CN114659792B - Belt tension control method and control system - Google Patents
Belt tension control method and control system Download PDFInfo
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- CN114659792B CN114659792B CN202210267800.4A CN202210267800A CN114659792B CN 114659792 B CN114659792 B CN 114659792B CN 202210267800 A CN202210267800 A CN 202210267800A CN 114659792 B CN114659792 B CN 114659792B
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M15/00—Testing of engines
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L5/00—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes
- G01L5/04—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes for measuring tension in flexible members, e.g. ropes, cables, wires, threads, belts or bands
Abstract
The application relates to the technical field of engines, and provides a control method and a control system for belt tension, wherein the control method comprises the following steps: stretching the initial tension value to perform a thermal test of fixed load and fixed rotation speed on the initial tension value, and determining that the initial tension value is an initial process tension value under the condition that the initial stable tension value of the initial tension value meets a first preset condition; and initially tensioning the retest belt by taking the initial tension value as the retest initial tension value, adjusting the retest initial tension value until the retest stable tension value of the retest belt meets a second preset condition, and determining the retest initial tension value as the installation tension value. The control method and the control system can continuously optimize the installation tension value, increase the success rate of the subsequent belt installation, accelerate the production beat and improve the working efficiency.
Description
Technical Field
The application relates to the technical field of engines, in particular to a belt tension control method and a belt tension control system.
Background
In the related art, the belt tension of the fixed front end wheel system of the engine is the tension generated by the elongation of the belt, and when each belt is pulled to the target tension, the belt cannot completely fall into the wedge groove of the belt pulley in the initial stage, so that the deviation between the actual stable tension value and the target tension value after the actual operation of the belt is larger, and the operation of the belt is influenced.
Disclosure of Invention
Accordingly, it is desirable to provide a method and a system for controlling belt tension.
In order to achieve the above object, the technical solution of the embodiment of the present application is as follows:
the embodiment of the application discloses a control method of belt tension, which is used for fixing a front-end gear train and comprises the following steps:
stretching an initial tension value to stretch the initial test belt, carrying out a thermal test of fixed load and fixed rotating speed on the initial test belt, and determining that the initial tension value is an initial test process tension value under the condition that an initial test stable tension value of the initial test belt meets a first preset condition;
and primarily tensioning the retest belt by taking the initial test process tension value as a retest initial tension value, adjusting the retest initial tension value until the retest stable tension value of the retest belt meets a second preset condition, and determining the retest initial tension value as an installation tension value.
In one embodiment, the number of retry belts is no greater than the number of initial test belts.
In an embodiment, the preliminary test process tension value is used as a preliminary test initial tension value to preliminarily tension the preliminary test belt, the preliminary test initial tension value is adjusted until the preliminary test stable tension value of the preliminary test belt meets a second preset condition, and the preliminary test initial tension value is determined to be an installation tension value, including:
selecting a part from the multiple retest belts as a first retest belt, and primarily stretching the first retest belt by taking the initial test process tension value as a retest initial tension value;
and carrying out thermal test on the first retest belt at a fixed load and a fixed rotating speed, determining that the retest stable tension value of the first retest belt meets the second preset condition, and determining that the retest initial tension value is the installation tension value, wherein the number of the first retest belts is 3% -7% of the number of the initial test belts.
In an embodiment, the preliminary test process tension value is used as a preliminary test initial tension value to preliminarily tension the preliminary test belt, the preliminary test initial tension value is adjusted until the preliminary test stable tension value of the preliminary test belt meets a second preset condition, and the preliminary test initial tension value is determined to be an installation tension value, including:
under the condition that the retest stable tension value of the first retest belt does not meet the second preset condition, selecting a part from the retest belt according to a preset proportion as an additional retest belt, and adjusting the retest initial tension value as an additional retest initial tension value to primarily tension the additional retest belt;
and carrying out thermal test on the additional retest belt at a fixed load and a fixed rotating speed, determining that the retest stable tension value of the additional retest belt meets the second preset condition, and determining that the additional retest initial tension value is an installation tension value.
In one embodiment, the predetermined proportion is 50% -100% of the number of the preliminary test belts.
In one embodiment, a preliminary test belt is tensioned with an initial tension value, the preliminary test belt is subjected to a thermal test with a fixed load and a fixed rotation speed, and the initial tension value is determined to be a preliminary test process tension value under the condition that a preliminary test stable tension value of the preliminary test belt meets a first preset condition, and the control method comprises:
carrying out a thermal test of fixed rotating speed and fixed load on a test belt to obtain a target tension value of the test belt in a stable period; wherein the first preset condition includes determining that an absolute value of a difference between the preliminary test steady tension value and the target tension value is less than a target tolerance, and determining that a process capability index Cpk of the preliminary test belt is greater than or equal to a threshold value.
In one embodiment, performing a thermal test of a test belt at a constant rotational speed and a constant load to obtain a target tension value for a stationary phase of the test belt, includes:
carrying out a thermal test of fixed rotating speed and fixed load on a test belt, and recording the tension value of the test belt along with time so as to obtain a decay curve of the tension value of the test belt along with time;
and according to the attenuation curve of the test belt, the tension value of the test belt in the stable period is a target tension value.
In one embodiment, the second preset condition includes:
the second preset condition includes determining that an absolute value of a difference between the retry stable tension value and the target tension value is less than the target tolerance;
determining that the process capability index Cpk of the retry belt is greater than or equal to the threshold value.
Another aspect of the embodiments of the present application discloses a system for controlling belt tension, comprising:
installing an actuator;
control means capable of controlling the installation actuator installation belt to implement the control method according to any one of claims 1 to 8.
In one embodiment, the control system includes:
and the alarm device is electrically connected with the control device, and can control the alarm device to send an alarm signal under the condition that the retest stable tension value of the retest belt does not meet the second preset condition.
The embodiment of the application discloses a control method and a control system for belt tension, wherein an initial test belt is tensioned by an initial tension value in the early stage, an initial stable tension value after stabilization meets a preset condition to determine an initial test process tension value, then the initial test process tension value is taken as a retest tension value to tension the retest belt, the process tension value is determined after the retest stable tension after stabilization meets the preset condition, and the process tension value is continuously optimized, so that the installation tension value can be directly adjusted to the process tension value when a large number of belts are installed in the follow-up process, the measurement times are reduced, and the production beat is accelerated.
Drawings
FIG. 1 is a flow chart of a method for controlling belt tension according to an aspect of the present application;
FIG. 2 is a schematic diagram of a structure in which a generator pulley is regulated by an adjusting lever in a fixed front-end gear train, wherein a broken line is an initial position of the generator pulley;
FIG. 3 is a schematic view of the belt fully dropped into the pulley sheaves;
fig. 4 is a schematic view of the belt not fully dropped into the pulley sheaves.
Description of the reference numerals
Fixing a front wheel train 1; a belt 11; a generator pulley 12; a water pump pulley 13; idler 14; a compressor pulley 15; a crankshaft pulley 16; and an adjusting rod 2.
Detailed Description
It should be noted that, in the case of no conflict, the embodiments of the present application and the technical features of the embodiments may be combined with each other, and the detailed description in the specific embodiments should be interpreted as an explanation of the gist of the present application and should not be construed as unduly limiting the present application.
The application will be described in further detail with reference to the accompanying drawings and specific examples. The description of "first," "second," etc. in embodiments of the application is for descriptive purposes only and is not to be construed as indicating or implying relative importance or implicitly including at least one feature. In the description of the embodiments of the present application, the meaning of "plurality" is at least two, for example, two, three, etc., unless explicitly defined otherwise.
Before describing a control method and a control system for belt tension provided by the embodiment of the application, in order to make the embodiment of the application clearer, a fixed front end gear train of an engine is described:
referring to fig. 2, a fixed front wheel train 1 of an engine includes: the belt 11, the generator pulley 12, the water pump pulley 13, the idler pulley 14, the compressor pulley 15, and the crankshaft pulley 16, the belt 11 sequentially passes around the generator pulley 12, the water pump pulley 13, the idler pulley 14, the compressor pulley 15, and the crankshaft pulley 16. Tension is generated by extending the belt 11, so that the belt 11 is tightened, and the belt 11 can drive each belt pulley to rotate when the engine works. After the belt 11 is installed, the positions of the respective pulleys are not substantially moved again due to a change in load or the like.
In the related art, when the belt 11 is installed in a workshop, when the belt 11 is driven to move by manually rotating the crankshaft pulley 16 for three circles, as each accessory (the compressor and the generator) is not loaded, the tension of the belt 11 is smaller in the operation process of the belt 11, the belt 11 cannot well fall into the corresponding wedge groove, and meanwhile, the depth of the belt 11 falling into the wedge groove is influenced by the speed of rotating the crankshaft. As in fig. 3, the belt 11 falls completely into the wedge groove, as in fig. 4, the belt 11 does not fall completely into the wedge groove. Since the belt 11 does not fall into the wedge groove completely, if the tension of the belt 11 measured at this time is (for example, 500N), during the subsequent operation, the dynamic tension of the belt 11 is greatly increased (for example, maximum 1500N) due to the dynamic operation (load increase of the compressor and the generator, and increase of the engine speed), and the belt 11 falls into the wedge groove rapidly in a short time, so that rapid and large-scale attenuation (for example, short-time operation attenuation to 350N) of the initial tension of the belt 11 reaches the actual stable tension value, and a larger deviation between the actual stable tension value and the target tension value is caused. However, in the case of the wheel system, too small an actual stable tension value can cause problems of slipping and abnormal sound; an excessively large actual steady tension value may affect the life of the belt 11 and the bearings in the vicinity thereof, while an excessively large actual steady tension value may also cause an excessively high fuel consumption problem.
In view of this, an aspect of the present application provides a method for controlling belt tension, for fixing a front wheel train 1, referring to fig. 1, the method includes:
s1, stretching an initial tension value to stretch the initial test belt, carrying out a thermal test of fixed load and fixed rotating speed on the initial test belt, and determining that the initial tension value is an initial test process tension value under the condition that an initial test stable tension value of the initial test belt meets a first preset condition.
Specifically, the initial tension value refers to a tension value when the initial test belt is primarily tensioned after the initial test belt is wound on the fixed front wheel train 1. The initial stable tension value refers to the tension value when the tensile state of the initial belt reaches basic stability after the initial belt is subjected to a thermal test.
It will be appreciated that the tension of the primary test belt reaching substantially steady means that the tension of the primary test belt decays into a steady decay period, where there may be less fluctuation in the tension value of the primary test belt, but less fluctuation in the steady decay period than in the rapid decay period of the primary test belt.
Here, the number of preliminary test belts is plural. Illustratively, taking the installation of the shop belt 11 as an example, the planned production volume of the day may be taken as the overall volume, and at least a portion of the overall volume, such as 95% or 100%, may be taken as the initial belt. For example, 200 production runs are planned on the same day, and then 190 or 200 production runs may be taken for initial belt installation.
On the one hand, the initial test process tension value can be accurately obtained through measurement and acquisition analysis of the initial test belt, the measurement times of the subsequent belt 11 can be reduced, and the working efficiency is improved.
On the other hand, the constant rotation speed means that the engine drives the crank pulley 16 to rotate at a constant rotation speed. The fixed load means that the fuel injection quantity of the engine is fixed by controlling the opening degree of an accelerator. The belt 11 can be effectively embedded into wedge grooves in each belt wheel by adopting a thermal test with fixed rotating speed and fixed load, so that the installation accuracy of the belt 11 is improved, the uncertainty of tension measurement of the belt 11 is reduced, and the production quality is improved.
S2, primarily tensioning the retest belt by taking the initial test process tension value as a retest initial tension value, adjusting the retest initial tension value until the retest stable tension value of the retest belt meets a second preset condition, and determining the retest initial tension value as an installation tension value.
Specifically, the initial tension value of the retest refers to the tension value when the retest belt is primarily tensioned after the retest belt is wound on the fixed front wheel train 1. The retest stable tension value refers to the tension value when the tensile state of the retest belt reaches basic stability after the retest belt is subjected to a thermal test.
The installation tension value may be used for subsequent batch installation of the belt 11. The installation tension value refers to a tension value when the belt 11 is primarily tensioned after the belt 11 is wound on the fixed front end pulley train 1.
It is understood that the tension state of the retest belt reaching a substantially stable state means that the tension of the retest belt is attenuated into a stable attenuation period, and the tension value of the retest belt in the stable attenuation period may have smaller fluctuation, but the fluctuation of the stable attenuation period is smaller than that of the tension in the rapid attenuation period of the retest belt.
Illustratively, in some embodiments, the number of retry belts is no greater than the number of initial test belts. Therefore, verification and adjustment of the initial testing process tension value initially set in the early stage can be completed through a proper amount of retest belts, and efficiency and accuracy are considered. The initial process tension value can be optimized on the premise of not reducing the working efficiency, so that the success rate of the subsequent belt 11 installation is increased.
The manner of adjusting the retry initial tension value is not limited, and referring to fig. 2, for example, the retry initial tension value may be adjusted by moving the position of any one of the pulleys of the fixed front wheel train 1, and after the position of the pulley is moved, the adjusted pulley may be fixedly locked by a fastener such as a bolt or a screw. For example, taking the adjustment of the generator pulley 12 as an example, the generator pulley 12 is disposed in a preset track, the preset track may be linear, curved, or other shapes, and one end of the preset track is an initial end, and when the generator pulley 12 is located at the initial end, the position of the preset track is close to that of other pulleys, so that the retry belt is easily installed on each pulley in the front-end gear train, after the retry belt is installed, the adjustment rod 2 is pulled to drive the generator pulley 12 to move away from the initial end in the preset track, at this time, the retry belt is slowly tightened, and the retry initial tension value is gradually increased, thereby achieving the purpose of adjusting the retry initial tension value.
According to the embodiment of the application, the initial test process tension value is determined by the initial test stable tension value after the initial test belt is stabilized meeting the first preset condition, then the retest belt is tensioned by the initial test process tension value, and the installation tension value of the subsequent belt 11 is determined under the condition that the stabilized retest stable tension value meets the second preset condition. Thus, after the initial process tension value is obtained and primarily optimized through the initial test belts in a large batch in the earlier stage, the obtained initial process tension value is tensioned to verify and further optimize the retest belts in a small number, so that the uncertainty of the installation tension value of the subsequent belt 11 is reduced, the success rate of the installation is increased, the batch installation of the belt 11 can be efficiently completed, the production beat is effectively accelerated, and the production efficiency is improved.
In an embodiment, S1, tensioning an initial tension value to perform a thermal test with a fixed load and a fixed rotation speed on the initial tension value, and determining that the initial tension value is an initial process tension value when an initial stable tension value of the initial tension value meets a first preset condition, where the control method includes:
s11, performing heat test on a test belt at a fixed rotating speed and a fixed load to obtain a target tension value of the test belt in a stable period; wherein the first preset condition includes determining that an absolute value of a difference between the preliminary test steady tension value and the target tension value is less than a target tolerance, and determining that a process capability index Cpk of the preliminary test belt is greater than or equal to a threshold value.
For example, 2 to 5 belts 11 are taken as test belts to perform a constant-speed and constant-load thermal test, and the tension value after the test belts are stabilized is obtained as a target tension value. The target tolerance is a preset value, and an operator can determine the target tolerance according to the requirement, for example, the target tolerance can be between 5N (newton) and 10N, for example, the target tolerance can be 10N; the target tolerance can also be obtained by obtaining a plurality of target tension values after the test belts are stabilized and corresponding calculation. And then ensuring that the initial stable tension value falls within the range of the target tension value by the absolute value of the difference between the initial stable tension value and the target tension value after the initial belt is stabilized and the magnitude of the target tolerance. The target tolerance may also be optimized based on engineering physical capabilities.
The process capability index (Cpk) as referred to herein refers to the extent to which process capability meets product quality standards, such as specification ranges, etc. The calculation formula is as follows: cpk=min [ (USL-Mu)/3σ, (Mu-LSL)/3σ ], USL is the upper specification limit, LSL is the lower specification limit, mu is the average value, and σ is the standard deviation.
Illustratively, the threshold is 1.33. And (3) judging whether the process capability coefficient is greater than or equal to 1.33 or not by calculating the process capability coefficient between the initial stable tension value of the initial belt and the range of the target tension value of the test belt, so as to ensure that the initial stable tension value meets the yield requirement. When Cpk is not less than 1.33, the indicating ability is good, the state is stable, and the initial stable tension value is close to the target tension value. In the embodiment, the absolute value of the difference between the initial stable tension value and the target tension value is determined to be smaller than the target tension, and if the absolute value does not meet the requirement, the initial tension value of the initial stable tension value can be adjusted until the initial tension value meets the requirement; after the foregoing requirement is met, the process capability index Cpk of the preliminary test belt is calculated to be greater than or equal to the threshold value, and if Cpk is smaller than the threshold value, it is indicated that the preliminary test stable tension value deviates from the target tension value, and if the preliminary test stable tension value is greater than or less than the target tension value, the preliminary tension value may be correspondingly reduced, and if the preliminary test stable tension value is less than the target tension value, the preliminary tension value may be correspondingly increased until the process capability index Cpk of each preliminary test belt is greater than or equal to the threshold value. The accuracy of the tension value of the initial test process can be improved, the measurement times for the verification of the follow-up retried belt can be reduced, and the production efficiency can be improved. Of course, the threshold value can be 1.67, so that the accuracy of the initial process tension value is further improved.
In one embodiment, S11, performing a thermal test of a constant rotational speed and a constant load on a test belt to obtain a target tension value of the test belt in a stationary phase, including:
s111, performing thermal test on a test belt at a fixed rotating speed and a fixed load, and recording the tension value of the test belt along with time to obtain an attenuation curve of the tension value of the test belt along with time;
s112, according to the attenuation curve of the test belt, the tension value of the test belt in the stable period is a target tension value.
For example, taking 5 belts 11 as test belts to perform a thermal test of constant rotation speed and constant load, recording tension values of the test belts at regular intervals, for example, 10min, drawing a time-dependent attenuation curve of the tension values of the test belts, and taking the tension values after a steady attenuation period, for example, 20min, as target tension values according to the time-dependent attenuation curve of the tension values of the test belts. It is understood that in the decay curve of tension with time, the tension decay is approximately divided into two periods, the period of rapid decrease in tension is a rapid decay period, the period of substantial steady tension is a steady decay period, and the time of steady decay period from the rapid decay period is a turning time, so that the turning time corresponds to the tension value of the test belt having entered the steady period, and the tension value in the steady period is the target tension value.
Therefore, fewer test belts are adopted, the target tension value can be rapidly obtained within limited times, and the working efficiency is improved.
In some embodiments, the time-dependent attenuation curve of the tension of the test belt can be output to a computer screen or to paper, so that an operator can intuitively observe the time-dependent attenuation curve of the tension of the test belt, find the turning time of the tension of the test belt from the rapid attenuation period to the steady attenuation period according to the time-dependent attenuation curve of the tension of the test belt, and determine the target tension value according to the turning time. Of course, the target tension value may be directly output instead of the time-dependent attenuation curve of the tension of the test belt. In actual operation, the operator selects according to the requirements of the belt 11. In still other embodiments, the target tension value may not be directly output to the computer screen or paper, and may be cached in the detection device or processor, so long as it is available for further processing.
Illustratively, the manner of determining the stabilization period by the turn time is: can be determined from the slope of the decay curve corresponding to the point in time. For example, the corresponding time point when the slope of the decay curve is first 0 is the turning time, which indicates that the tension value has entered the stationary phase.
In an embodiment, S2, taking the initial process tension value as a retry initial tension value, primarily tensioning the retry belt, adjusting the retry initial tension value until the retry stable tension value of the retry belt meets a second preset condition, and determining the retry initial tension value as an installation tension value, including:
s21, selecting a part from the multiple retest belts as a first retest belt, and primarily stretching the first retest belt by taking the initial test process tension value as a retest initial tension value;
s22, carrying out thermal test on the first retest belt at a fixed load and a fixed rotating speed, determining that the retest stable tension value of the first retest belt meets the second preset condition, and determining that the retest initial tension value is the installation tension value, wherein the number of the first retest belts is 3% -7% of the number of the initial test belts.
For example, 5 first retest belts are selected from a plurality of retest belts, the first retest belts are primarily tensioned by taking the initial test process tension value as the retest initial tension value, then the thermal test of fixed rotation degree and fixed load is carried out, the tension value of the first retest belts along with time is recorded every 10min, the attenuation curve of the tension value of the first retest belts along with time is drawn, the corresponding tension value is obtained as the retest stable tension value according to the attenuation curve of the tension of the first retest belts along with time, the turning time is taken as the stable period after 20min, then whether the retest stable tension value meets the second preset condition is judged, and the retest initial tension value is determined as the installation tension value. According to the embodiment of the application, the part of the multiple retest belts is taken as the first retest belt, the initial testing process tension value is taken as the retest initial tension value for tensioning, the initial testing process tension value acquired in the earlier stage can be verified, and further optimized and adjusted, so that an accurate value is provided for the installation of the subsequent mass belts 11, the installation success rate is increased, the subsequent installation time is shortened, the production beat is accelerated, and the production efficiency is improved.
In some embodiments, the time-dependent attenuation curve of the tension of the first retest belt may be output to a computer screen or output to paper, so that an operator may intuitively observe the time-dependent attenuation curve of the tension of the first retest belt, find a turning time when the tension of the first retest belt enters a steady attenuation period from a rapid attenuation period according to the time-dependent attenuation curve of the tension of the first retest belt, and determine a retest steady tension value according to the turning time. Of course, the test belt tension decay curve with time may be directly output instead of the test belt tension decay curve. In actual operation, the operator selects according to the requirements of the belt 11. In still other embodiments, the retest stabilized tension value may not be directly output to a computer screen or paper, but may be buffered within a detection device or processor, as long as it is available for further processing.
In one embodiment, the second preset condition includes:
s23, determining that the absolute value of the difference between the retest stable tension value and the target tension value is smaller than the target tolerance;
s24, determining that the process capability index Cpk of the retried belt is greater than or equal to the threshold value.
Illustratively, the target tolerance is a preset value, and the operator can determine the target tolerance according to needs, for example, the target tolerance can be between 5N (newton) and 10N, for example, the target tolerance can be 10N; the target tolerance can also be obtained through corresponding calculation by acquiring target tension values determined by the attenuation curves of the tension of a plurality of test belts along with time. And then judging the difference between the retest stable tension value and the target tension value, and ensuring that the retest stable tension value falls into the range of the target tension value. The target tolerance may also be optimized appropriately according to the engineering practice.
The threshold may be 1.33. And judging whether the process capability index is greater than or equal to 1.33 or not by calculating the process capability index between the process capability index of the retest belt and the range of the target tension value of the test belt, so as to ensure that the retest stable tension value meets the yield requirement.
In the embodiment, the absolute value of the difference between the retest stable tension value and the target tension value is determined to be smaller than the target tension, and if the absolute value does not meet the requirement, the initial tension value of the retest stable tension value can be adjusted until the absolute value meets the requirement; after meeting the requirements, calculating the process capability index of the retest belt to be greater than or equal to a threshold value, if Cpk is smaller than the threshold value, indicating that the retest stable tension value deviates from the target tension value, possibly being greater than or smaller than the target tension value, if the retest stable tension value is greater than the target tension value, the retest initial tension value can be correspondingly reduced, if the retest stable tension value is smaller than the target tension value, the retest initial tension value can be correspondingly increased until the process capability index of each primary test belt is greater than or equal to the threshold value. By further optimizing, the accuracy of the installation tension value can be improved, time is saved for the subsequent batch of the belt 11, and the production efficiency is improved. Of course, the threshold value may also be 1.67, improving the accuracy of the installation tension value.
In an embodiment, S2, taking the initial process tension value as a retry initial tension value, primarily tensioning the retry belt, adjusting the retry initial tension value until the retry stable tension value of the retry belt meets a second preset condition, and determining the retry initial tension value as an installation tension value, including:
s25, selecting a part from the retest belt as an additional retest belt according to a preset proportion under the condition that the retest stable tension value of the first retest belt does not meet the second preset condition, and adjusting the retest initial tension value as an additional retest initial tension value to primarily tension the additional retest belt;
s26, carrying out thermal test on the additional retest belt at a fixed load and a fixed rotating speed, determining that the retest stable tension value of the additional retest belt meets the second preset condition, and determining that the additional retest initial tension value is an installation tension value.
The method includes the steps of taking a part of the retest belt as an additional retest belt according to a preset proportion, for example, taking 100 additional retest belts from the retest belts as additional retest initial tension values, tensioning the additional retest belt by taking the retest initial tension values as the additional retest initial tension values, performing hot test with fixed rotating speed and fixed load, recording the tension values of the additional retest belt along with time every 10min, drawing an attenuation curve of the tension values of the additional retest belt along with time, taking the turning time as a stable period after 20min according to the attenuation curve of the additional retest belt along with time, obtaining the corresponding tension values as the retest stable tension values, judging whether the additional retest stable tension values meet a second preset condition, and determining the additional retest initial tension values as installation tension values. It is understood that the minimum requirement of the target tension value herein refers to the minimum limit size of the obtained target tension value by calculating the target tension value and the target tolerance.
For example, in some embodiments, the preset proportion is 50% -100% of the number of primary test belts, for example, when the number of primary test belts is 200, in the case that the stable retry tension value of the first retry belt does not meet the second preset condition, 50% of the number of primary test belts, that is, 100, may be taken as the additional retry belts for testing; if the retest stable tension value of the additional retest belt does not meet the second preset condition, continuously taking 100% of the initial test belts, namely 200, continuously testing, and readjusting the retest initial tension value. The method can further optimize the initial tension value of the retried test after timely correcting and adjusting the belt 11 with problems, reduce the rejection rate and improve the qualification rate of the subsequent belt 11 installation.
It will be appreciated that the process capability index is greater than or equal to 1.33, which corresponds to a PPM (reject rate in one million) of 66.07, i.e., as the throughput increases, while the belt 11 is stabilized at a tension value close to the target tension value, some will deviate from the target tension value, and therefore, the installation tension value needs to be constantly optimized and adjusted to reduce the reject rate.
In an embodiment, after the installation tension value is determined, 5000 production cycles, for example, can be produced, and the installation tension value can be tensioned through the determined installation tension value, so that thermal test on each batch of belts 11 can be omitted, the production tact can be quickened, and the production efficiency can be improved.
In one embodiment, when the short mileage slip abnormal sound fault occurs in the loose inspection or after-sale of the belt 11 installed in batches, part of the belt 11 installed in batches is selected to be used as a retest belt for retesting, the retest initial tension value is optimized and adjusted, and the installation tension value is redetermined.
In another aspect, the present application provides a system for controlling tension of a belt 11, including an installation actuator and a control device. The control device is capable of controlling the mounting actuator mounting belt 11 to implement the control method described above. For example, taking a primary test belt as an example, an installation executor can automatically assemble the primary test belt according to an initial tension value, control an engine to rotate a crankshaft at a certain rotating speed, for example, at a rotating speed of 1r/min for 3 circles, and then perform a thermal test of fixed rotating speed and fixed load after the primary test belt enters wedge grooves of all belt wheels; the control device is electrically connected with the installation executor, can record the initial test stable tension value of the initial test belt entering the stable period, calculate the process capability index of the initial test belt, and can adjust the initial tension value according to the magnitude relation between the process capability index and the threshold value, if Cpk is smaller than 1.33, the installation executor is correspondingly controlled to increase or decrease the initial tension value until Cpk is larger than or equal to 1.33, thereby determining that the initial tension value is the initial test process tension value.
In one embodiment, taking a retest belt as an example, an installation executor can automatically assemble a primary test belt according to a retest initial tension value, and control an engine to rotate a crankshaft at a certain rotating speed, for example, at a rotating speed of 1r/min for 3 circles, and then perform a thermal test of fixed rotating speed and fixed load after the retest belt enters wedge grooves of all belt wheels; the control device is electrically connected with the installation executor, can record the retest stable tension value of the retest belt entering the stable period, calculate the process capability index of the retest belt, and can adjust the retest initial tension value according to the magnitude relation between the process capability index and the threshold value, if Cpk is smaller than 1.33, the installation executor is correspondingly controlled to increase or decrease the retest initial tension value until Cpk is larger than or equal to 1.33, thereby determining that the retest initial tension value is the installation tension value.
In the prior art, because the assembly, the heat test and the tension detection after the heat test stabilization of the belt 11 are not in the same station, and the too low stable tension value needs to be reworked again, a great amount of manpower is required to be coordinated and solved in a centralized way, the normal operation of the production line is affected, and the production takt is severely dragged.
The control system in this embodiment is through installing installation executor and controlling means, with assembly, hot examination and the tension detection after the hot examination is stable concentrate on a station, can in time adjust it in the test process, when there is stable tension value to not satisfy the condition of predetermineeing, can adjust initial tension value voluntarily, uses manpower sparingly for production beat, improvement production efficiency.
In one embodiment, the control system includes an alarm system electrically connected to the control device, and the control device is capable of controlling the alarm device to emit an alarm signal when the initial steady tension value of the initial belt does not satisfy the first preset condition and/or when the retest tension value of the retest belt does not satisfy the second preset condition. The alarm signal may be a light, a sound, or otherwise.
Taking a primary test belt as an example, when the stable primary test tension value of the primary test belt is smaller than the minimum requirement of the target tension value, the control system controls the alarm device to send out an alarm signal that the red light is always on, and reminds the primary test belt to be reassembled and adjusts the initial tension value; when the process capability index of the initial test belt is smaller than the threshold value, the control device controls the alarm device to send out a red light flickering alarm signal to remind that the initial tension value needs to be adjusted.
In one embodiment, taking a retest belt as an example, when the stable retest stable tension value of the retest belt is smaller than the minimum requirement of the target tension value, the control system controls the alarm device to send an alarm signal that the red light is always on, so as to remind the retest belt of needing to be reassembled and adjust the retest initial tension value; when the process capability index of the retest belt is smaller than the threshold value, the control device controls the alarm device to send out an alarm signal of red light flickering to remind the retest initial tension value of needing to be adjusted.
According to the embodiment, the alarm system is installed, and the control device is used for controlling the alarm device to send an alarm signal when the initial stable tension value of the initial belt does not meet the first preset condition and/or the retest tension value of the retest belt does not meet the second preset condition, so that the belt 11 is convenient to check and data statistics, and the working efficiency is improved.
In an embodiment, the alarm device may control the alarm device to send a qualified signal when the initial stable tension value of the initial belt meets the first preset condition and/or when the repeated stable tension value of the repeated belt meets the second preset condition. The qualifying signal may be a light, a sound, or otherwise. For example, when the process ability index of the primary test belt is greater than or equal to a threshold, the alarm device sends a green light flashing signal to prompt the primary test belt to be installed. And data statistics are convenient to carry out.
In one embodiment, when the process capability index of the retest belt is greater than or equal to the threshold value, the alarm device sends a signal that the green light flashes to prompt that the retest belt is qualified in installation.
Another aspect of the embodiments of the present application provides a storage medium having stored thereon a computer program which, when executed by a processor, implements the steps of the control method in any of the embodiments of the present application.
The above description is only of the preferred embodiments of the present application, and is not intended to limit the present application, but various modifications and variations can be made by those skilled in the art. All such modifications, equivalents, alternatives, and improvements are intended to be within the spirit and scope of the application.
Claims (10)
1. A method for controlling belt tension for fixing a front-end gear train, the method comprising:
stretching an initial tension value to stretch the initial test belt, carrying out a thermal test of fixed load and fixed rotating speed on the initial test belt, and determining that the initial tension value is an initial test process tension value under the condition that an initial test stable tension value of the initial test belt meets a first preset condition;
and primarily tensioning the retest belt by taking the initial test process tension value as a retest initial tension value, adjusting the retest initial tension value until the retest stable tension value of the retest belt meets a second preset condition, and determining the retest initial tension value as an installation tension value.
2. The control method according to claim 1, wherein the number of the retry belts is not greater than the number of the preliminary test belts.
3. The control method according to claim 1, wherein the preliminary tensioning of the retry belt with the preliminary process tension value as the retry initial tension value, adjusting the retry initial tension value to a retry stable tension value of the retry belt satisfying a second preset condition, determining the retry initial tension value as an installation tension value, comprises:
selecting a part from the multiple retest belts as a first retest belt, and primarily stretching the first retest belt by taking the initial test process tension value as a retest initial tension value;
and carrying out thermal test on the first retest belt at a fixed load and a fixed rotating speed, determining that the retest stable tension value of the first retest belt meets the second preset condition, and determining that the retest initial tension value is the installation tension value, wherein the number of the first retest belts is 3% -7% of the number of the initial test belts.
4. A control method according to claim 3, wherein the preliminary tensioning of the retry belt with the preliminary process tension value as the retry initial tension value, adjusting the retry initial tension value to a retry stable tension value of the retry belt satisfying a second preset condition, determining the retry initial tension value as an installation tension value, comprises:
under the condition that the retest stable tension value of the first retest belt does not meet the second preset condition, selecting a part from the retest belt according to a preset proportion as an additional retest belt, and adjusting the retest initial tension value as an additional retest initial tension value to primarily tension the additional retest belt;
and carrying out thermal test on the additional retest belt at a fixed load and a fixed rotating speed, determining that the retest stable tension value of the additional retest belt meets the second preset condition, and determining that the additional retest initial tension value is an installation tension value.
5. The control method according to claim 4, wherein the preset proportion is 50% to 100% of the number of the preliminary test belts.
6. The control method according to claim 1, wherein the initial tension value is used for tensioning the initial test belt, the initial test belt is subjected to a thermal test with a constant load and a constant rotation speed, and the initial tension value is determined to be an initial process tension value when the initial test stable tension value of the initial test belt satisfies a first preset condition, the control method comprising:
carrying out a thermal test of fixed rotating speed and fixed load on a test belt to obtain a target tension value of the test belt in a stable period; wherein the first preset condition includes determining that an absolute value of a difference between the preliminary test steady tension value and the target tension value is less than a target tolerance, and determining that a process capability index Cpk of the preliminary test belt is greater than or equal to a threshold value.
7. The control method according to claim 6, wherein performing a constant-speed and constant-load thermal test on a test belt to obtain a target tension value at a stationary phase of the test belt comprises:
carrying out a thermal test of fixed rotating speed and fixed load on a test belt, and recording the tension value of the test belt along with time so as to obtain a decay curve of the tension value of the test belt along with time;
and according to the attenuation curve of the test belt, the tension value of the test belt in the stable period is a target tension value.
8. The control method according to claim 6, wherein the second preset condition includes:
the second preset condition includes determining that an absolute value of a difference between the retry stable tension value and the target tension value is less than the target tolerance;
determining that the process capability index Cpk of the retry belt is greater than or equal to the threshold value.
9. A belt tension control system, comprising:
installing an actuator;
control means capable of controlling the installation actuator installation belt to implement the control method according to any one of claims 1 to 8.
10. The control system of claim 9, wherein the control system comprises:
the alarm device is electrically connected with the control device, and can control the alarm device to send an alarm signal when the initial stable tension value of the initial belt does not meet the first preset condition and/or when the repeated stable tension value of the repeated belt does not meet the second preset condition.
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