Failure detection
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R25/00—Arrangements for measuring phase angle between a voltage and a current or between voltages or currents
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R29/00—Arrangements for measuring or indicating electric quantities not covered by groups G01R19/00 - G01R27/00
- G01R29/02—Measuring characteristics of individual pulses, e.g. deviation from pulse flatness, rise time or duration
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Abstract
An engine sensor testing system comprises an engine sensor testing tool, a computer, a two-way trackable signal generator, a two-way alternating current/direct current amplifier, a current measuring module, a signal processing module, a signal selection control module and a two-way synchronous acquisition module; the system can be used for quickly and efficiently testing the performance parameters of signals of the crankshaft position sensor and the cam sensor, and comprises signal voltage and power supply current inspection, signal edge time inspection under various simulated rotating speed conditions, first signal rising edge phase precision of sensor electrification, first signal falling edge phase precision of sensor electrification, signal rising edge phase precision, signal falling edge phase precision, signal rising edge jitter phase precision range distribution, signal falling edge jitter phase precision range distribution and other parameters, and signal pulse width and pulse number inspection, so that the strict and accurate performance test of the engine sensor is realized, and the delivery quality is ensured.
Description
Technical Field
The invention relates to the technical field of engine sensor testing, in particular to an engine sensor testing tool, and particularly relates to a testing system comprising the engine sensor testing tool and a testing method of the testing system.
Background
With the rapid development of the automobile industry, the application of automobile sensors is increasing, wherein the engine sensors are very critical sensors in automobile engine control systems and automobile safety systems, and the engine sensors are mainly divided into a crankshaft position sensor and a camshaft position sensor according to positions, and the crankshaft position sensor and the camshaft position sensor directly determine the working performance of an engine; therefore, after the crankshaft position sensor and the camshaft sensor are produced, strict and accurate performance tests are required to be carried out so as to ensure the quality of products leaving factories.
However, the existing crankshaft position sensor and camshaft sensor tests have the following disadvantages:
1. the method that the motor drives or drives the crankshaft gear or the cam to rotate is adopted, and the measurement precision is low due to the shaking of the motor; the requirement on the rotating speed of the motor is high, so that the performance requirement of the motor is high and the price is high; meanwhile, the motor testing structure is complex and heavy, and is inconvenient to carry for field measurement; the motor drives the crankshaft gear or the camshaft gear to have a small number, so that the number of sensors for single test is small, the efficiency is low, and meanwhile, a mechanism for mechanical motion of the motor cannot meet the requirements of long-time continuous endurance test and monitoring test under various high-temperature and low-temperature severe test environments;
2. the method for detecting the signals of the crank position sensor or the cam position sensor by adopting the oscilloscope has the advantages of human factors, easy fatigue and incapability of efficiently testing performance parameters of the signals of the crank position sensor or the cam position sensor, and comprises signal voltage and power supply current inspection, signal edge time inspection under various simulation rotating speed conditions, first signal rising edge phase accuracy of sensor electrification, first signal falling edge phase accuracy of sensor electrification, signal rising edge phase accuracy, signal falling edge phase accuracy, signal rising edge jitter phase accuracy range distribution, signal falling edge jitter phase accuracy range distribution and other parameters, and signal pulse width and pulse number inspection. The signal parameters in the test process cannot be automatically monitored, recorded, judged, analyzed and the like;
3. by adopting the method of generating the periodically-changed magnetic field by the alternating current power supply, an effective rotating excitation magnetic field cannot be formed on a new generation of crank shaft position sensor or cam position sensor containing double Hall elements, and the crank shaft position sensor or the cam position sensor has no signal output, so that the parameter tests of the statistics of the initial phase difference of signal electrification, the phase difference of signal rising edge, the phase difference of signal falling edge, the jitter phase difference range of signal edge and the like cannot be performed strictly;
4. the method for detecting the mechanical geometric displacement of the crankshaft signal wheel is adopted, the mechanical geometric displacement is converted into a pulse signal, and the pulse signal is compared with a sensor pulse signal of a sensor signal receiving unit to detect, only the function of counting the crankshaft position sensor signal pulse is detected, and the performance parameter test cannot be carried out.
Disclosure of Invention
The invention aims to solve the technical problem of the prior art and provides an engine sensor testing tool which can be used for conveniently mounting a crankshaft position sensor or a cam sensor, can form a simulated rotation signal panel and can excite a new generation of crankshaft position sensor or cam sensor to output signals.
The invention aims to solve another technical problem of providing a test system and a test method of the test system, wherein the test system comprises the engine sensor test tool and can quickly and efficiently test the performance parameters of the signals of the crankshaft position sensor or the cam sensor.
The technical problem to be solved by the present invention is achieved by the following technical means. The invention relates to an engine sensor testing tool which comprises a shell and a fixing plate arranged in the shell, wherein a sensor mounting bracket convenient for mounting an engine sensor is fixedly arranged outside the shell; fixed mounting has 2 at least group's coil skeleton on the fixed plate, all is provided with the sensor mounting hole on the casing of every group coil skeleton department, and every group coil skeleton includes that 2 one end tip lean on the coil skeleton together, all overlaps on the coil skeleton to be equipped with the coil, and equal cartridge has the iron core in the coil skeleton, and one of them coil on every group coil skeleton establishes ties each other or connects in parallel and form first coil group, and another coil on every group coil skeleton establishes ties each other or connects in parallel and form second coil group.
The technical problem to be solved by the present invention can be further solved by the following technical solution, in the above-mentioned engine sensor testing tool, an input port X3 and an input port X4 are installed on the coil fixing plate, the input port X3 is connected with the first coil group, and the input port X4 is connected with the second coil group.
The technical problem to be solved by the invention can be further realized by the following technical scheme that for the engine sensor testing tool, the included angle formed between 2 coil frameworks of each group of coil frameworks is 30-60 degrees.
The technical problem to be solved by the invention can be further realized by the following technical scheme that for the engine sensor testing tool, the center position of the sensor mounting hole at each group of coil frameworks is just opposite to the vertical center line position of the end faces of 2 coil frameworks of the group of coil frameworks.
The technical problem to be solved by the invention can be further realized by the following technical scheme that for the engine sensor testing tool, the engine sensor testing system comprises the engine sensor testing tool, a computer, a two-way trackable signal generator, a two-way alternating current/direct current amplifier, a current measuring module, a signal processing module, a signal selection control module and a two-way synchronous acquisition module;
the computer is respectively connected with the double-channel trackable signal generator, the signal selection control module and the double-channel synchronous acquisition module through serial ports; two output ports of the two-way trackable signal generator are respectively connected to two input ports of the two-way alternating current-direct current amplifier, and one of the two output ports of the two-way trackable signal generator is simultaneously connected to one input end of the signal selection control module; two output ports of the two-way AC/DC amplifier are respectively connected to a first coil group and a second coil group for testing work; the multi-path input end of the current measuring module is respectively used for being connected with a sensor of the engine to be measured, and the multi-path output end of the current measuring module is connected with the multi-path input end of the signal selection control module; the multi-path input end of the signal processing module is respectively used for being connected with the engine sensor to be tested, and the multi-path output end of the signal processing module is connected with the multi-path input end of the signal selection control module; and two output ports of the signal selection control module are connected with two input ports of the double-channel synchronous acquisition module.
The technical problem to be solved by the invention can be further realized by the following technical scheme, and for the engine sensor testing system, the engine sensor testing method comprises the following steps:
(1) installation of standard part sensor and sensor to be measured
Selecting a sensor mounting bracket matched with a standard sensor and a sensor to be measured, fixedly mounting the sensor mounting bracket on the upper part of a shell, then fixedly mounting the standard sensor in a sensor mounting hole of the sensor mounting bracket, and enabling the front surface of the head of the sensor to be opposite to the end surfaces of iron cores in two corresponding framework coils, so that the head of the sensor is close to the end surfaces of the iron cores and is within 3mm of the end surfaces of the iron cores;
fixedly mounting a sensor to be measured in another sensor mounting hole of the sensor mounting bracket to enable the front surface of the head of the sensor to be opposite to the end surfaces of the iron cores in the two corresponding framework coils;
(2) determination of calibration values
In a computer, setting the model, parameters and working conditions of a standard component sensor;
one output channel of the computer-controlled double-channel trackable signal generator outputs a sine wave or square wave signal with certain direct current bias, the other output channel is controlled to carry out follow-up output on the bias, voltage, waveform and frequency parameters, and the phase difference of the output channel and the output signal of the first channel is 90 degrees or 270 degrees, so that two output signals with the mutual difference of 90 degrees are output; the two paths of output signals are sent to the input of a two-path AC/DC amplifier, the two-path AC/DC amplifier amplifies two paths of signals of a two-path trackable signal generator to generate two paths of AC/DC amplified signals, the two paths of AC/DC amplified signals are sent to input ports X3 and X4 of two groups of coils in a testing tool, the two groups of coils respectively generate an alternating magnetic field with a certain DC component in the space of the end face of each group of iron cores, and the DC component of the magnetic field meets the testing requirement of a sensor with back magnetism; because two paths of electric signals have a 90-degree difference in time and are alternating, and meanwhile, each group of iron cores are crossed, a magnetic field simulating a rotating signal panel is formed in the end face space of each group of iron cores, and the magnetic field excites a new generation of standard part sensor containing double Hall elements to output signals;
the computer controls the signal selection control module through the communication port, so that a signal transmitted by one path of output of the two-path trackable signal generator is transmitted to one path of output end of the signal selection control module through one path of input end of the signal selection control module under the control of the signal selection control module and then is sent to one path of input end of the two-path synchronous acquisition module; simultaneously, the computer controls the signal selection control module through the communication port, so that the current signal of the standard component sensor transmitted by the output of the current measurement module and the output signal of the standard component sensor transmitted by the output of the signal processing module are sequentially converted and transmitted to the other output end of the signal selection control module by the multi-path input end of the signal selection control module according to the computer command through the control of the signal selection control module, and then are sent to the other input end of the dual-channel synchronous acquisition module;
the two-channel synchronous acquisition module is controlled by a computer to perform two-channel synchronous acquisition and transmit acquired data to the computer;
the computer analyzes and processes the acquired data to realize the calibration of the signal test value of the standard component sensor;
(3) testing of a sensor to be tested
In a computer, calling the calibration value stored in the step (2) through software, selecting or setting the model and the parameters of the sensor to be tested, enabling the model and the parameters of the sensor to be tested to be consistent with those of the standard sensor in the step (2), and simultaneously setting working conditions;
the computer controls one output channel of the dual-path trackable signal generator to output a sine wave or square wave signal with certain direct current bias, controls the other output channel to carry out follow-up output on direct current bias, voltage, waveform and frequency parameters, and simultaneously has a phase difference of 90 degrees or 270 degrees with the output signal of the first channel; the two paths of output signals are sent to the input of a two-path AC/DC amplifier, the two-path AC/DC amplifier amplifies two paths of signals of a two-path trackable signal generator to generate two paths of AC/DC amplified signals, the two paths of AC/DC amplified signals are sent to two groups of coils in a testing tool, the two groups of coils respectively generate an alternating magnetic field with a certain DC component in each group of iron cores, and the DC component of the magnetic field meets the testing requirement of a sensor with back magnetism; because two paths of electric signals have a 90-degree difference in time and are alternating, and meanwhile, each group of iron cores are crossed, a magnetic field simulating a rotating signal panel is formed on the end face of each group of iron cores, and the magnetic field excites a new generation of sensor to be detected containing double Hall elements to output signals;
the computer controls the signal selection control module through the communication port, so that a signal transmitted by one path of output of the two-path trackable signal generator is transmitted to one path of output end of the signal selection control module through one path of input end of the signal selection control module under the control of the signal selection control module and then is sent to one path of input end of the two-path synchronous acquisition module; simultaneously, the computer controls the signal selection control module through the communication port, so that the signals of the two to-be-detected sensors transmitted by the output of the current measurement module and the signals of the two to-be-detected sensors transmitted by the output of the signal processing module are sequentially converted and transmitted to the other output end of the signal selection control module by the multi-path input end of the signal selection control module according to computer commands through the control of the signal selection control module, and then are sent to the other input end of the dual-path synchronous acquisition module;
the two-channel synchronous acquisition module is controlled by a computer to perform two-channel synchronous acquisition and transmit acquired data to the computer;
and the computer analyzes and processes the data to realize the automatic test of the crankshaft position sensor and/or the camshaft sensor.
The technical problem to be solved by the invention can be further realized by the following technical scheme that in the step (2), the dual-channel synchronous acquisition module carries out two-channel synchronous acquisition under the control of a computer, and one output of the dual-channel trackable signal generator is used as a synchronous trigger signal to control the dual-channel synchronous acquisition module to realize synchronous acquisition.
The technical problem to be solved by the present invention can be further solved by the following technical solution, for the above-mentioned engine sensor testing method, in the step (2), the computer calibrates the signal testing value of the standard sensor, and calculates the signal parameters of the standard sensor collected by using the signal of the signal generator as the reference edge, including the signal edge time under various simulated rotation speed conditions, the phase precision of the first signal rising edge electrified by the sensor, the phase precision of the first signal falling edge electrified by the sensor, the phase precision of the signal rising edge, the phase precision of the signal falling edge, the phase precision range distribution of the signal rising edge jitter, the phase precision range distribution of the signal falling edge jitter, and other parameters, the signal pulse width and the pulse number check, and then normalizes the analysis and calculation result to obtain the normalization relationship, meanwhile, the normalization processing result is used as a calibration value and stored for later test calling and comparison.
The technical problem to be solved by the invention can be further realized by the following technical scheme that in the step (2), the dual-channel synchronous acquisition module performs two-channel synchronous acquisition under the control of a computer, and one output of the dual-channel trackable signal generator is used as a synchronous trigger signal to control the dual-channel synchronous acquisition module to realize synchronous acquisition.
The technical problem to be solved by the present invention can be further solved by the following technical solution, for the above-mentioned engine sensor testing method, in step (3), the computer analyzes and processes the data, and calculates the signal parameters of the acquired sensor to be tested by using the signal of one output Y1 of the two-path trackable signal generator as a reference edge, including the inspection of parameters such as signal edge time under various simulated rotation speeds, the phase precision of the first signal rising edge electrified by the sensor, the phase precision of the first signal falling edge electrified by the sensor, the phase precision of the signal rising edge, the phase precision of the signal falling edge, the phase precision range distribution of the signal rising edge jitter, the phase precision range distribution of the signal falling edge jitter, and the signal pulse width and number; and (3) further normalizing the detection result of the sensor to be detected by adopting the normalization relation obtained in the step (2), and comparing the normalization processing result with the calibration value stored in the step (2) to finish the test, automatic recording, judgment and analysis of the crankshaft position sensor and/or the camshaft sensor.
Compared with the prior art, the engine sensor testing tool can be used for conveniently mounting a crankshaft position sensor or a cam sensor, can form a simulated rotating signal disc magnetic field signal, replaces the traditional motor driving gear mode, has the advantages of light weight, small volume, low cost, convenience in carrying and field testing, can eliminate the error influence caused by mechanical vibration of a motor motion mode, and is high in measurement precision and high in testing efficiency;
the engine sensor testing system comprises an engine sensor testing tool, and can quickly and efficiently complete the durability aging tests of the reliability, the quality stability and the like of the crankshaft position sensor or the cam sensor; the signal selection control module can be used for collecting and testing electrical parameters of a reference signal and various output signals of a crankshaft position sensor or a cam sensor, so that the cost is effectively reduced; the system can quickly and efficiently test performance parameters of signals of a crankshaft position sensor or a cam sensor, and comprises signal voltage and power supply current inspection, signal edge time inspection under various simulated rotating speed conditions, first signal rising edge phase accuracy of sensor electrification, first signal falling edge phase accuracy of sensor electrification, signal rising edge phase accuracy, signal falling edge phase accuracy, signal rising edge jitter phase accuracy range distribution, signal falling edge jitter phase accuracy range distribution and other parameters, signal pulse width and pulse number inspection, and can quickly and efficiently automatically record, judge, analyze and the like the signal parameters in the testing process.
Drawings
FIG. 1 is a block diagram schematically illustrating an arrangement of the present invention;
fig. 2 is a schematic structural diagram of the test fixture of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings of the present invention, and it is obvious that the described embodiments are some embodiments of the present invention, but not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
the shell 61 is made of a rectangular structure and a metal material, two round holes or square holes are formed in the upper surface of the shell 61, the size of each hole is larger than the diameter of the head of the sensor, and connecting terminal holes matched with the input port X3 and the input port X4 are formed in the side surface of the shell 61;
the fixing plate 62 is arranged in the housing 61 and fixed in the housing 61 through screws, and the coil frameworks 641 and 642 and 681 and 682 are fixedly installed on the fixing plate 62;
the sensor mounting bracket 63 is made of an aluminum alloy material, the sensor mounting bracket 63 is fixedly mounted on the shell 61 through screws, so that the sensor mounting bracket is convenient to disassemble and assemble, and the sensor mounting bracket 63 is a replaceable part matched with the standard part sensor 4 and the sensor 5 to be measured; two sensor mounting holes are formed in the sensor mounting bracket 63, the diameters of the sensor mounting holes are the same as the diameters of the heads of the standard part sensor 4 and the sensor 5 to be measured, the center of each sensor mounting hole is consistent with the center of the hole in the shell 61, and meanwhile, the center of each mounting hole is over against the vertical center line of the end faces of the two crossed iron cores in the coil skeleton group; the sensor mounting bracket 63 is provided with screw holes for mounting the standard sensor 4 and the sensor 5 to be measured, and the positions of the screw holes are determined by the shape and the size of the sensors; the thickness of the sensor mounting bracket 63 is determined by the lengths of the heads of the standard sensor 4 and the to-be-measured sensor 5, so that after the sensor is mounted on the sensor mounting bracket 63, the distance between the head of the sensor and the end surfaces of the iron cores 641 and 642 and 671 and 672 is preferably 0-3 mm;
the coil frameworks 641 and 642 and 681 and 682 are hollow frameworks which are made of non-magnetic and high-temperature resistant materials, and the hollow hole structure is rectangular; every two coil frameworks form a group; in the direction towards the sensor mounting bracket 63, the heads of the two coil frameworks are close to each other, and meanwhile, the two coil frameworks are crossed to form a certain angle of 30-60 degrees, and the two groups of frameworks have the same placement structure;
the iron cores 641-642 and 671-672 of the invention adopt high magnetic permeability materials, such as silicon steel sheets and the like; the iron cores 641-642 and 671-672 are fixedly sleeved in the coil frameworks 641-642 and 681-682 respectively, and the lengths of the iron cores 641-642 and 671-672 are the same as those of the coil frameworks 641-642 and 681-682;
the coils 661, 662, 691, 692 are respectively wound on coil frameworks 641-; the coil on the other coil skeleton is connected with the coil on the other coil skeleton corresponding to the other coil skeleton in parallel or in series, and the other coil skeleton forms the other group of coils after connection, and simultaneously forms the other input port X4 to be connected to an external circuit; the specific connection mode of the coil is determined by the requirement of an external circuit;
the standard part sensor 4 is a standard crankshaft position sensor and/or a camshaft sensor, and the to-be-detected part sensor 5 is a to-be-detected crankshaft position sensor and/or a to-be-detected camshaft sensor. The standard part sensor 4 and the sensor 5 to be measured are a new generation of crankshaft position sensor and/or camshaft sensor containing double Hall elements and are fixedly arranged in holes of the sensor mounting bracket 63 through screws.
Embodiment 2, an engine sensor test system, as shown in fig. 1, includes a computer 1, a two-way trackable signal generator 2, a two-way ac/dc amplifier 3, a standard part sensor 4, a sensor 5 to be tested, a test fixture 6 in embodiment 1, a current measurement module 7, a signal processing module 8, a signal selection control module 9, and a two-way synchronous acquisition module 10;
the computer 1 is respectively connected with the double-channel trackable signal generator 2, the signal selection control module 9 and the double-channel synchronous acquisition module 10 through serial ports;
the double-path trackable signal generator 2 is a double-path signal generator, can output two paths of sine waves, square waves, programmable arbitrary wave signals and direct current bias voltage, and has the functions of voltage tracking, waveform tracking, frequency tracking, phase tracking and arbitrary parameter adjustment; two output ports Y1 and Y2 of the two-way trackable signal generator 2 are respectively connected to two input ports X1 and X2 of the two-way AC/DC amplifier 3, and one port Y1 of the two output ports of the two-way trackable signal generator 2 is simultaneously connected to one input end S0 of the signal selection control module 9;
the dual-path AC/DC amplifier 3 can amplify AC signals and DC signals at the same time, two input ports X1 and X2 of the dual-path AC/DC amplifier 3 are respectively connected to output ports Y1 and Y2 of the dual-path trackable signal generator 2, and two output ports Y3 and Y4 of the dual-path AC/DC amplifier 3 are respectively connected to an input port X3 and an input port X4 of a crankshaft position sensor and/or camshaft sensor test tool 6;
the standard part sensor 4 and the sensor 5 to be tested are arranged on the testing tool 6, the standard part sensor 4 is a crankshaft position sensor or a camshaft sensor, and the sensor 5 to be tested is a crankshaft position sensor or a camshaft sensor; the standard part sensor 4 and the to-be-measured part sensor 5 are a new generation of crankshaft position sensor and/or camshaft sensor containing double Hall elements;
two input ports X3 and X4 of the test tool 6 are connected to two output ports Y3 and Y4 of the two-way alternating current and direct current amplifier 3;
the current measuring module 7 is an alternating current-direct current voltage conversion circuit, the current measuring module 7 comprises two inputs and two outputs, and the two inputs of the current measuring module 7 are respectively connected in series with the power supply ends of the standard sensor 4 and the sensor 5 to be measured; two-way output ends of the current measuring module 7 are connected to the multi-way input ends SI1 and SI2 of the signal selection control module 9.
The signal processing module 8 is an output signal pull-up resistor circuit and an output signal capacitor filter circuit of the standard sensor 4 and the sensor 5 to be tested, and the signal processing module 8 comprises two input ends and two output ends; two input ends of the signal processing module 8 are respectively connected with the corresponding standard part sensor 4 and the corresponding sensor 5 to be measured, and two output ends of the signal processing module 8 are connected with the multi-input ends SS1 and SS2 of the signal selection control module 9;
the signal selection control module 9 is a multi-channel selection switch circuit controlled by the computer 1, and includes a multi-channel input port S0, SI1, SI2, SS1, SS2, two-channel output ports Y5, Y6, and a communication port. The multi-path input ports SI1 and SI2 of the signal selection control module 9 are connected with the two paths of outputs of the current measuring module 7; the multiple input ports SS1 and SS2 of the signal selection control module 9 are connected with the two outputs of the signal processing module 8. Meanwhile, one port S0 of the multi-path input port of the signal selection control module 9 is connected with one path output port Y1 of the two-path trackable signal generator 2, and two paths of output ports Y5 and Y6 of the signal selection control module 9 are connected with two paths of input ports X5 and X6 of the two-path synchronous acquisition module 10;
the communication port of the signal selection control module 9 is connected with the computer 1, the computer 1 controls the signal selection control module 9 through the communication port, a signal led out from one output Y1 of the dual-path trackable signal generator 2 is converted into one output port Y5 of the signal selection control module 9 to be output through one input S0 of the signal selection control module 9, and then the signal is transmitted to one input X5 of the dual-path synchronous acquisition module 10;
simultaneously, the computer 1 controls the signal selection control module 9 to convert two output end signals of the current measurement module 77 and two output end signals of the signal processing module 8 into another output end Y6 of the signal selection control module 9 in sequence according to instructions of the computer 1 from the multiple input ports SI1, SI2, SS1 and SS2 of the signal selection control module 9 respectively, and then transmits the other input end X6 of the dual-channel synchronous acquisition module 10;
the dual-channel synchronous acquisition module 10 is an analog acquisition card with two analog signal input channels and a synchronous acquisition function; the output end of the dual-channel synchronous acquisition module 10 is connected to the computer 1 through a serial port, the analog signal input ends X5 and X6 of the dual-channel synchronous acquisition module 10 are connected with the output ports Y5 and Y6 of the signal selection control module 9, and the computer 11 controls the dual-channel synchronous acquisition module 10 through the serial port to synchronously acquire and transmit two paths of signals Y5 and Y6 at the output end of the signal selection control module 9 to the computer 1 for processing.
Embodiment 3, an engine sensor testing method using the engine sensor testing system of embodiment 2, comprising the steps of:
(1) mounting of standard part sensor 4 and to-be-tested part sensor 5
Selecting a sensor mounting bracket 63 matched with the standard sensor 4 and the sensor 5 to be measured, and fixedly mounting the sensor mounting bracket 63 on the upper part of the shell 61;
the standard component sensor 4 is fixedly arranged in a sensor mounting hole of the sensor mounting bracket 63 through a screw, so that the front surface of the head of the sensor is opposite to the end surfaces of the two corresponding crossed iron cores, and the head of the sensor is close to the end surfaces of the iron cores within 3 mm;
fixedly mounting the sensor 5 to be measured in the other sensor mounting hole of the sensor mounting bracket 63 through a screw, so that the front surface of the head of the sensor is opposite to the end surfaces of the two corresponding crossed iron cores;
(2) determination of calibration values
In the computer 1, the model, parameters, working conditions and the like of the standard component sensor 4 are set through software, and the software is operated;
the computer 1 controls one output channel Y1 of the two-way trackable signal generator 2 to output sine wave or square wave signals with certain direct current bias, controls the other output channel Y2 to follow and output on the bias, voltage, waveform and frequency parameters, and simultaneously has a phase difference of 90 degrees or 270 degrees with the output signal of the first channel Y1, thus outputting two output signals with a mutual difference of 90 degrees; the two paths of output signals Y1 and Y2 are sent to input X1 and X2 of a two-path alternating current and direct current amplifier 3, the two-path alternating current and direct current amplifier 3 amplifies two paths of input X1 and X2 signals of a two-path trackable signal generator 2 to generate two paths of alternating current and direct current amplified signals Y3 and Y4, the two paths of alternating current and direct current amplified signals are sent to an input port X3 of a coil and an input port X4 of the coil in a testing tool 6, two groups of coils respectively generate an alternating magnetic field with a certain direct current component in the end face space of each group of iron cores, and the direct current component of the magnetic field meets the testing requirement of a sensor with; because two paths of electric signals have a 90-degree difference in time, are alternating, and simultaneously, each group of iron cores are crossed, a magnetic field simulating a rotating signal panel is formed in the end face space of each group of iron cores, and the magnetic field excites a new generation of standard part sensor 4 containing double Hall elements to output signals;
the computer 1 controls the signal selection control module 9 through the communication port, so that a signal transmitted by one path of output Y1 of the dual-path trackable signal generator 2 is transmitted to one path of output Y5 of the signal selection control module 9 through one path of input end S0 of the signal selection control module 9 under the control of the signal selection control module 9, and then is sent to one path of input X5 of the dual-path synchronous acquisition module 10; meanwhile, the computer 1 controls the signal selection control module 9 through the communication port, so that the current signal of the standard part sensor 4 transmitted by the output of the current measurement module 7 and the output signal of the standard part sensor 4 transmitted by the output of the signal processing module 8 are sequentially converted and transmitted to the other output end Y6 of the signal selection control module 9 through the multi-path input ends SI1 and SS1 of the signal selection control module 9 according to the command of the computer 1 and then are sent to the other input end X6 of the dual-channel synchronous acquisition module 10 under the control of the signal selection control module 9;
the dual-channel synchronous acquisition module 10 is controlled by the computer 1 to perform two-channel synchronous acquisition and transmit acquired data to the computer 1;
the computer 1 analyzes and processes the acquired data to realize the calibration of the signal test value of the standard component sensor 4;
preferably, the dual-channel synchronous acquisition module 10 performs two-channel synchronous acquisition under the control of the computer 1, and controls the dual-channel synchronous acquisition module 10 to realize synchronous acquisition by using one output Y1 of the dual-channel trackable signal generator 2 as a synchronous trigger signal;
preferably, the computer 1 calibrates the signal test value of the standard component sensor 4, and uses the collected signal of one output Y1 of the two-way trackable signal generator 2 as a reference edge; calculating the collected signal parameters of the standard component sensor 4, including signal edge time under various simulated rotation speed conditions, first signal rising edge phase precision of sensor electrification, first signal falling edge phase precision of sensor electrification, signal rising edge phase precision, signal falling edge phase precision, phase precision range distribution of signal rising edge jitter, phase precision range distribution of signal falling edge jitter and the like, and checking signal pulse width and pulse number, then normalizing the analysis and calculation result to obtain a normalization relation, and simultaneously using the normalization processing result as a calibration value for storage for later test, calling and comparison;
(3) testing of a sensor 5 to be tested
In the computer 1, the calibration value saved in the step (2) is called through software, the model and the parameters of the sensor 5 to be measured are selected or set, the model and the parameters of the sensor 5 to be measured are made to be consistent with those of the standard sensor 4 in the step (2), meanwhile, working conditions are set, and the like, and the software is operated.
The computer 1 controls one output channel Y1 of the dual-path trackable signal generator 2 to output a sine wave or square wave signal with certain direct current bias, controls the other output channel Y2 to follow and output the sine wave or square wave signal on direct current bias, voltage, waveform and frequency parameters, and simultaneously has a phase difference of 90 degrees or 270 degrees with the output Y1 signal of the first channel; the two paths of Y1 and Y2 output signals are sent to input X1 and X2 of a two-path AC/DC amplifier 3, the two-path AC/DC amplifier 3 amplifies the two paths of signals of a two-path trackable signal generator 2 to generate two paths of AC/DC amplified output Y3 and Y4 signals, the two paths of AC/DC amplified signals Y3 and Y4 are sent to an input port X3 of a coil 6 and input ports X4 of coils 661, 662, 691 and 692 in a testing tool 6, two groups of coils respectively generate an alternating magnetic field with a certain DC component in each group of iron cores, and the DC component of the magnetic field meets the testing requirement of a sensor with back magnetism; because two paths of electric signals have a 90-degree difference in time and are alternating, and meanwhile, each group of iron cores are crossed, a magnetic field simulating a rotating signal panel is formed on the end surface of each group of iron cores, and the magnetic field excites a new generation of sensor 5 to be detected containing double Hall elements to output signals;
the computer 1 controls the signal selection control module 9 through the communication port, so that a signal transmitted by one path of output Y1 of the dual-path trackable signal generator 2 is transmitted to one path of output Y5 of the signal selection control module 9 through one path of input end S0 of the signal selection control module 9 under the control of the signal selection control module 9, and then is sent to one path of input X5 of the dual-path synchronous acquisition module 10; simultaneously, the computer 1 controls the signal selection control module 9 through the communication port, so that the signal of the sensor 5 to be measured transmitted from the output of the current measurement module 7 and the signal of the sensor 5 to be measured transmitted from the output of the signal processing module 8 are transmitted to the other output end Y6 of the signal selection control module 9 through the multi-path input ends SI2 and SS2 of the signal selection control module 9 according to the sequential conversion of the commands of the computer 1 and then are sent to the other input X6 of the dual-channel synchronous acquisition module 10 under the control of the signal selection control module 9;
the dual-channel synchronous acquisition module 10 is controlled by the computer 1 to perform two-channel synchronous acquisition and transmit acquired data to the computer 1;
and the computer 1 analyzes and processes the data to realize the test of the crankshaft position sensor and/or the camshaft sensor.
Preferably, the dual-channel synchronous acquisition module 10 performs two-channel synchronous acquisition under the control of the computer 1, and uses one output Y1 of the dual-channel trackable signal generator 2 as a synchronous trigger signal to control the dual-channel synchronous acquisition module 10 to realize synchronous acquisition.
Preferably, the computer 1 analyzes and processes the data, and calculates the signal parameters of the sensor 5 to be detected, which include the signal edge time under various simulated rotation speeds, the first signal rising edge phase precision of the sensor electrification, the first signal falling edge phase precision of the sensor electrification, the signal rising edge phase precision, the signal falling edge phase precision, the phase precision range distribution of the signal rising edge jitter, the phase precision range distribution of the signal falling edge jitter, and other parameters, the signal pulse width and the pulse number check, by taking the one-way output Y1 signal of the two-way trackable signal generator 2 as a reference edge; and normalizing the calculation result, and storing the processing result as a calibration value for later test calling and comparison.
And (3) further normalizing by adopting the normalization relation obtained in the step (2), and comparing the normalization processing result with the calibration value stored in the step (2) to finish the test, automatic recording, judgment, analysis and the like of the crankshaft position sensor and/or the camshaft sensor.
Claims (10)
1. The utility model provides an engine sensor test fixture which characterized in that: the tool comprises a shell and a fixing plate arranged in the shell, wherein a sensor mounting bracket convenient for mounting an engine sensor is fixedly arranged outside the shell; fixed mounting has 2 at least group's coil skeleton on the fixed plate, all is provided with the sensor mounting hole on the casing of every group coil skeleton department, and every group coil skeleton includes that 2 one end tip lean on the coil skeleton together, all overlaps on the coil skeleton to be equipped with the coil, and equal cartridge has the iron core in the coil skeleton, and one of them coil on every group coil skeleton establishes ties each other or connects in parallel and form first coil group, and another coil on every group coil skeleton establishes ties each other or connects in parallel and form second coil group.
2. The engine sensor test tool of claim 1, wherein: an input port X3 and an input port X4 are attached to the coil fixing plate, the input port X3 is connected to the first coil group, and the input port X4 is connected to the second coil group.
3. The engine sensor test tool of claim 1, wherein: the included angle formed between 2 coil skeletons of each group of coil skeletons is 30-60 degrees.
4. The engine sensor test tool of claim 1, wherein: the center position of the sensor mounting hole at each group of coil frameworks is just opposite to the vertical center line position of the end faces of 2 coil frameworks of the group of coil frameworks.
5. An engine sensor testing system characterized by: the system comprises the engine sensor testing tool set forth in any one of claims 1-4, and further comprises a computer, a two-way trackable signal generator, a two-way AC/DC amplifier, a current measuring module, a signal processing module, a signal selection control module and a two-way synchronous acquisition module;
the computer is respectively connected with the double-channel trackable signal generator, the signal selection control module and the double-channel synchronous acquisition module through serial ports; two output ports of the two-way trackable signal generator are respectively connected to two input ports of the two-way alternating current-direct current amplifier, and one of the two output ports of the two-way trackable signal generator is simultaneously connected to one input end of the signal selection control module; two output ports of the two-way AC/DC amplifier are respectively connected to a first coil group and a second coil group for testing work; the multi-path input end of the current measuring module is respectively used for being connected with a sensor of the engine to be measured, and the multi-path output end of the current measuring module is connected with the multi-path input end of the signal selection control module; the multi-path input end of the signal processing module is respectively used for being connected with the engine sensor to be tested, and the multi-path output end of the signal processing module is connected with the multi-path input end of the signal selection control module; and two output ports of the signal selection control module are connected with two input ports of the double-channel synchronous acquisition module.
6. An engine sensor testing method is characterized in that: the method uses the engine sensor testing system of claim 5, and comprises the steps of:
(1) installation of standard part sensor and sensor to be measured
Selecting a sensor mounting bracket matched with a standard sensor and a sensor to be measured, fixedly mounting the sensor mounting bracket on the upper part of a shell, then fixedly mounting the standard sensor in a sensor mounting hole of the sensor mounting bracket, and enabling the front surface of the head of the sensor to be opposite to the end surfaces of iron cores in two corresponding framework coils, so that the head of the sensor is close to the end surfaces of the iron cores and is within 3mm of the end surfaces of the iron cores;
fixedly mounting a sensor to be measured in another sensor mounting hole of the sensor mounting bracket to enable the front surface of the head of the sensor to be opposite to the end surfaces of the iron cores in the two corresponding framework coils;
(2) determination of calibration values
In a computer, setting the model, parameters and working conditions of a standard component sensor;
one output channel of the computer-controlled double-channel trackable signal generator outputs a sine wave or square wave signal with certain direct current bias, the other output channel is controlled to carry out follow-up output on the bias, voltage, waveform and frequency parameters, and the phase difference of the output channel and the output signal of the first channel is 90 degrees or 270 degrees, so that two output signals with the mutual difference of 90 degrees are output; the two paths of output signals are sent to the input of a two-path AC/DC amplifier, the two-path AC/DC amplifier amplifies two paths of signals of a two-path trackable signal generator to generate two paths of AC/DC amplified signals, the two paths of AC/DC amplified signals are sent to input ports X3 and X4 of two groups of coils in a testing tool, the two groups of coils respectively generate an alternating magnetic field with a certain DC component in the space of the end face of each group of iron cores, and the DC component of the magnetic field meets the testing requirement of a sensor with back magnetism; because two paths of electric signals have a 90-degree difference in time and are alternating, and meanwhile, each group of iron cores are crossed, a magnetic field simulating a rotating signal panel is formed in the end face space of each group of iron cores, and the magnetic field excites a new generation of standard part sensor containing double Hall elements to output signals;
the computer controls the signal selection control module through the communication port, so that a signal transmitted by one path of output of the two-path trackable signal generator is transmitted to one path of output end of the signal selection control module through one path of input end of the signal selection control module under the control of the signal selection control module and then is sent to one path of input end of the two-path synchronous acquisition module; simultaneously, the computer controls the signal selection control module through the communication port, so that the current signal of the standard component sensor transmitted by the output of the current measurement module and the output signal of the standard component sensor transmitted by the output of the signal processing module are sequentially converted and transmitted to the other output end of the signal selection control module by the multi-path input end of the signal selection control module according to the computer command through the control of the signal selection control module, and then are sent to the other input end of the dual-channel synchronous acquisition module;
the two-channel synchronous acquisition module is controlled by a computer to perform two-channel synchronous acquisition and transmit acquired data to the computer;
the computer analyzes and processes the acquired data to realize the calibration of the signal test value of the standard component sensor;
(3) testing of a sensor to be tested
In a computer, calling the calibration value stored in the step (2) through software, selecting or setting the model and the parameters of the sensor to be tested, enabling the model and the parameters of the sensor to be tested to be consistent with those of the standard sensor in the step (2), and simultaneously setting working conditions;
the computer controls one output channel of the dual-path trackable signal generator to output a sine wave or square wave signal with certain direct current bias, controls the other output channel to carry out follow-up output on direct current bias, voltage, waveform and frequency parameters, and simultaneously has a phase difference of 90 degrees or 270 degrees with the output signal of the first channel; the two paths of output signals are sent to the input of a two-path AC/DC amplifier, the two-path AC/DC amplifier amplifies two paths of signals of a two-path trackable signal generator to generate two paths of AC/DC amplified signals, the two paths of AC/DC amplified signals are sent to two groups of coils in a testing tool, the two groups of coils respectively generate an alternating magnetic field with a certain DC component in each group of iron cores, and the DC component of the magnetic field meets the testing requirement of a sensor with back magnetism; because two paths of electric signals have a 90-degree difference in time and are alternating, and meanwhile, each group of iron cores are crossed, a magnetic field simulating a rotating signal panel is formed on the end face of each group of iron cores, and the magnetic field excites a new generation of sensor to be detected containing double Hall elements to output signals;
the computer controls the signal selection control module through the communication port, so that a signal transmitted by one path of output of the two-path trackable signal generator is transmitted to one path of output end of the signal selection control module through one path of input end of the signal selection control module under the control of the signal selection control module and then is sent to one path of input end of the two-path synchronous acquisition module; simultaneously, the computer controls the signal selection control module through the communication port, so that the signals of the two to-be-detected sensors transmitted by the output of the current measurement module and the signals of the two to-be-detected sensors transmitted by the output of the signal processing module are sequentially converted and transmitted to the other output end of the signal selection control module by the multi-path input end of the signal selection control module according to computer commands through the control of the signal selection control module, and then are sent to the other input end of the dual-path synchronous acquisition module;
the two-channel synchronous acquisition module is controlled by a computer to perform two-channel synchronous acquisition and transmit acquired data to the computer;
and the computer analyzes and processes the data to realize the automatic test of the crankshaft position sensor and/or the camshaft sensor.
7. The engine sensor testing method according to claim 6, characterized in that: in the step (2), the dual-channel synchronous acquisition module performs two-channel synchronous acquisition under the control of a computer, and controls the dual-channel synchronous acquisition module to realize synchronous acquisition by using one output of the dual-channel trackable signal generator as a synchronous trigger signal.
8. The engine sensor testing method according to claim 6, characterized in that: in the step (2), the computer calibrates the signal test value of the standard component sensor, and calculates the signal parameters of the standard component sensor, including the signal edge time under various simulated rotation speeds, the first signal rising edge phase precision of the sensor power-on, the first signal falling edge phase precision of the sensor power-on, the signal rising edge phase precision, the signal falling edge phase precision, the phase precision range distribution of the signal rising edge jitter, the phase precision range distribution of the signal falling edge jitter, and other parameters, and the signal pulse width and pulse number check, with the signal of the collected signal generator as the reference edge, and then normalizes the analysis calculation result to obtain the normalization relation, and the normalization processing result is used as the calibration value to be stored for the following test calling comparison.
9. The engine sensor testing method according to claim 6, characterized in that: in the step (2), the dual-channel synchronous acquisition module performs two-channel synchronous acquisition under the control of a computer, and controls the dual-channel synchronous acquisition module to realize synchronous acquisition by using one output of the dual-channel trackable signal generator as a synchronous trigger signal.
10. The engine sensor testing method according to claim 8, characterized in that: in the step (3), the computer analyzes and processes the data, and uses one path of signal output Y1 of the two paths of collected trackable signal generators as a reference edge to calculate the collected signal parameters of the sensor to be detected, including the signal edge time under various simulated rotating speed conditions, the first signal rising edge phase precision of the sensor electrification, the first signal falling edge phase precision of the sensor electrification, the signal rising edge phase precision, the signal falling edge phase precision, the phase precision range distribution of the signal rising edge jitter, the phase precision range distribution of the signal falling edge jitter and other parameters, and the signal pulse width and pulse number check; and (3) further normalizing the detection result of the sensor to be detected by adopting the normalization relation obtained in the step (2), and comparing the normalization processing result with the calibration value stored in the step (2) to finish the test, automatic recording, judgment and analysis of the crankshaft position sensor and/or the camshaft sensor.
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